Investigation of the under-vehicle plastic protection parts manufactured by core-back injection process in terms of strength and weight

Yıl 2023, Cilt: 12 Sayı: 4, 133 - 143, 30.12.2023

Yasemin Gültekin , Mustafa Atakan Akar , Anıl Altındağ , Doğukan Duran , Umut Kumlu

https://doi.org/10.18245/ijaet.1331175

Öz

Material type, chemical foaming agent, NOx level, core-back distance, and cavity temperature, being the influential parameters in an injection process, significantly affect the weight-based issues and mechanical properties of the resulting product. When the product under inspection is an automotive part, in terms of both the weight and the mechanics are considered to be of high importance. This work is carried out due to a recent task, assigned to NOVARES Engineering and R&D Departments, about the weight reduction of the vehicle underbody plastic protection part (VUPPP), which is located in the rear-lower section of the vehicles. As the core-back process is mostly applied in industry to parts with thickness values of 2.5 mm, the present work involves a challenge due to the fact that before core-back the initial thickness of VUPPP changes between 1.5-1.8 mm. In this study, prototypes are produced with recycled two different polypropylene materials from (PP1 and PP2), two different chemical foaming agents (CFA-X and CFA-Y), six different core-back distances, and two different NOx levels. Finally, laboratory tests are performed on the prototypes to evaluate the weight-based and mechanical features. Experimental data are debated in particular to outline the individual and combined effects of the influential parameters.

Anahtar Kelimeler

Core-back process, mold injection, weight reduction, mechanical properties, chemical foaming

Destekleyen Kurum

TÜBİTAK-TEYDEB

Proje Numarası

3190913

Teşekkür

The authors would like to thank the TÜBİTAK TEYDEB for financial support.

Kaynakça

• Akar M. A., Tosun A. T., Yel F., Kumlu U., "The Usage of Natural Fibers for Automotive Applications", Macromolecular Symposia, 404, 1, 1–3 2022.
• Liu B., Gu J., Jiang T., Deng R., Yang J., Zeng X., Zhang C., He L., Gong W., "Designer petals shape ZnO nanoparticles as nucleating agents: Verification the mechanism of cavity nucleation in the polymer for foaming", Polymer Testing, 104, 107398, 1-10, 2021.
• Wang L., Okada K., Hikima Y., Ohshima M., Sekiguchi T., Yano H., "Effect of cellulose nanofiber (CNF) surface treatment on cellular structures and mechanical properties of polypropylene/CNF nanocomposite foams via core-back foam injection molding", Polymers, 11, 2, 1–18, 2019.
• Bai T., Dong B., Xiao M., Liu H., Wang N., Wang Y., Wang C., Liu C., Cao W., Zhang J., Ma Y.,Guo Z., "Polystyrene Foam with High Cell Density and Small Cell Size by Compression-Injection Molding and Core Back Foaming Technique: Evolution of Cells in Cavity", Macromolecular Materials and Engineering, 303, 9,1–11, 2018.
• Wu H., Zhao G., Wang G., Zhang W., Li Y., "A new core-back foam injection molding method with chemical blowing agents", Materials and Design, 144, 331–342, 2018.
• Muñoz-Pascual S., Saiz-Arroyo C., Vananroye A., Moldenaers P., Rodriguez-Perez M. A., "Effect on the Impact Properties of Adding Long-Chain Branched Polypropylene in Polypropylene-Polyolefin Elastomer Cellular Polymers Produced by Core-Back Injection Molding", Macromolecular Materials and Engineering, 306, (2000728), 1–17, 2021.
• Jiang T., Zhang H., Zeng X., Zhang C., Gong W., He L., "The effect of injection process for microcellular foaming on the cell morphology and surface quality of Polyamide 6", Materials Research Express, 8, 4, 1-11, 2021.
• Ishikawa T., Ohshima M., "Visual observation and numerical studies of polymer foaming behavior of polypropylene/carbon dioxide system in a core-back injection molding process", Polymer Engineering & Science, 51, 8, 1617–1625, 2011.
• Wu H., Zhao G., Wang J., Wang G., Zhang W., "Effects of process parameters on core-back foam injection molding process", Express Polymer Letters, 13, 4, 390–405, 2019.
• Ruiz J. A. R., Vincent M., Agassant J-F, "Numerical Modeling of Bubble Growth in Microcellular Polypropylene Produced in a Core-Back Injection Process Using Chemical Blowing Agents", International Polymer Processing, 31, 1, 26–36, 2016.
• Park H. S., Anh D. B. H., "A new approach for molding multi component parts", International Journal of Precision Engineering and Manufacturing, 11, 2, 291–297, 2010.
• Ozunlu B. G., Guner F. S., "An Industrial Case for Polypropylene Nanocomposite Foams : Lightweight, Soundproof Exterior Automotive Parts", Polymers(Basel), 14, 1192, 1–19, 2022.
• Park J-M., Kim P-G., Jang J-H., Wang Z., Hwang B-S., DeVries K. L., "Interfacial evaluation and durability of modified Jute fibers/polypropylene (PP) composites using micromechanical test and acoustic emission", Composites Part B: Engineering, 39, 6, 1042–1061, 2008.
• Cho D., Seo J. M., Lee H.S , Cho C. W., Han S. O., Park W. H., "Property improvement of natural fiber-reinforced green composites by water treatment", Advanced Composite Materials: The Official Journal of the Japan Society of Composite Materials, 16, 4, 299–314, 2007.
• Hariprasad K., Ravichandran K., Jayaseelan V., Muthuramalingam T., "Acoustic and mechanical characterisation of polypropylene composites reinforced by natural fibres for automotive applications", Journal of Materials Research and Technology, 9, 6, 14029–14035, 2020.
• H S N., S S., Kakkeri S., R S., "Development and mechanical testing of natural fibre reinforced polypropylene resin hybrid composite", Advances in Materials and Processing Technologies, 8, 2, 790-801, 2021.
• Ladhari A., Kucukpinar E., Stoll H., Sängerlaub S., "Comparison of Properties with Relevance for the Automotive Sector in Mechanically Recycled and Virgin Polypropylene", Recycling, 6, 76, 1–11, 2021.
• Bunjes A., Arndt J., Geertz G., Barton B., "Characterization and chemometric modelling of mechanically recycled polypropylene for automotive manufacturing", Polymer, 249, 124823, 1–10, 2022.
• Kim D., Hikima Y., Ohshima M., "Millefeuille‐like cellular structures of biopolymer blend foams prepared by the foam injection molding technique", Journal of Applied Polymer Science, 139, 14, 1–14, 2022.
• Taki K., Menale M., Pisante G., Di Maio E., "A design tool for core‐back timing in foam injection molding", Journal of Applied Polymer Science, 139, 45, 1–10, 2022.
• Weng Z., Ren Q., Wu M., Zhu X., Li W., Wang L., Zheng W., "Lightweight and tough PVDF foams via high‐pressure foam injection molding with core‐back operation", Polymer Engineering & Science, 62, 11, 3543–3452, 2022.