OPTIMIZATION OF FABRICATION PARAMETERS OF POLYPROPYLEN COMPOSITE AND SILICA SAND POWDER USING MOLTEN MIXING METHOD

Abstract

The optimization of parameters in the screw extruder setup is crucial for enhancing productivity, quality, and cost-effectiveness in the production of final
products. In the manufacturing of Polypropylene (PP) thermoplastic with silica sand filler (BCSi), parameters such as temperature, heating time, and screw speed
are pivotal in determining the properties of PP/BCSi composite materials. This study focuses on evaluating the effectiveness of surface response analysis
methodology in experimental design, modeling, and optimizing manufacturing conditions for the properties of PP/BCSi composite materials. Parameters including
mixing temperature, mixing time, and screw speed have been carefully selected to optimize technological factors in material fabrication. Employing the surface
response methodology with Box-Behnken experimental design to optimize manufacturing conditions, Shore D hardness, impact strength, tensile strength, and
elongation at break serve as objective functions for the optimization process. Statistical modeling results indicate significant correlations, with corresponding high
coefficients of determination (R2
) of 0.9912, 0.9975, 0.9990 and 0.9981 for Shore D hardness, impact strength, tensile strength, and elongation at break,
respectively. Under the optimal conditions of PP/BCSi material fabrication at 190°C, mixing time of 5 minutes, and screw speed of 50 rounds per minute,
experimental objective function values align closely with predictions, with errors less than 5% for each response, indicating the suitability of experimental data
and theoretical models. From the research findings, it can be concluded that the surface response methodology with the Box-Behnken design is an effective
approach for determining the optimal conditions for manufacturing PP/BCSi composite materials.