Innovative Approaches to Enhance Thermal Efficiency and Reduce Sprue Backflow in Zamak Hot Chamber Injection Moulding

Rita de Cássia Mendonça Sales-Contini; André Filipe Varandas Pedroso; Pedro Leitão; Rafael Resende Lucas; Raul Duarte Salgueiral Gomes Campilho; Arnaldo Gomes Pinto; Carlos Roberto Regattieri

doi:10.53941/jmem.2025.100004

Journal of Mechanical Engineering and Manufacturing ›› 2025, Vol. 1 ›› Issue (1) :4 -4. DOI: 10.53941/jmem.2025.100004

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Innovative Approaches to Enhance Thermal Efficiency and Reduce Sprue Backflow in Zamak Hot Chamber Injection Moulding

Rita de Cássia Mendonça Sales-Contini ¹^,²^,^*
, André Filipe Varandas Pedroso ¹
, Pedro Leitão ¹
, Rafael Resende Lucas ¹^,³
, Raul Duarte Salgueiral Gomes Campilho ¹
, Arnaldo Gomes Pinto ¹
, Carlos Roberto Regattieri ¹^,⁴

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Abstract

This study uses a Design Science Research (DSR) approach to improve the thermal performance of an injection nozzle for die-casting Zamak components. This involves identifying the problem, creating an iterative design and simulation, implementing solutions and evaluating them through computational and experimental validation. A combination of computational fluid dynamics (CFD) simulations and thermal modelling in SolidWorks Flow Simulation was used to analyse temperature distributions and identify geometric modifications aimed at reducing heat loss and preventing solidification within the nozzle. Key results include the development of a modified nozzle design featuring reduced length and optimised channel diameters, which has led to improved thermal efficiency. Experimental validation using temperature measurements near the nozzle tip demonstrated close agreement with simulation predictions, confirming the efficacy of the optimised design. The findings conclude that strategic geometric alterations and refined modelling assumptions can significantly improve heat retention, ensuring more reliable Zamak injection processes.

Keywords

sprue backflow / thermal management / die-casting / nozzle design innovation / process automation / Zamak moulding / injection system reliability

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Rita de Cássia Mendonça Sales-Contini, André Filipe Varandas Pedroso, Pedro Leitão, Rafael Resende Lucas, Raul Duarte Salgueiral Gomes Campilho, Arnaldo Gomes Pinto, Carlos Roberto Regattieri. Innovative Approaches to Enhance Thermal Efficiency and Reduce Sprue Backflow in Zamak Hot Chamber Injection Moulding. Journal of Mechanical Engineering and Manufacturing, 2025, 1(1): 4-4 DOI:10.53941/jmem.2025.100004

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