Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene
In the present study, semi-crystalline polypropylene (PP) and amorphous polystyrene (PS) were adopted as matrix materials. After the exothermic foaming agent azodicarbonamide was added, injection molding was implemented to create samples. The mold flow analysis program Moldex3D was then applied to v...
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-07-01
|
| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/13/14/2331 |
| _version_ | 1797526285463846912 |
|---|---|
| author | Chen-Yuan Chung Shyh-Shin Hwang Shia-Chung Chen Ming-Chien Lai |
| author_facet | Chen-Yuan Chung Shyh-Shin Hwang Shia-Chung Chen Ming-Chien Lai |
| author_sort | Chen-Yuan Chung |
| collection | DOAJ |
| description | In the present study, semi-crystalline polypropylene (PP) and amorphous polystyrene (PS) were adopted as matrix materials. After the exothermic foaming agent azodicarbonamide was added, injection molding was implemented to create samples. The mold flow analysis program Moldex3D was then applied to verify the short-shot results. Three process parameters were adopted, namely injection speed, melt temperature, and mold temperature; three levels were set for each factor in the one-factor-at-a-time experimental design. The macroscopic effects of the factors on the weight, specific weight, and expansion ratios of the samples were investigated to determine foaming efficiency, and their microscopic effects on cell density and diameter were examined using a scanning electron microscope. The process parameters for the exothermic foaming agent were optimized accordingly. Finally, the expansion ratios of the two matrix materials in the optimal process parameter settings were compared. After the experimental database was created, the foaming module of the chemical blowing agents was established by Moldex3D Company. The results indicated that semi-crystalline materials foamed less due to their crystallinity. PP exhibits the highest expansion ratio at low injection speed, a high melt temperature, and a low mold temperature, whereas PS exhibits the highest expansion ratio at high injection speed, a moderate melt temperature, and a low mold temperature. |
| first_indexed | 2024-03-10T09:27:06Z |
| format | Article |
| id | doaj.art-e2a82de9cb54416baafeb9631d4a735d |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-10T09:27:06Z |
| publishDate | 2021-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-e2a82de9cb54416baafeb9631d4a735d2023-11-22T04:46:39ZengMDPI AGPolymers2073-43602021-07-011314233110.3390/polym13142331Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and PolystyreneChen-Yuan Chung0Shyh-Shin Hwang1Shia-Chung Chen2Ming-Chien Lai3Department of Mechanical Engineering, National Central University, Taoyuan City 320317, TaiwanDepartment of Mechanical Engineering, Chien Hsin University of Science and Technology, Taoyuan City 320312, TaiwanDepartment of Mechanical Engineering, Chung Yuan Christian University, Taoyuan City 320314, TaiwanDepartment of Mechanical Engineering, National Central University, Taoyuan City 320317, TaiwanIn the present study, semi-crystalline polypropylene (PP) and amorphous polystyrene (PS) were adopted as matrix materials. After the exothermic foaming agent azodicarbonamide was added, injection molding was implemented to create samples. The mold flow analysis program Moldex3D was then applied to verify the short-shot results. Three process parameters were adopted, namely injection speed, melt temperature, and mold temperature; three levels were set for each factor in the one-factor-at-a-time experimental design. The macroscopic effects of the factors on the weight, specific weight, and expansion ratios of the samples were investigated to determine foaming efficiency, and their microscopic effects on cell density and diameter were examined using a scanning electron microscope. The process parameters for the exothermic foaming agent were optimized accordingly. Finally, the expansion ratios of the two matrix materials in the optimal process parameter settings were compared. After the experimental database was created, the foaming module of the chemical blowing agents was established by Moldex3D Company. The results indicated that semi-crystalline materials foamed less due to their crystallinity. PP exhibits the highest expansion ratio at low injection speed, a high melt temperature, and a low mold temperature, whereas PS exhibits the highest expansion ratio at high injection speed, a moderate melt temperature, and a low mold temperature.https://www.mdpi.com/2073-4360/13/14/2331exothermic chemical foaming agentfoam injection moldingsemi-crystalline materialamorphous material |
| spellingShingle | Chen-Yuan Chung Shyh-Shin Hwang Shia-Chung Chen Ming-Chien Lai Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene Polymers exothermic chemical foaming agent foam injection molding semi-crystalline material amorphous material |
| title | Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene |
| title_full | Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene |
| title_fullStr | Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene |
| title_full_unstemmed | Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene |
| title_short | Effects of Injection Molding Process Parameters on the Chemical Foaming Behavior of Polypropylene and Polystyrene |
| title_sort | effects of injection molding process parameters on the chemical foaming behavior of polypropylene and polystyrene |
| topic | exothermic chemical foaming agent foam injection molding semi-crystalline material amorphous material |
| url | https://www.mdpi.com/2073-4360/13/14/2331 |
| work_keys_str_mv | AT chenyuanchung effectsofinjectionmoldingprocessparametersonthechemicalfoamingbehaviorofpolypropyleneandpolystyrene AT shyhshinhwang effectsofinjectionmoldingprocessparametersonthechemicalfoamingbehaviorofpolypropyleneandpolystyrene AT shiachungchen effectsofinjectionmoldingprocessparametersonthechemicalfoamingbehaviorofpolypropyleneandpolystyrene AT mingchienlai effectsofinjectionmoldingprocessparametersonthechemicalfoamingbehaviorofpolypropyleneandpolystyrene |