Neglecting to regularly clean cooling channels can have serious consequences for both the mold and the production process. As contaminants accumulate, water flow is reduced, which lowers the cooling system's capacity. Lower heat removal capacity as a result of a layer of insulation with low thermal conductivity, combined with throttled flow, can cause localized overheating in the mold (known as hot spots), leading to uneven cooling and unstable part quality. As a result, the percentage of defective parts increases, production costs rise, and more frequent mold repairs or even mold replacement becomes necessary. In critical cases, cooling channels can become completely clogged, forcing mold downtime, the need to dismantle the mold and mechanically reaming out the blockage, which generates huge costs. This not only increases operating costs, but also negatively affects the ability to meet production deadlines. At a time when customers' quality requirements are so exorbitant, maintaining stable molding quality with the shortest possible cycle time is crucial.
Potential problems arising from tool thermal disturbances:
- Extended cycle times: Clogged cooling channels result in slower heat transfer, which means the mold takes longer to cool. This leads to longer production cycles, reducing overall process efficiency and increasing operating costs.
- Disadvantages of molding: Uneven cooling can affect part quality. Defects such as deformations, sink marks and dimensional deviations become more common, leading to more rejections by the quality control department. In addition, the uneven cooling process of the workpiece can lead to stresses, reduced product strength and cracking under load.
- Faster mold wear: Low cooling efficiency forces the mold to operate at higher temperatures for longer periods, accelerating wear on mold components. This can shorten tool life and require more frequent repairs and reconditioning.
- Higher energy consumption: An inefficient cooling system requires more energy to maintain the proper mold temperature, leading to increased energy costs and greater environmental impact.
