Using foamed polypropylene to reduce weight and injection moulding cycle time in toyota ch-r suv door panel production

Abstract

In recent years, new technologies that encourage the use of cheaper and less raw materials have emerged in the automotive industry, with the increase in raw material costs because of the consumption of natural raw material resources and the occurrence of environmental problems. This study aimed to lighten the door panel and reduce the injection cycle time by using foam in the door panel production of the Toyota CH-R model car. Injection parameters such as barrel temperature, injection speed, injection back pressure, holding pressure and holding time were changed. 1%, 1.5% and 2% by weight chemical foaming agent (CFA) were added to the polypropylene (PP) matrix. Approximately 4% lightening and 5.5 sec/shot injection cycle time reduction was achieved using foaming agents. Also, it was observed that cell morphologies, mechanical properties and sample weights changed due to changes in parameters and CFA ratio by weight.