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A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods

The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced thr...

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Autores principales: Llewelyn, Gethin, Rees, Andrew, Griffiths, Christian, Jacobi, Martin
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2020
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7287706/
https://www.ncbi.nlm.nih.gov/pubmed/32443909
http://dx.doi.org/10.3390/ma13102358
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author Llewelyn, Gethin
Rees, Andrew
Griffiths, Christian
Jacobi, Martin
author_facet Llewelyn, Gethin
Rees, Andrew
Griffiths, Christian
Jacobi, Martin
author_sort Llewelyn, Gethin
collection PubMed
description The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM.
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spelling pubmed-72877062020-06-15 A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods Llewelyn, Gethin Rees, Andrew Griffiths, Christian Jacobi, Martin Materials (Basel) Article The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM. MDPI 2020-05-20 /pmc/articles/PMC7287706/ /pubmed/32443909 http://dx.doi.org/10.3390/ma13102358 Text en © 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Llewelyn, Gethin
Rees, Andrew
Griffiths, Christian
Jacobi, Martin
A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title_full A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title_fullStr A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title_full_unstemmed A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title_short A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
title_sort design of experiment approach for surface roughness comparisons of foam injection-moulding methods
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7287706/
https://www.ncbi.nlm.nih.gov/pubmed/32443909
http://dx.doi.org/10.3390/ma13102358
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