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

Gethin Llewelyn, Andrew Rees, Christian Griffiths, Martin Jacobi

Materials, Volume: 13, Issue: 10, Start page: 2358

Swansea University Authors: Gethin Llewelyn, Andrew Rees, Christian Griffiths

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DOI (Published version): 10.3390/ma13102358

Abstract

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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Published in: Materials
ISSN: 1996-1944
Published: MDPI AG 2020
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URI: https://cronfa.swan.ac.uk/Record/cronfa54298
first_indexed 2020-05-21T19:08:25Z
last_indexed 2025-04-09T04:00:49Z
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spelling 2025-04-08T10:59:51.6519274 v2 54298 2020-05-21 A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods 7454b3dde334f8d8876851bc894bea29 Gethin Llewelyn Gethin Llewelyn true false e43e88c74976e714e1d669a898f8470d Andrew Rees Andrew Rees true false 84c202c256a2950fbc52314df6ec4914 Christian Griffiths Christian Griffiths true false 2020-05-21 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. Journal Article Materials 13 10 2358 MDPI AG 1996-1944 polypropylene; talc; TecoCell®; MuCell®; foam injection moulding 20 5 2020 2020-05-20 10.3390/ma13102358 COLLEGE NANME COLLEGE CODE Swansea University This research was part funded by the EU’s European Funding Office and the Engineering and Physical Sciences Research Council (EPRSC) and the Welsh European Funding Office (WEFO). 2025-04-08T10:59:51.6519274 2020-05-21T14:56:18.0246611 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Gethin Llewelyn 1 Andrew Rees 2 Christian Griffiths 3 Martin Jacobi 4 54298__17320__952da8e2612848489eaea9d1878e9387.pdf 54298.pdf 2020-05-21T15:15:04.7667327 Output 447555 application/pdf Version of Record true This is an open access article distributed under the Creative Commons Attribution License (CC-BY). true English https://creativecommons.org/licenses/by/4.0/
title A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
spellingShingle A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
Gethin Llewelyn
Andrew Rees
Christian Griffiths
title_short 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_sort A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods
author_id_str_mv 7454b3dde334f8d8876851bc894bea29
e43e88c74976e714e1d669a898f8470d
84c202c256a2950fbc52314df6ec4914
author_id_fullname_str_mv 7454b3dde334f8d8876851bc894bea29_***_Gethin Llewelyn
e43e88c74976e714e1d669a898f8470d_***_Andrew Rees
84c202c256a2950fbc52314df6ec4914_***_Christian Griffiths
author Gethin Llewelyn
Andrew Rees
Christian Griffiths
author2 Gethin Llewelyn
Andrew Rees
Christian Griffiths
Martin Jacobi
format Journal article
container_title Materials
container_volume 13
container_issue 10
container_start_page 2358
publishDate 2020
institution Swansea University
issn 1996-1944
doi_str_mv 10.3390/ma13102358
publisher MDPI AG
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
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.
published_date 2020-05-20T04:43:46Z
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