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VSRD-MAP, Vol. 2 (1), 2012,

34-43

RESEARCH
COMMUNICATION

Design
Development Of
Test-Rig To
Evaluate

Of Heat Pipes In
Comparison
To Conventional
Water Jackets In
Mould Cooling
1

Ashish Khare*, 2Amitesh Paul and

AC Tiwari

ABSTRACT

Design Development of test-rig to

evaluate of heat pipes in comparison to
conventional water jackets in mould
cooling to improve part quality, increase
heat transfer rate, and reduce cycle time
and maintenance, lower the mould
making cost, operating cost. In method of
heat extraction from mould we used
copper heat pipe with 12mm diameter
and 50mm length.

Keywords : Test- Rig, Heat Pipe,

Mould, Water Jacket.

1. INTRODUCTION

The test conducted in design development

manufacturing assembly and test trail of the

above setup the supervision of paramount

industries. Developing a suitable heat
transfer from heat source that is the mould

1.1. Elements and performance

Criteria

Prepare for trial

Set mould and machine

Test and evaluate and advanced injection

mould

____________________________

Assistant

Professor,
Department of Mechanical Engineering,
LNCT, Indore, Madhya
Pradesh,
INDIA.
2

Assistant

Professor &
Head, Department of Mechanical Engineering,
SSSIST, Sehore, Madhya
Pradesh,
INDIA.
3

Professor & Head, Department of Mechanical

Engineering, UTT, RGPV, Bhopal, Madhya
Pradesh, INDIA. *Correspondence :
ashish_khare09@rediffmail.com

Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

1.2. Test Conditions

Water jacket system Heat pipe system

1.3. Heat Pipe Injection Moulding And Die Casting Cooling Application

Heat Pipe in Moulds

Temperature Range : Heat Pipes are available in two temperature ranges.

For Injection Moulds : Heat Pipes having temperature range from +5 deg. C to + 200 deg. C. The
main application of these types of Heat Pipes is in Injection Moulding, Compression / Transfer
Moulding and Rotation Moulding, Spiral Screws.

For Die-Casting Dies : Heat Pipes having temperature range from +5 deg. C to + 350 deg. C. The main
application of these types of Heat Pipes is in Die-Casting, Spiral Screws in plastic moulding. It is advisable
to order the Heat Pipes suitable to the applications temperature range. If the Heat Pipe gets heated above
its operating temperature, it releases a small amount of non-toxic gas and becomes inoperative.

Material of Construction : Copper / Stainless Steel[1]

Typical Applications Of Heat Pipes In Mould Cooling

Ball Pen & Syringe Moulds : In small cores like ball pen barrel and disposable syringes, normal
water-cooling becomes very difficult. Cooling channels get blocked either due to rust or impurities in
water causing production problems. Heat Pipes are now first choice for all pen mould manufacturers.
It was found that moulding cycle reduces up to 40% compared to normal cooling. In case of
disposable syringes rejection due to warping was very high with normal water-cooling. But after
introduction of Heat Pipes total cycle and rejection came down substantially.

Fig.1 : Ball Pen & Syringe Moulds

Double Wall Container Mould : In double wall containers due to thin section of core, normal watercooling becomes impossible and then one has to continue moulding at very long uneconomical
cycles. Now in this and similar applications, Heat Pipes have come to the rescue of the plastic
industry. With freely available Heat Pipes of international quality at very affordable prices, mould
makers now can very liberally use Heat Pipes in such applications and enhance mould productivity.
Investment made towards Heat Pipes in any such moulds will pay for itself in no time.

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Fig.

Double

Old Moulds with Cracks or Blocked Water Cooling : In case of very old moulds where watercooling is blocked due to moulds rusting or due to some cracks developed on moulds, circulating
water through mould becomes impossible. But by introduction of Heat Pipes it is possible to produce
such moulds. So you can give new life to your old moulds.

Fig. 3 : Old Moulds with Cracks or Blocked Water Cooling

Reverse Moulds : On some products like luggage bags gating is required to be given from coreside. This is done
to avoid gate marks on the external face. Ejection system in such moulds is to be provided from the same
injection side and such moulds are known as reverse moulds. These reverse moulds have some problems like
getting sink marks opposite gate, circular flow marks, shining patches around gate. Due to all these defects
moulding becomes very difficult and normally rejection is very high. With the introduction of Heat Pipes, opposite
gate heat transfer is very fast and even. They eliminate hot spots, which cause all above defects.

