The aim of the research was to examine the behaviour of porous polystyrene during grinding realised in a knife grinder. The assessment of the porous structure influence on the effectiveness of polystyrene disintegration was conducted in relation to previously obtained results of knife cutting realised at the same research site. These unquestionable advantages have caused that even over 1*106 kg of thermoplastic material includes in its structure the gas phase. The observed trend results from the tendency aiming to obtain plastic parts of light structures that may be used as construction materials. Due to the complex polymer-gaseous structure of porous materials, their mechanical recycling requires adapting special, different from typical for solid materials, cutting and grinding conditions. The behaviour of polymer materials under applied load is tightly connected with their structure. Earlier process analysis indicates that together with the cutting velocity increase, the impact cracking ratio in the material division increases. As a result of the conducted research, polystyrene recyclate was obtained, which might be reused in re-processing for new product production. Polystyrene porous structure is conductive to effective grinding, which is characterised by low energy consumption for grinding and high effectiveness in relation to the grinding degree.
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