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

Gethin Llewelyn1, Andrew Rees1, Christian Griffiths1

  • 1College of Engineering, Swansea University, Swansea, Wales SA1 8EN, UK.

Materials (Basel, Switzerland)
|May 24, 2020
PubMed
Summary
This summary is machine-generated.

Foam injection moulding (FIM) can now produce polymer parts with surface roughness similar to conventional methods. This advancement allows for weight savings without compromising surface quality in FIM applications.

Keywords:
Foam Injection MouldingMuCell®PolypropyleneTalcTecoCell®

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Area of Science:

  • Polymer processing
  • Materials science
  • Manufacturing engineering

Background:

  • Expanding the application of foam injection moulding (FIM) requires achieving surface roughness comparable to conventional processing.
  • Talc-filled copolymer polypropylene (PP) is a key material for lightweight component development.

Purpose of the Study:

  • To investigate the effects of processing parameters on the surface roughness and mechanical properties of talc-filled PP parts produced via FIM.
  • To determine if FIM can achieve surface quality suitable for broader industrial applications.

Main Methods:

  • Utilized a design of experiments (DoE) approach to systematically vary processing parameters.
  • Investigated both physical and chemical blowing agents for FIM.
  • Analyzed surface roughness, Young's modulus, and tensile strength of the produced PP parts.

Main Results:

  • Higher mould temperatures and longer holding times improved mechanical performance.
  • Using chemical blowing agents (CBA) at low-pressure yielded surface roughness comparable to conventional injection moulding.
  • Optimized FIM parameters can achieve desired surface quality and mechanical properties.

Conclusions:

  • Foam injection moulding (FIM) is a viable technique for producing lightweight polymer parts with excellent surface finish.
  • This research overcomes previous limitations of surface defects in FIM, enabling wider adoption.
  • FIM offers a pathway to weight reduction without sacrificing surface quality in polymer components.