A STUDY ON THE ABRASION RESISTANCE ......carried out on natural rubber- coconut fibre composites,...

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International Journal of Advanced Research in Engineering and Technology

(IJARET) Volume 7, Issue 3, May–June 2016, pp. 42–55, Article ID: IJARET_07_03_004

Available online at

http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=7&IType=3

ISSN Print: 0976-6480 and ISSN Online: 0976-6499

© IAEME Publication

A STUDY ON THE ABRASION

RESISTANCE, COMPRESSIVE STRENGTH

AND HARDNESS OF BANANA– FIBRE

REINFORCED NATURAL RUBBER

COMPOSITES

R. Gopa Kumar and Dr R. Rajesh

Noorul Islam University,

Kanyakumari, Tamil Nadu, India

ABSTRACT

The abundance of natural fibres, particularly banana fibres in India as an

agricultural waste and the good properties offered by them like tensile

strength, wear resistance, hardness, bio-degradability and eco-friendliness

make it a good substitute to the non-biodegradable, toxic and costly synthetic

fibres in many engineering applications. India is a lead producer of Banana

fibre. The main challenge faced by researchers in the development of natural

fibre composites is the attainment of a good interfacial bonding, so as to

transfer the load effectively from matrix to fibre. To achieve the desired level

of fibre-matrix interphase strength, the fibres are given four different surface

treatments- alkalization, benzoylation, permanganate treatment and fibre

surface impregnation with rubber. The pretreatment of fibres and the

composite manufacturing process has a great influence on the properties of

banana fibre reinforced elastomer composites. In this work composites are

made of short (6mm) banana fibre in the natural rubber matrix, with a 30%

v/v fibre content. Banana fibre and natural rubber are selected for our work,

because of their abundance of natural resources in India and their total

environment friendliness. The composites are prepared using compression

moulding at 150°C and the specimens obtained evaluated for their mechanical

properties like compression, abrasion resistance and hardness. Six specimens

are made and they are subjected to various mechanical tests to study the effect

of the different fibre surface treatments.

Abrasion resistance is best for the composite with untreated fibre

reinforcement followed by alkali-permanganate treated fibre composites. Best

hardness value obtained for rubber composite with impregnated fibre followed

by untreated fibre composite. This work establishes improvements in

mechanical properties by the alkalization and other surface treatments of

cellulose filler used as reinforcing material for natural rubber.

A Study on the Abrasion resistance, Compressive strength and Hardness of Banana–Fibre

Reinforced Natural Rubber Composites


Key words: Alkalisation; Pre-impregnation; Banana fibre; Natural fibre;

Compression set; Hardness; Abrasion.

Cite this article: R. Gopa Kumar and Dr R. Rajesh. A Study on the Abrasion

resistance, Compressive strength and Hardness of Banana–Fibre Reinforced

Natural Rubber Composites. International Journal of Advanced Research in

Engineering and Technology, 7(3), 2016, pp 42–55

http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=7&IType=3

1. INTRODUCTION

The birthplace of natural rubber is Central America but is cultivated mainly in

Southeast Asia, in India, Malaysia, and Indonesia. The interest in natural fibres is

growing globally as a cheap, abundant and eco-friendly alternative to the toxic, non-

biodegradable and expensive synthetic fibres [1]. Many lignocelluloses fibres like

banana, sisal, bamboo, hemp etc., are more and more applied as reinforcement of

composites [2]. Natural fibres such as jute, hemp, sisal, pineapple, abaca and coir

have been studied as reinforcement and filler in composites [3]. Abundance of banana

fibre and its excellent tensile properties makes it a good choice for reinforcement in

composites. The aim of our work is to develop an eco-friendly, economical and useful

elastomer composite by using natural materials only- with natural rubber as matrix

and banana fibre as reinforcement. This should have good wear resistance,

compressive strength and hardness. Such a material can find a lot of applications in

modern industries, consumer articles and load bearing bushes etc.

2. LITERATURE SURVEY

Composites are formed by combining materials together to form an overall structure

that is better than the sum of the individual components. The new material can be

stronger, lighter or less expensive when compared to traditional materials.

A lot of research has been done in the field of fibre reinforced elastomer

composites. Researchers have studied the effect of different fibres’ in natural and

synthetic rubber [4].

Wear of rubber and its components is of great importance because rubber parts are

widely used in different engineering applications. The wear resistance may be defined

as the resistance to wearing away by rubbing or sliding the surface against abrasives

materials, resulting in materials removal. Rubber composite applications in

compressive and abrasion loadings are limited by incomplete understanding of their

abrasion resistance and the means by which it can be controlled and improved. A

number of studies on polymer matrix composites subjected to sliding and abrasive

war indicated that wear resistance depends on the properties of the materials as well

as on the external wear conditions such as applied pressure and contact velocity [5-

8].The right combination of polymers, rubber chemicals and reinforcing filler systems

can change their performance[9]. For most of these researches petroleum - based

resources have been used, however, they are non- biodegradable and their disposal

contribute to many environmental problems. This motivated research to develop

biodegradable materials [10].The investigation of physical- mechanical properties

carried out on natural rubber- coconut fibre composites, showed that coconut fibre is

potential reinforcing filler for natural rubber compounds. In addition, palm kernel

husk was also found to be potential reinforcing filler for natural rubber compounds

[11]. Previous work also indicated that the use of lignocellulosic fibres as fillers can



improve the properties of polymers. The aim of this research work is to explore the

possibilities of banana cellulose fibres as potential reinforcement in natural rubber.

