Effect of Gas Counter Pressure on the Surface Roughness, Morphology, and Tensile Strength between Microcellular and Conventional Injection-Molded PP Parts

Ren, Jianping; Liu, Lin; Jiang, Jing; Li, Qian; Hwang, Shyh‐Shin

doi:10.3390/polym14061078

Cited by 14 publications

(6 citation statements)

References 34 publications

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“…The main idea of this approach is to transform the response function into a suitable function and then optimize it. The overall desirability function was synthesized from the expectation functions of each response [54][55][56]. The object here maximizes the overall desirability function.…”

Section: Multi-response Optimizationmentioning

confidence: 99%

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

et al. 2023

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Mold heating is an essential process in plastic injection molding. Raising the temperature of the mold before injecting liquefied plastic can ease the mold-filling process. A cooling channel can be used to transport high-temperature fluids for this purpose, such as hot water or oil. This dual purpose is a cost-effective solution for heating the mold because the target temperature is easily achieved using this method. In addition, a conformal cooling channel (CCC) can provide more efficient mold heating than a straight cooling channel. This study used the response surface methodology to determine the optimum CCC shape for heat distribution in a mold, and the simulation results confirmed its optimization. The average temperature of the mold using a CCC was better than that using a straight cooling channel, and the heat zone was uniform across the mold surface.

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Section: Multi-response Optimizationmentioning

confidence: 99%

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

et al. 2023

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“…This process effectively suppresses gate‐nucleated bubbles during the filling stage, and nucleation occurs only after the gas release‐induced pressure drops. GCP prevents foaming during the filling stage, enhancing surface quality without the cost of extended cooling time due to additional increments of the mold temperature 30,31 . Lee et al 32 proposed the integration of GCP with the core‐back process for producing high‐quality foamed components.…”

Section: Introductionmentioning

confidence: 99%

Study on surface quality and cell morphology of foamed components fabricated using gas counter‐pressure with core‐back and high‐pressure foam injection molding with core‐back process

Chiu,

Yang,

Yeh

2024

Polymer Engineering & Sci

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The core‐back process has substantially increased the range of applicability of foam injection molding (FIM) by increasing the pressure drop rate and expansion ratio. However, cell nucleation and growth occur concurrently with the flow of the melt/gas mixture during the filling stage, resulting in poor surface quality and a non‐uniform cell structure. This study investigated foam injection molding with gas counter pressure (GCP) and core‐back to produce foamed components, with comparison to high‐pressure FIM with core‐back process. Through this method, the nucleation during filling is suppressed. The surface roughness was improved to 0.987 μm, a 59% reduction compared to high‐pressure injection molding foam with core‐back. In addition, the cell uniformity was improved, measured at two locations near and far from the gate, the cell density reaching 1.7 × 105 and 2.1 × 105 cells/cm3, and cell size measuring 120.88 and 129.57 μm, respectively. GCP also prevented the formation of the bubbles larger than 500 μm at the location far from the gate. Even at the lowest recommended mold temperature, the combination of GCP and core‐back enables the production of high‐quality foamed components with reduced cooling time.Highlights Preventing the simultaneous occurrence of cell nucleation, growth and melt flow. Foamed material with high surface quality produced by FIM. Improving the cell uniformity throughout the foamed component. Feasibility of GCP technology in conjunction with core‐back process.

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“…The second approach is to stop bubbles from getting trapped between the mould cavity and melt in the filling stage. Techniques, such as gas counter pressure (GCP) system [ 13 , 14 , 15 , 16 , 17 , 18 ], gas-assisted microcellular injection moulding (GAMIM) [ 19 ] and pressure-temperature (P-T) control system [ 20 , 21 ], were developed based on this principle by increasing the mould cavity pressure to a certain level at the beginning of the filling stage. It was also reported that both GCP technology [ 22 ] and GAMIM [ 19 ] can improve mechanical properties by increasing solid skin thickness.…”

Section: Introductionmentioning

confidence: 99%

Modelling and Simulation of MuCell®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction

et al. 2022

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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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Effect of Gas Counter Pressure on the Surface Roughness, Morphology, and Tensile Strength between Microcellular and Conventional Injection-Molded PP Parts

Cited by 14 publications

References 34 publications

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

Conformal Cooling Channel Design for Improving Temperature Distribution on the Cavity Surface in the Injection Molding Process

Study on surface quality and cell morphology of foamed components fabricated using gas counter‐pressure with core‐back and high‐pressure foam injection molding with core‐back process

Modelling and Simulation of MuCell®: The Effect of Key Processing Parameters on Cell Size and Weight Reduction

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