Fig. 4 : Reverse Moulds

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Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

All Normal Moulds : Earlier a few mould makers were using Heat Pipes only in areas where giving
normal water-cooling was a problem. Very high cost and long time to import the same

was discouraging the mould makers from using Heat Pipes though they are very effective.

Now since Heat Pipes are locally manufactured and available at rock bottom prices (Compared to
imported ones) it is possible to use the same in place of normal water cooling in solid cores and
cavities as shown in the sketch. Based on shot weight, plastic to be moulded and desired cycle time, it
is possible to calculate size and quantity of Heat Pipes required cooling the mould efficiently.[2]

Fig. 5 : All Normal Moulds

1.4. Heat Pipe Operation

A heat pipe is essentially a passive heat transfer device with an extremely high effective thermal
conductivity. The two-phase heat transfer mechanism results in heat transfer capabilities from one
hundred to several thousand times that of an equivalent piece of copper.

As shown in Figure 6, the heat pipe in its simplest configuration is a closed, evacuated cylindrical
vessel with the internal walls lined with a capillary structure or wick that is saturated with a working
fluid. Since the heat pipe is evacuated and then charged with the working fluid prior to being sealed,
the internal pressure is set by the vapor pressure of the fluid.

As heat is input at the evaporator, fluid is vaporized, creating a pressure gradient in the pipe. This
pressure gradient forces the vapor to flow along the pipe to a cooler section where it condenses giving
up its latent heat of vaporization. The working fluid is then returned to the evaporator by the capillary
forces developed in the wick structure.

Fig. 6 : Heat Pipe Operation

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Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

Heat pipes can be designed to operate over a very broad range of temperatures from cryogenic (<
-243C) applications utilizing titanium alloy/nitrogen heat pipes, to high temperature applications
(>2000C)using tungsten/silver heat pipes. In electronic cooling applications where it is desirable to
maintain junction temperatures below 125-150C, copper/water heat pipes are typically used.
Copper/methanol heat pipes are used if the application requires heat pipe operation below 0C. [3]

2. PROBLEMS IN MOULD COOLING AND PROPOSED SOLUTION

Injection moulding and Die-casting moulds are cooled by the conventional water jacket method, where in
water jackets or runners are provided all around the mould to effect the cooling. Mould cooling is absolutely
essential considering the quality of parts and cycle time. The conventional water jacket method used in
conjunction with bubblers, baffles, fountains or blades offers the following disadvantages:

Heat transfer with water jacket takes place with laminar flow, which is very low as compared to heat
transfer by turbulent flow.

Hot spots are produced due to inability of water jackets to cool the in accessible areas of mould.

Increased cycle time due to slow cooling.

Rejection of parts due to defects such as sink marks, pulling and spotting that takes place due to
insufficient cooling.

Mould making cost is high owing to increased machining and construction time in attempt to provide
effective cooling by water jacket method.

Increased maintenance and operating cost as there is tendency of scale formation, calcium deposits
and clogging of ports in water jacket cooling system.

2.1. Solution

Heat Pipe is a heat transfer device specifically designed for optimal performance in plastic injection molds
and dies for the die casting industries. The Heat Pipe consists of a vacuum-tight copper tube containing a
wick and a non-toxic working fluid. The two ends of the Heat Pipe perform distinct functions one end is an
evaporator, the opposite end is a condenser. Thermal energy is gathered at the evaporator end, vaporizing
the working fluid. This vapor then travels through the Heat Pipe to the condenser end. At the condenser end

the vapor condensates back into a liquid, giving up its latent heat in the process. To complete the cycle the
condensed liquid then travels along the wick, via capillary action, back to the evaporator section. This
process repeats itself continuously, transferring heat many times faster than pure copper.

3. SYSTEM DESIGN AND SELECTION

3.1. Heat pipe Geometry and Size Selection

Heat pipes are available in standard diameters from 3 to 12mm and in lengths from 50mm to 250 mm, shape be

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Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

as shown in figure below:

Fig. : Heat Transfer Capability For Above Heat Pipe

Maximum Watts at Different Temperature

DIAMETER
20

C
40

C
80

C
120

12 mm
73 WATT

89 WATT
98 WATT
108 WATT

The power handling figures are for heat pipe working in horizontal position.

Length 50mm long

Evaporator length 25 mm

Condenser length 25 mm

Working fluid water

4. ELEMENTS AND PERFORMANCE CRITERIA

Element 1

Prepare for trial.

Performance Criteria

Information relevant to the trial and available at the enterprise is gathered and interpreted

Range: Information may include trial objectives, product specification, Production specification,
material specification, mould construction, and operation.

Machine suitability is confirmed in accordance with enterprise procedure.

