A Methodology for the Design of Effective Cooling System in Injection Moulding

In this work, the forming behaviour of a commercial sheet of AZ31B magnesium alloy at elevated temperatures is investigated and reported. The experimental activity is performed in two phases. The first phase consists in free bulging test and the second one in analysing the ability of the sheet in filling a closed die. Different pressure and temperature levels are applied. In free bulging tests, the specimen dome height is used as characterizing parameter; in the same test, the strain rate sensitivity index is calculated using an analytical approach. Thus, appropriate forming parameters, such as temperature and pressure, are individuated and used for subsequent forming tests. In the second phase, forming tests in closed die with a prismatic shape cavity are performed. The influence of relevant process parameters concerning forming results in terms of cavity filling, fillet radii on the final specimen profile are analysed. Closed die forming tests put in evidence how the examined commercial magnesium sheet can successfully be formed in complicated geometries if process parameters are adequately chosen.