Abstract
A numerical simulation for foaming a melted thermoplastic by extrusion process is conducted, where thermo-expandable microcapsules are used as a blowing agent. Firstly, a growth model for an encapsulated bubble is developed to match experimental results. Then, the growth model is used to numerically solve a 2D non-isothermal die-swell problem, making possible to simulate the extrusion foaming process. In particular, the model is able to predict the foaming location. Numerical results are compared with experimental data obtained by optical microscopy observations and density measurements on extruded samples. The effects of thermoplastic melt rheology on foaming and the die swell induced by foaming are also investigated. This simulation helps to estimate process parameters such as extrusion speed and to predict die swell and sample porosity in whole, to finally optimize the industrial process.
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