photo: engel

Moulding masterclass | processing feature

The best
mould cooling
channel layout
can be
compromised
on mould
installation.
Moulding
expert John
Goff explains
why

Effective mould cooling means

making the right connection
The best efforts of the tool designer in placing the

likely in the case of large mould tools weighing in

correct number of cooling channels in the mould and to

excess of one tonne.

locate the inlet and outlet ports at the optimum

cooling circuit

connections continue to be so widely used:

placed in the machine if appropriate consideration is

l Ease of mould tool set-up

not paid to how those channels are connected.

l Insufficient time for mould changeovers

selection and sizing of connectors can restrict the rate

connection can

There are a number of reasons why looped circuit

positions can so easily be undone when the mould is

In the previous instalment we considered how poor

Above: Careful

pay big benefits

in final part
quality

l Lack of available inlet/outlet ports on distribution

manifolds

of cooling medium flow into the moulds cooling

l Shortage of connecting hoses

circuits. In this instalment we will take a detailed look at

l Established practice employed within the moulding

how those circuits should be connected to achieve the

optimum results in terms of part quality and production

division.
However, whatever the reason, it must be under-

efficiency. This is an important issue, particularly when

stood that the effectiveness of heat energy removal

it is necessary to achieve the maximum performance

from within the mould is greatly impaired, especially as

from the mould.

the number of looped circuits increases.

The two main options available to moulders are the

Figure 1 highlights a typical set up that often results

in cycle time and moulding quality issues. The mould

option, where each cooling circuit connects to a

tool shown has been well designed, providing the ability

distribution manifold or flow regulator, is the most

to effectively remove residual heat energy through the

effective. Unfortunately, it is far more common to see

numerous cooling circuits in the mould tool. However,

looped circuitry used installations where external

the majority of the individual circuits are looped, which

loops are fitted to create a single path of coolant that

prevents the residual energy from being uniformly and

cascades through the mould and this is even more

effectively removed.

www.injectionworld.com 

use of looped circuits or independent circuits. The latter

April 2012 | injection world

53

processing feature | Moulding masterclass

Figure 1 (above

This scenario will very often result in moulding

can often also influence the ultimate outcome.

left) shows a

quality issues such as dimensional inconsistency across

looped mould

different impressions within a multi-cavity mould tool,

moulding machine and therefore tend to be more popular

set-up against

surface finish variations, and poor shape retention of

(Figure 3). Aside from the availability, they are often

Figure 2 (right)

moulded parts. These issues will differ according to the

preferred by users as they readily display the flow rate

which uses a

polymeric material being used and the wall thickness

value and temperature of the cooling medium. Distribu-

more effective

distribution within the component.

tion manifolds are supplied in pairs or zones, where all

independent
solution

In the case of processing a semi-crystalline material,

the presence of looped circuits will often dictate the

Flow regulators are sometimes supplied with the

the respective inlet/outlet circuits are connected to a

designated manifold or zoned section.

extent of crystallinity created within sections of the

Traditionally, distribution manifolds relied upon part

moulding where there is a non-conformity or sharp

quality indicatiors to assess the flow rate - where a lack

change in wall section, resulting in warpage or change in

of coolant flow rate caused the mould surface tempera-

shape or dimension of the part after it has been produced.

ture to increase this would often be reflected in changes

Where an amorphous material is being processed,

in part quality. Today, the use of electronic or ultrasonic

however, the use of looped circuits may result in an

flow meters, in association with a distribution manifold,

extension of the time required to cool the part to below

is becoming more popular and in such situations output

its heat distortion temperature (HDT), particularly

values can be accurately measured without flow rate

within thicker sections of the moulding. This will result

restriction/reduction.

in an unnecessary extension of the cooling time in order

Good moulding practice entails the use of distribu-

to overcome possible shape and dimensional changes

tion manifolds with the appropriate flow meters or

on removal from the mould. Such a shape change is

suitably sized flow regulators. In addition, the position

termed distortion.

of flow regulators on the moulding machine is also

Very often, the cooling circuits within a mould tool

are machined to accommodate a manifold that is
permanently secured to one of its faces. Such techniques have evolved to accommodate the need to
increase the surface temperature in certain parts of the
mould tool, such as to

important. Common problems that can occur include:

l Over lengthy pipe runs from the mould tool to the
regulator
l Flow restrictions within the area around the control
valve
l Poor visibility of flow rate values due to

Figure 3 (right)

improve polymer flow

discoloration of flow tubes

shows a typical

when producing larger

l Lack of resolution of the scale on

flow regulator,

components with long

the flow tube necessitating the use

flow length to wall

of flow markers

thickness ratios.

l Leakages between flow tube and

in this case by
Wittmann

As stated earlier, for

54

control valves

effective heat removal to

l Staining of flow tubes due to dirty

take place the use of

or untreated water

independent circuits is

l Blockages due to the presence of

preferred. However, the

sediment or silt in the cooling

choice of whether flow

medium

regulators or distributor

l Incorrect tube and float sizing

manifolds are employed

restricting flow rate

injection world | April 2012

www.injectionworld.com

Moulding masterclass | processing feature

through mould tool

Figure 4 (left)
shows a

l Restricted temperature range for cooling medium

number of

due to plastic flow tubes.

Figure 4 highlights the type of flow meters available

different flow
meters

for flow rate measurement. Various meters now offer

an electronic output which is received by a central data

installed on a

collection facility enabling both the temperature of the

test rig

cooling medium and the flow rate to be displayed either

on the process data collection page on the moulding
machine or at an independent central display.

With the mould cooling system connectors and the

cooling circuitry and flow regulation optimised, we can
now turn our attention to the performance of the mould
temperature controller and/or chiller. This third

element in optimising mould cooling mould temperaTHE INJECTION MOULDING

INDUSTRY
ture controller selection
will be discussed in the next
instalment in this series.
IN SPAIN AND PORTUGAL

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About
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John Goff is managing director of G&A Moulding

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