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Modelling and Simulation of MuCell ®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction. Polymers (Basel) 2022; 14:polym14194215. [PMID: 36236163 PMCID: PMC9572263 DOI: 10.3390/polym14194215] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/03/2022] [Revised: 09/30/2022] [Accepted: 10/06/2022] [Indexed: 11/06/2022] Open
Abstract
Microcellular injection moulding is an important injection moulding technique to create foaming plastic parts. However, there are no consistent conclusions on the impact of processing parameters on the cell morphology of microcellular injection moulded parts. This paper investigates the influence of the main processing parameters, such as melt temperature, mould temperature, injection pressure, flow rate, shot volume and gas dosage amount, on the average cell size and weight reduction of a talc-reinforced polypropylene square part (165 mm × 165 mm × 3.2 mm), using the commercial software Moldex 3D. The effect of each parameter is investigated considering a range of values and the simulation results were compared with published experimental results. The differences between numerical and experimental trends are discussed.
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Radhakrishna G, Dugad R, Gandhi A. Morphological evaluation of microcellular foamed composites developed through gas batch foaming integrating Fused Deposition Modeling (FDM) 3D printing technique. CELLULAR POLYMERS 2021. [DOI: 10.1177/02624893211040938] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/01/2023]
Abstract
In this article, the development of microcellular structure foams has developed by integrating the two successful and existing technologies, namely CO2 gas batch foaming and Fused Deposition Modeling (FDM) 3D printing technique. It is a novel approach to manufacture complex design porous products for customized applications. The eventual cell morphologies of the extruded 3D printing filament depends on the process parameters pertaining to both microcellular foaming and 3D printing processes. Further, morphological study has been conducted to evaluate the cell morphologies of the 3D printing filament developed through customized FDM setup. During this process, the significance of various process parameters including saturation pressure, saturation time, desorption time, feed rate and extrusion temperature were thoroughly studied. To pursue this study base material used was acrylonitrile butadiene styrene (ABS). The 3D printed filaments consisted of cells with an average cell size in the range of 2.3–276 µm and the average cell density in the range of 4.7 × 104 to 4.3 × 109 cells/cm3. Finally, it has found that by controlling the process parameters different cell morphologies can be developed as per the end application.
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Affiliation(s)
- G Radhakrishna
- CIPET: School for Advanced Research in Polymers (SARP)—APDDRL, Bengaluru, Karnataka, India
- CIPET: School for Advanced Research in Polymers (SARP)—LARPM, Bhubaneswar, Odisha, India
| | - Rupesh Dugad
- CIPET: School for Advanced Research in Polymers (SARP)—APDDRL, Bengaluru, Karnataka, India
- CIPET: School for Advanced Research in Polymers (SARP)—LARPM, Bhubaneswar, Odisha, India
| | - Abhishek Gandhi
- CIPET: School for Advanced Research in Polymers (SARP)—APDDRL, Bengaluru, Karnataka, India
- CIPET: School for Advanced Research in Polymers (SARP)—LARPM, Bhubaneswar, Odisha, India
- CIPET: IPT Murthal, Sonepat, Haryana, India
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Abstract
Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.