The most important parameters that effect the fibre reinforcement are fibre dispersion,

fibre orientation and adhesion between the fibre and matrix [12]. Natural fibres have

advantages over synthetic fibres because of their renewable nature, low cost,

biodegradability and ease of chemical modification [13] and currently find

applications in automobile and building industries.

The Characteristics and properties of fillers which are imparted to a rubber

compound are particle size, particle shape, surface area and surface activity. Surface

activity relates to the compatibility of the filler with a specific elastomer and the

ability of the elastomer to adhere to the filler [5]. Fillers have been used to colour,

reinforce, extend and cheapen compounds. Two major classes are used: particulate

and fibres .Parameters affecting composite properties are fibre properties, matrix

properties, modifier properties, fibre volume content, curing conditions of resins and

process parameters (pressure, temperature, cure time etc).

For a continuous fibre reinforced composite, the fibre content and modulus in

composites is governed by the Rule of mixture (ROM) :E- EfVf+EmVm where Ef,

Vf, Em and Vm are the moduli and volume fractions of the fiber and matrix

respectively, when the load is applied along the fibre direction. This is not applicable

to a randomly oriented short fibre reinforced composites.

2.1. Banana Fibre

Bilba et al. determined the chemical composition of banana pseudostem by elemental

analysis and the results are cellulose-14-17% and lignin 15-16% [14]. Dynamic and

Mechanical behaviour of banana -glass hybrid fibre reinforced polyester composites

were studied by Pothan et al. [15]; Reinforcing efficiency of natural fibre is depends

on upon the nature of cellulose and its crystallinity [16]. Components which are

present in natural fibres are cellulose hemicelluloses, lignin, pectin and waxes.

Cellulose is a natural polymer consisting of Danhydroglucose repeating units [17].

Hemicellulose is different from cellulose. It comprises a group of polysaccharides.

Lignin is a complex hydrocarbon polymer with both aliphatic and aromatic

constituents and it is totally insoluble in most of the solvents and can't be broken

down into monomeric units. It is totally amorphous and hydrophobic in nature. It is

not hydrolyzed by acids, but soluble in hot alkali, readily oxidised and easily

condensable with phenol [18, 19, and 20].Lignin is considered to be a thermoplastic

polymer having a glass transition temperature of around 90°C and melting

temperature of around 170°C [21].




Table 1 Banana Fibre Properties.

Properties Fibre

Cellulose (%) 63-64

Micro fibril angle 11

Hemi cellulose 6-19

Lignin (%) 5-10

Moisture content (%) 10-11

Density (kg/cm³) 1350

Lumen size (mm) 5

Tensile strength (MPa) 529-914

Young’s modulus (GPa) 27-32

Figure 1 SEM of an untreated banana fibre [22].

Natural fibres, often referred to as vegetable fibres, are extracted from plants and

are classified into three categories, depending on the part of the plant they are

extracted from like Fruit fibres: extracted from the fruits of the plant, they are light

and hairy, and allow the wind to carry the seeds (coconut Fibres). Bast fibres: are

found in the stems of the plant providing the plant with its strength, they run across

the entire length of the stem and are therefore very long (banana fibre). Leaf fibres:

extracted from the leaves, are rough and sturdy and form part of the plant

transportation system (sisal fibres).

Figure 2 Cellulose fibre ingredients (a) cellulose (b) hemicelluloses (c) lignin [23]



Figure 3 Natural fibre Cell [23]

2.2. Natural Rubber (NR).

Natural rubber is a linear polymer of an unsaturated called isoprene (2-methyl

butadiene).there may be as many 11,000 to 20, 0000 isoprene units in a polymer chain

of natural rubber. Natural rubber is the prototype of all elastomers and is a major

produce of India. NR is an elastomer and a thermoplastic. On vulcanization, it turns

into a thermoset. It is extracted from the latex of a tree, the Hevea braziliensis. It has a

density of 0.93 at 20°C, and has a very uniform microstructure that provides the

material with some very unique and important characteristics, namely the ability to

crystallise under strain, a phenomenon known as strain-induced crystallisation, and

has a very low hysteresis. The final properties of a rubber product depends on the

polymer and also on the modifiers used like reinforcing fibres, filler powders etc [21].

