Comparison of Conventional and Microcellular Injection Using New Chemical Agents

ABSTRACT

This study is mainly focused to obtain stable dimensions for plastic products used in manufacturing industries. A technique of microcellular foaming injection method was chosen with added chemical blowing agents to decrease the mass, clamping force, and cycle time. Mold flow analysis was run to compare the conventional plastic injection (KP) method with chemical foaming injection molding method using added TecoCell H1 (TH) and CS (TCS). The primary process conditions are considered as temperature of the mold, velocity of injection, pressure and time of holding, and cooling time. The experiments were carried under polymer material as (polypropylene) Moplen EP548P. The new chemical blowing agents TH and TCS, having different reactive material ratios (50% and 25% endothermic) and gas concentration ratios, were utilized at a rate of 1% by weight claiming to be a novel method for producing the parts with high efficiency. The results of both the flow analysis and the injection molding experiments demonstrate that, plastic samples produced by conventional plastic injection could be made approximately 7.5% lesser weight, with 33% lesser force of clamping, and a gain of cycle time nearly 15% by adding chemical blowing agents to the process. Topsis technique is carried for determining the best fabrication method. It was observed that, the injection molding method with Tecocell H1 (TH) chemical foaming agent exhibited better results in terms of less clamping force, reduced cycle time, and weight of the product. The experimental results are validated using the Topsis method and the results are satisfied. Hence, the chemical blowing agent Tecocell H1 (TH) can be applied as a foaming agent for manufacturing the plastic products and increase the efficiency of the production.

KEYWORDS:

• Polypropylene
• microcellular
• agents
• injection
• moldflow
• analysis

Acknowledgments

We would like to thank Mr. Martin Jacobi and Mr. Yılmaz Yığcıoğlo, Mr. Hakan Aktas, Mr. Sven Theissen for their help in experimentation work. We would also like to thank Michael Gossen, Bright works Engineering Trade for his help in experimental work.

Disclosure statement

Prof Hasan Oktem and Dr Naresh Kumar Konada are working in the same area of friction material composites and manufacturing processes of materials. In order to facilitate and promote good quality of research works, both are working combined to share their research knowledge and perform good research studies useful for the society.

Data availability statement

The data used in the current research work was taken after performing experimentation using injection molding method and performing simulation studies using mold flow analysis Autodesk software. This data is available with the corresponding author https://vidwan.inflibnet.ac.in/profile/264475.