Function-oriented machining of turbulence-generating surface structures on cooling channel surfaces of injection moulds

Cooling time has a significant impact on efficiency, productivity, and sustainability in various applications. One innovative approach to improve cooling efficiency is the generation of turbulent flows in the cooling channels by a novel and function-oriented texturing of the channel wall surfaces, which enhances heat transfer. A predictive model was developed to understand the interdependence of surface topography and cooling channel topology on turbulent flow and cooling time reduction. The model uses a combination of material removal simulation for machining processes and CFD simulations for cooling behavior. Experimental validation of this approach confirms a 37% reduction in cooling time.