Thermal Evaluation of Optimal Molding Material Selection Through ANSYS Simulation

Abstract

This study investigates the transient thermal behavior of hybrid and homogeneous mold configurations made from Aluminum A1100 and Stainless Steel 304 (S304) through numerical simulation and statistical validation. Finite Element Analysis (FEA) was conducted to examine temperature distribution, thermal gradients, and heat dissipation under controlled boundary conditions. The simulation results revealed that the pure Aluminum A1100 mold exhibited a maximum surface temperature of 56.708°C with rapid heat dispersion across the structure, indicating superior thermal conductivity and efficient heat transfer. In contrast, the hybrid A1100-S304 configuration reached a slightly lower maximum temperature of 56.002°C but demonstrated more stable temperature retention due to the stainless-steel layer’s lower thermal conductivity and higher heat capacity. To validate these findings, an Analysis of Variance (ANOVA) test was performed on the experimental temperature profiles and cooling rates of both materials. The ANOVA results (p < 0.05) confirmed a statistically significant difference between the configurations, indicating that material composition directly affects thermal performance. Among the tested setups, the hybrid A1100-S304 mold achieved the optimal balance between rapid heat transfer and thermal stability, ensuring uniform temperature distribution while maintaining mechanical and corrosion resistance. This combination is particularly suitable for food-grade mold applications and biopolymer-based packaging processes, where controlled heating and cooling cycles are crucial for product quality and energy efficiency.