Optimization of process parameters during flax and polypropylene composite manufacturing using Box-Behnken design of experiments

Abstract

Composites produced from recyclable polymers are of greater scope in the industrial sector owing to their better quality, sustainability, and environmental considerations. In this study, flax fibre utilized as reinforcement and polypropylene fibre used as a matrix were used for producing thermoplastic composites. Flax/polypropylene needle punched non-woven was performed by a compression moulding process. Process parameters, temperature, time, and pressure were selected to optimize the flax/polypropylene (PP) production process using Box- Behnken Experimental Design (BBD) and response surface methodology. The effects of the process parameters on the material's tensile, flexural, and short beam shear strengths were studied. Furthermore, the research parameters were used to analyze of variance (ANOVA) and regression models for estimating the mechanical properties. Also, Scanning Electron Microscope (SEM) analyses were performed on the composites to study the surface morphologies in composites. The findings revealed that temperature was the ultimate cause influencing the mechanical properties, followed by pressure and time. Surface morphologies confirm the better bonding between the flax fibres and PP matrix. This work shall effectively choose the ideal values of process parameters for producing natural fibre-reinforced thermoplastic composites.