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Range: Machine suitability ancillary equipment, machine capability.

Mould state is confirmed in accordance with enterprise procedure.

Range: Mould state may include inspected; cleaned; handling and lifting Facility available;
connections for water.

Raw material readiness is confirmed in accordance with enterprise procedure.

Range: Raw material readiness may include material mixed, dried.

Element 2

Set mould and machine.

Performance Criteria

Mould is fitted with consideration to its special features.

Range: Special features may include sliding blocks or cores, actuation System, ancillary equipment,
cooling circuits.

Initial machine conditions are set according to product configuration, material Type, and mould
construction.

Machine and mould are dry cycled in accordance with enterprise procedure.

Element 3

Trial and evaluate an advanced injection mould.

Performance Criteria

Trial procedures are carried out in a systematic manner to meet trial objectives, In accordance with
enterprise procedure.

Process limitations are determined with respect to product and production Specifications.

Trial results are recorded in accordance with enterprise procedure.

5. TEMPERATURE SENSORE

Pt-1OO, 6 MM, 2M length, Temperature sensing element

Display is multi channel temperature indicator.

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Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

6. TEST-RIG SETUP

7. SELECTION OF BAND HEATER

Heating Element Type: Nichrome wire (honeycomb/cross hatch wire mesh)

Insulation Base type: Ceramic or Bakelite base

Maximum wattage Range: 125 watt

Temperature Range: 60 to 180 C

Mounting type: Round Head Clamp

8. PROCEDURE OF TRIAL

The trial is basically divided in two parts as:

Phase-1: Water Jacket System

The trial is conducted on the water jacket system to determine the temperature difference at cold
water outlet and cold water inlet .Procedure is as follows:

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Ashish Khare et al / VSRD International Journal of Mechanical, Auto. & Prod. Engg. Vol. 2 (1), 2012

Close stop cock on the cold water inlet to the heat pipe system, open stop cock on the cold water inlet
to water jacket system.

Start power supply to ceramic band heater, let achieve steady state.

Start circulation pump.

Take temperature readings at cold water inlet and outlet and readings for mass flow rate.

Temperature readings are taken for different set of mass flow conditions.

Phase-2: Heat Pipe System

The trial is conducted on the heat pipe system to determine the temperature difference at cold water outlet and

cold water inlet .Procedure is as follows:

Close stop cock on the cold water inlet to the water jacket system, open stop cock on the cold water
inlet to heat pipe system.

Start power supply to ceramic band heater, let achieve steady state.

Start circulation pump.

Take temperature readings at cold water inlet and outlet and readings for mass flow rate.

Temperature readings are taken for different set of mass flow conditions.

9. RESULTS

Prepare a piping and instrumentation diagram (P&ID) of the apparatus. Suggest modifications that
may be desirable for the P&ID based on your experience.

After conducting experiments, evaluate the heat balances for the individual systems and for each of
the heat transfer equipment within the facility. Discuss findings.

Estimate the heat transfer coefficient in each of the set up.

Using the data collected during trials on each unit determine effectiveness of heat pipe system over
water jacket cooling system

10. COMPARISION BETWEEN HEAT PIPE SYSTEM AND WATER JACKET SYSTEM

Cooling

Even cooling achieved

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Economy

Lot product Low price

Individual product Higher price

Risk

Leakage of water because sealant failure

11. FUTURE SCOPE

The Test Conduct for comparison between the water jacket in mould cooling system and heat pipe in
mould cooling system for increasing the quality of parts, reduce cycle time, reduce maintenance and
operating cost. This test-rig is beneficial for industries purpose.

12. REFERENCES

http://www.heatpipeindia.com/apps/injmoulddie1.htm

http://www.heatpipeindia.com/apps/moulds.htm

Scott D. Garner P.E. Thermacore Inc., 780 Eden Road, Lancaster PA17601 USA

Brennan, P.J. and Kroliczek, E.J., Heat Pipe Design Handbook, B&K Engineering, NASA Contract
No.NAS5-23406, June 1979.
Chi, S.W., Heat Pipe Theory and Practice, Hemisphere Publishing Corporation, 1976

Dunn, P.D. and Reay, D.A., Heat Pipes, 3rd. Edition, Permagon Press, 1982.

Eastman, G. Yale and Ernst D.M., Heat Transfer Technology (Heat Pipe), Kirk-Othmer: Encyclopaedia of
Chemical Technology, Volume 12, John Wiley and Sons, Inc., 1980.
Peterson, G.P., an Introduction to Heat Pipes Modelling, Testing, and Applications, John Wiley and Sons,
Inc., 1994.

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