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Affiliation(s)
| | - Andrew Rees
- College of Engineering, Swansea University, Swansea, UK
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Martín-de León J, Van Loock F, Bernardo V, Fleck NA, Rodríguez-Pérez MÁ. The influence of cell size on the mechanical properties of nanocellular PMMA. POLYMER 2019. [DOI: 10.1016/j.polymer.2019.121805] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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Realinho V, Arencón D, Antunes M, Velasco JI. Effects of a Phosphorus Flame Retardant System on the Mechanical and Fire Behavior of Microcellular ABS. Polymers (Basel) 2018; 11:polym11010030. [PMID: 30960014 PMCID: PMC6401830 DOI: 10.3390/polym11010030] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/13/2018] [Revised: 12/20/2018] [Accepted: 12/21/2018] [Indexed: 11/16/2022] Open
Abstract
The present work deals with the study of phosphorus flame retardant microcellular acrylonitrile–butadiene–styrene (ABS) parts and the effects of weight reduction on the fire and mechanical performance. Phosphorus-based flame retardant additives (PFR), aluminum diethylphosphinate and ammonium polyphosphate, were used as a more environmentally friendly alternative to halogenated flame retardants. A 25 wt % of such PFR system was added to the polymer using a co-rotating twin-screw extruder. Subsequently, microcellular parts with 10, 15, and 20% of nominal weight reduction were prepared using a MuCell® injection-molding process. The results indicate that the presence of PFR particles increased the storage modulus and decreased the impact energy determined by means of dynamic-mechanical-thermal analysis and falling weight impact tests respectively. Nevertheless, the reduction of impact energy was found to be lower in ABS/PFR samples than in neat ABS with increasing weight reduction. This effect was attributed to the lower cell sizes and higher cell densities of the microcellular core of ABS/PFR parts. All ABS/PFR foams showed a self-extinguishing behavior under UL-94 burning vertical tests, independently of the weight reduction. Gradual decreases of the second peak of heat release rate and time of combustion with similar intumescent effect were observed with increasing weight reduction under cone calorimeter tests.
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Affiliation(s)
- Vera Realinho
- Centre Català del Plàstic, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Universitat Politècnica de Catalunya (UPC Barcelona Tech), C/Colom 114, E-08222 Terrassa, Barcelona, Spain.
| | - David Arencón
- Centre Català del Plàstic, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Universitat Politècnica de Catalunya (UPC Barcelona Tech), C/Colom 114, E-08222 Terrassa, Barcelona, Spain.
| | - Marcelo Antunes
- Centre Català del Plàstic, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Universitat Politècnica de Catalunya (UPC Barcelona Tech), C/Colom 114, E-08222 Terrassa, Barcelona, Spain.
| | - José Ignacio Velasco
- Centre Català del Plàstic, Departament de Ciència dels Materials i Enginyeria Metal·lúrgica, Universitat Politècnica de Catalunya (UPC Barcelona Tech), C/Colom 114, E-08222 Terrassa, Barcelona, Spain.
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Influence of injection molding parameters on the morphology, mechanical and surface properties of ABS foams. ADVANCES IN POLYMER TECHNOLOGY 2018. [DOI: 10.1002/adv.21944] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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Zhang ZX, Zhang T, Wang D, Zhang X, Xin Z, Prakashan K. Physicomechanical, friction, and abrasion properties of EVA/PU blend foams foamed by supercritical nitrogen. POLYM ENG SCI 2017. [DOI: 10.1002/pen.24598] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Zhen Xiu Zhang
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
| | - Tao Zhang
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
| | - Dan Wang
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
| | - Xin Zhang
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
| | - Zhenxiang Xin
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
| | - K. Prakashan
- Key Laboratory of Rubber-Plastics, Ministry of Education/Shandong Provincial Key Laboratory of Rubber-Plastics; Qingdao University of Science and Technology; Qingdao 266042 China
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Zhang C, Zhang C, Huang R, Gu X. Effects of hollow microspheres on the thermal insulation of polysiloxane foam. J Appl Polym Sci 2017. [DOI: 10.1002/app.44778] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
- Chunling Zhang
- Key Laboratory of Automobile Materials (Ministry of Education), College of Materials Science and Engineering, Jilin University; Changchun 130025 People's Republic of China
| | - Chunyu Zhang
- Key Laboratory of Automobile Materials (Ministry of Education), College of Materials Science and Engineering, Jilin University; Changchun 130025 People's Republic of China
| | - Rong Huang
- Key Laboratory of Automobile Materials (Ministry of Education), College of Materials Science and Engineering, Jilin University; Changchun 130025 People's Republic of China
| | - Xiaoyan Gu
- Key Laboratory of Automobile Materials (Ministry of Education), College of Materials Science and Engineering, Jilin University; Changchun 130025 People's Republic of China
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