The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization
This study proposes an eco-friendly (ECO) mold that is fabricated using the laser powder bed fusion (LPBF) method, which utilizes a three-dimensional (3D) cooling channel. Unlike previous studies, we designed surface-type conformal cooling channels (CCC) based on the design concept for additive manu...
| Main Authors: | , , , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2022-10-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127522007109 |
| _version_ | 1811180841079930880 |
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| author | Woongbeom Heogh Si Mo Yeon Dong-Seok Kang Seonghwan Park Seongjun Park Kwanho Ryu Juhyun Sun Leecheol Ji Yong Son Kyunsuk Choi Cheol Woo Ha |
| author_facet | Woongbeom Heogh Si Mo Yeon Dong-Seok Kang Seonghwan Park Seongjun Park Kwanho Ryu Juhyun Sun Leecheol Ji Yong Son Kyunsuk Choi Cheol Woo Ha |
| author_sort | Woongbeom Heogh |
| collection | DOAJ |
| description | This study proposes an eco-friendly (ECO) mold that is fabricated using the laser powder bed fusion (LPBF) method, which utilizes a three-dimensional (3D) cooling channel. Unlike previous studies, we designed surface-type conformal cooling channels (CCC) based on the design concept for additive manufacturing, at a constant depth corresponding to the casting part. Pin fins were installed inside the surface-type cooling channels and aligned through numerical analysis to induce the turbulence of the coolant uniformly through the cooling channel while generating less thermal stress during solidification of the as-cast Al-Si alloy-based product, which increased the cooling efficiency of the proposed ECO mold. Moreover, the ECO mold was utilized to cast an automobile piston to demonstrate its feasibility at an industrial level. The results showed that, the casting process decreased significantly from 133 to 105 s per piston (21% reduction) compared to the conventional mold with a single columnar cooling channel. Additionally, the average grain size of the ECO mold decreased from 502 to 398 µm. The ultimate tensile strength and Rockwell hardness increased by 12.5% and 5.5%, respectively. |
| first_indexed | 2024-04-11T09:10:06Z |
| format | Article |
| id | doaj.art-1150b59ad98747aa98fe0cb76ded41b9 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-04-11T09:10:06Z |
| publishDate | 2022-10-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-1150b59ad98747aa98fe0cb76ded41b92022-12-22T04:32:32ZengElsevierMaterials & Design0264-12752022-10-01222111088The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimizationWoongbeom Heogh0Si Mo Yeon1Dong-Seok Kang2Seonghwan Park3Seongjun Park4Kwanho Ryu5Juhyun Sun6Leecheol Ji7Yong Son8Kyunsuk Choi9Cheol Woo Ha10Additive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of Korea; Department of Mechanical Design Engineering, Hanyang University, Seoul 04763, Republic of KoreaAdditive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of KoreaAdditive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of KoreaDepartment of Industrial Materials and Smart Manufacturing Engineering, University of Science and Technology, Daejeon 34113, Republic of KoreaAdditive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of Korea; HYU-KITECH Joint Department, Hanyang University, Seoul 04763, Republic of KoreaDong Yang Piston R&D Center, Ansan, Gyeonggi-do 15420, Republic of KoreaDong Yang Piston R&D Center, Ansan, Gyeonggi-do 15420, Republic of KoreaDong Yang Piston R&D Center, Ansan, Gyeonggi-do 15420, Republic of KoreaAdditive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of KoreaDepartment of Industry University Convergence, Hanbat National University, Daejeon 34158, Republic of Korea; Corresponding authors.Additive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung, Gyeonggi-do 15014, Republic of Korea; Corresponding authors.This study proposes an eco-friendly (ECO) mold that is fabricated using the laser powder bed fusion (LPBF) method, which utilizes a three-dimensional (3D) cooling channel. Unlike previous studies, we designed surface-type conformal cooling channels (CCC) based on the design concept for additive manufacturing, at a constant depth corresponding to the casting part. Pin fins were installed inside the surface-type cooling channels and aligned through numerical analysis to induce the turbulence of the coolant uniformly through the cooling channel while generating less thermal stress during solidification of the as-cast Al-Si alloy-based product, which increased the cooling efficiency of the proposed ECO mold. Moreover, the ECO mold was utilized to cast an automobile piston to demonstrate its feasibility at an industrial level. The results showed that, the casting process decreased significantly from 133 to 105 s per piston (21% reduction) compared to the conventional mold with a single columnar cooling channel. Additionally, the average grain size of the ECO mold decreased from 502 to 398 µm. The ultimate tensile strength and Rockwell hardness increased by 12.5% and 5.5%, respectively.http://www.sciencedirect.com/science/article/pii/S0264127522007109ECO moldAdditive manufacturingConformal cooling channelCastingPiston |
| spellingShingle | Woongbeom Heogh Si Mo Yeon Dong-Seok Kang Seonghwan Park Seongjun Park Kwanho Ryu Juhyun Sun Leecheol Ji Yong Son Kyunsuk Choi Cheol Woo Ha The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization Materials & Design ECO mold Additive manufacturing Conformal cooling channel Casting Piston |
| title | The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization |
| title_full | The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization |
| title_fullStr | The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization |
| title_full_unstemmed | The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization |
| title_short | The design and additive manufacturing of an eco-friendly mold utilized for high productivity based on conformal cooling optimization |
| title_sort | design and additive manufacturing of an eco friendly mold utilized for high productivity based on conformal cooling optimization |
| topic | ECO mold Additive manufacturing Conformal cooling channel Casting Piston |
| url | http://www.sciencedirect.com/science/article/pii/S0264127522007109 |
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