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ARS Home » Plains Area » Brookings, South Dakota » Integrated Cropping Systems Research » Research » Publications at this Location » Publication #199337
Title: PARAMETRIC SIMULATION OF INJECTION MOLDING PLASTIC COMPOSITES WITH BIO-BASED FILLERS

Author
item Rosentrater, Kurt
item VISSER, JERRY - SOUTH DAKOTA STATE UNIV

Submitted to: Meeting Proceedings
Publication Type: Proceedings
Publication Acceptance Date: 8/14/2006
Publication Date: 10/20/2006
Citation: Rosentrater, K.A., Visser, J. 2006. Parametric simulation of injection molding plastic composites with bio-based fillers. Meeting Proceedings for 2006 IJME/Intertech Conference, October 19-21, 2006, Union, NJ.

Interpretive Summary:

Technical Abstract: As the nation continues to demand greater supplies of energy, the fuel ethanol industry is poised to contribute substantial quantities of transportation fuel for the foreseeable future. Ethanol manufacturing from corn grain results in three main products: bioethanol, the primary end product; residual nonfermentable corn kernel components, which are typically sold as animal feed known as “distillers grains”; and carbon dioxide. The sale of distillers grains contributes substantially to the economic viability of each ethanol plant’s operations. This approach to utilization is well established, but must be augmented if it is to retain high-value returns as the generated quantities increase as the industry continues to grow throughout the nation. Thus other novel applications must also be pursued. Based on our laboratory investigations, it appears that these residues have much potential for manufacturing into various bio-based products, especially composites. Before they can be successfully used commercially, the compatibility of thermoplastics and bio-based fillers must first be examined. Additionally, appropriate methods of manufacture must be determined and optimized, because inclusion of biological materials can produce very unique processing conditions and final product behavior. Thus the objective of this study was to simulate the processing behavior of a plastic filled with a biological material, such as distillers grains, when subjected to injection molding. Simulations were conducted to determine the effects of parametrically altering the thermal, rheological, and physical properties of polypropylene, to simulate the inclusion of a biofiller. Injection mold filling, cooling, and final quality were predicted for each of the treatments under investigation. This study represents an initial step in an initiative to utilize biofillers in plastic composites. Thus the information generated here will be essential for further efforts to utilize biological materials, such as distillers grains, in manufactured products, as this utilization avenue has potential for high-value returns which are much greater than currently available as livestock feed alone.