Big Area Additive Manufacturing (BAAM) of thermoplastics enables the production of large tools for the production of composite parts while saving cost and time. The extrusion based 3D printing process fits this use case, as a high quantity material output of short fibre reinforced thermoplastics is possible. To achieve lower manufacturing cycle times of composite parts, cooling channels designed for optimal thermal behaviour are feasible, as additive manufacturing allows more freedom of design. This work investigates the thermal behaviour of different channel cross sections modelled in finite element analyses. The focus lies on the investigation of achievable cooling rates and even temperature distribution of a short fibre reinforced PAEK composite tooling, manufactured for the aerospace industry. The optimal cross sections considered in the numerical simulations regarding thermal behaviour of a composite tooling are presented. Results show, that a close integration of the cooling channels to the tool surface is fundamental, as the low heat conductivity of PAEK hinders heat flux. Cooling channel cross sections with large surfaces pointed towards the tool surface have a stronger influence on the cooling behaviour than circular cooling channels. The optimal cross sections for cooling channels in additively manufactured thermoplastic moulds are presented.
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