Effect of Chemical Foaming Process Parameters on the Performance of Epoxy Foam and Parameter Optimization Strategies

Abstract

To prepare polymer foams with low-density and high-energy absorption efficiency, this study designs epoxy foaming experiments employing the Box–Behnken method and investigates the impact of process parameters on the microscopic geometric parameters and uniaxial compression response of foam. Finite element analysis models are created to investigate the microscale deformation mechanism. The main results are as follows: 1) The average equivalent cell diameter is significantly affected by foaming temperature and foaming agent content, while cell wall thickness is more influenced by the foaming agent content and the precuring time. 2) The compression response is most significantly affected by foaming temperature, followed by foaming agent content, with precuring time showing less significant influence. The differences in the stress–strain curves during various stages of deformation are due to the buckling of cell walls and the subsequent collapse of cells. 3) Density exhibits a highly positive correlation with strength and modulus while showing a relatively high negative correlation with energy absorption efficiency. Based on these findings, process parameters are optimized using the Hooke–Jeeves algorithm and experimentally validated, demonstrating the reliability of the optimization strategy. The experimental design and process parameter optimization strategy can be applied to other polymer foaming research.