Sedan 1951 har Tetra Pak tillverkat livsmedelsförpackningar, formsprutningsverktyg och fyll-ningsmaskinerna för livsmedelsförpackningar. En del livsmedelsförpackningar som t.ex. gräddeoch yoghurt kan ha en formsprutad topp av plast. Det är nödvändigt att den formsprutade plas-ten stelnar så snabbt som möjligt. För att minska tiden för stelning så används formverktygmed hög värmeledningsförmåga, detta för att få stabila detaljer och ändå göra det möjligt atthålla en hög produktion. En acceptabel livslängd på verktygen uppnås genom att de ytbeläggs.Ytbeläggningen består dels av en hårdanodiserad yta, ett lager av teflon. Dessvärre har teflonen sämre värmeledningsförmåga än metaller som formverktygen är tillverkad i. I detta arbetehar en metod för att avgöra hur mycket ytbeläggningen påverkar värmeledningen utvecklats.Resultaten av arbetet kommer användas för att kunna göra nya materialval. Under projektetutvecklas en testrigg där testerna visar att verktyg utan ytbeläggning har en värmelednings-förmåga som är 24% bättre än för belagda verktyg. Därmed finns det mycket att vinna på attanvända en annan ytbeläggning. / Tetra Pak has since 1951 manufactured food packaging, injection molding tools and fillingmachines for food packaging. Some of the food packaging as for cream and yogurt may havea injection molded plastic top. It is necessary that the injection molded plastic solidifies asquickly as possible. In order to reduce the time for solidification, molding tools with highthermal conductivity are used, in order to obtain stable details and still make it possible tokeep a high production. To achieve an acceptable tool life, they are coated. The surface coatingconsists partly of a hard anodized surface and a layer of teflon. Unfortunately, teflon has worsethermal conductivity than metals that the molding tools are made of. In this project, a methodto determine how much the surface coating affect the thermal conductivity is being developed.The results of the project will be used to make new material choices. During the project, atest rig is developed where the tests show that tools without surface coating have a thermalconductivity that is 24% better than for coated tools. That means there are a lot to gain byselect a new surface coating.

Indiana University-Purdue University Indianapolis (IUPUI) / Plastic injection molding is a versatile process and a major part of the present plastic manufacturing industry. Traditional die design is limited to straight (drilled) cooling channels, which dont impart optimal thermal (or thermos-mechanical) per- formance. Moreover, reducing the cycle time in plastic injection molding has become significantly important to the industry nowadays. One approach that has been pro- posed is to use conformal cooling channels. With the advent of additive manufacturing technology, injection molding tools with conformal cooling channels are now possible. However, optimum conformal channels based on thermo-mechanical performance are not found. This study proposes a design methodology to generate optimized design configurations of such channels in plastic injection molds. Numerical models have been developed here to represent the thermo-mechanical behavior of the molds and predict the stress and cooling time. The model is then validated experimentally and used in conjunction with DOE (Design of Experiments) to study the effect of differ- ent design parameters of the channels on the die performance. Design of experiments (DOEs) is used to study the effect of critical design parameters of conformal channels as well as their cross section geometries. These DOEs are conducted to identify op- timal designs of conformal cooling channels which can be incorporated into injection molds that are used to manufacture cylindrical and conical shapes of plastic parts. Though these are simplified forms, the study provides useful insight into the poten- tial deign parameters for all kind of injection molds.Based on the DOEs, designs for best thermo-mechanical performance are identified (referred to as ”optimum”). The optimization study is basically a trade-off and the solution is based on a specific sample size. This approach is highly result-oriented and provides guidelines for selecting optimum design solutions given the plastic part thickness.

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