Table 2 Natural Rubber

Sl No. Natural Rubber %

1 Hydrocarbon 93.3

2 Acetone extract 2.9

3 Protein 2.8

4 Moisture 0.6

5 Ash 0.4

Natural Rubber NR

Polyisoprene IR

3. MATERIALS

ISNR20 a moderate grade natural rubber obtained from Silverstone rubbers,

Trivandrum. A density for the NR of 1g/cm 3 is determined, Banana fibres with an

average diameter of 80±2 microns, approximately, are used in the form of short fibres




(6 mm long) are collected from Tirunelveli. Sodium Hydroxide, Toluene, Potassium

permanganate, benzyl chloride Acetone from Trivandrum.

4. EXPERIMENTAL PROCEDURES

4.1 Fibre surface treatments

4.1.1. Alkalisation

The fibres are treated with aqueous solution (4% w/v) for 4 hrs at 30°C keeping the

fibre: water ratio 1:30. They are then washed with distilled water until all the sodium

hydroxide is eliminated. Dilute acetic acid is added to it to neutralise any alkali

residue in the fibres. Subsequently, the fibres are dried at 30°C for 24hrs and then at

60°C for 5hrs.

Fibre-OH + NaOH→Fiber-O⁻Na⁺ +H₂O

Figure 4 (i)Untreated&(ii)alkalised banana fiber [23]

Figure 5 NaOH treated fibers.

4.1.2. Benzoylation

The hydroxyl groups of the cellulose and lignin in the banana fibre is initially

activated by alkaline pre-treatment. Fibres are then suspended in 10% NaOH and

Benzyl chloride (C6H5COCl) solution for 15miniutes. The fibres are then removed

from the solution and soaked in ethanol for 1hr. to remove the benzyl chloride and

finally was washed with water and dried at 30°C for 24hrs. and then at 30°C for 24hrs

and then at 60°C for 5hrs.



4.1.3. Potassium permanganate treatment of alkalized fibres

The procedure involved a 4% alkaline treated fibre soaked in 0.2% potassium

permanganate solution (in 2% acetone) for 3minutes. The fibres then are taken out

and dried at 30°C for 24hrs and at 60°C for 5hrs.

4.1.4. Surface pre-impregnation with a natural rubber dilute solution

The banana fibres are impregnated with a 1.5% w/w NR-Toluene solution. Rubber in

particulate form is dissolved in toluene at 80°C in a steel vessel by continuous

stirring. The natural fibres are immersed in the hot solution and stirred continuously

for 1hr. Bunches of fibres are then transferred to a flat plate and dried at 30°C for

24hrs for complete solvent evaporation. The impregnated fibres are disposed before

mixing them with the matrix.

4.2. Composite processing

A 30% v/v fibre content natural rubber/banana fibre composite is chosen to determine

the effect of the different fibre surface treatments on the composite mechanical

properties. The banana fibres are mixed with the rubber in a laboratory model two roll

rubber mill. The mixing process was performed in a sequential order. One-half of the

rubber is placed in the two roll rubber mill for about 10minutes; the banana fibres are

added then over a period of 5minutes. The other half of rubber is then fed into the two

roll mill and mixed for 10minutes. The total mixing time is 25minutes. The resulting

material is compression moulded at a pressure of 2Ton using a Carver laboratory

press at a temperature of 150°C for about 10minutes. The specimens for the

mechanical tests were obtained from the according to ASTM standards.




Figure 6 Mould for Compression set

4.2.1. Compounding

The compounding recipe for the natural rubber composites is given the table below.

Mixing is carried out on a laboratory two roll mill in accordance with the method

described in ASTM-D3184-80. Cured samples produced on the electrically heated

press at 150°C for 10 minutes at a pressure of 2Ton.

Table 3 Compounding recipe

Sl No. Material Phr

1

2

3

4

5

6

Natural Rubber

Stearic acid

Zinc oxide

MBT

Sulphur

Banana Fibre

100

0.2

5

0.5

3

30% v/v

4.3. Mechanical Properties

4.3.1. Abrasive wear test

Two body abrasive wear tests were conducted on a pin-on-drum abrasive wear tester,

designed for standard wear tests described in ASTM standard D5963-97a. In this

method, the test specimen translates over the surface of an abrasive paper, which is

mounted on a revolving drum. The resulting wear of material expressed as volume

loss [24]. The test setup is schematically illustrated in Figure.7.

An alumina (Al₂O₃) abrasive which is substantially harder than the matrix and the

reinforcement is used. The pin specimen, 0.95mm diameter and 20mm long is placed

on the top of the drum. The drum 150 mm diameter rotates at 25rpm resulting in a

tangential velocity of 0.2m/s. While the drum is rotating, the specimens translated at a

speed of 4.2mm per revolution along the axis of rotation. Thus, the specimen is in

continuous contact with the abrasive drum surface. A static normal load L is applied

directly on the specimen to press it against the drum centre, its magnitude is varied

from 1to 5N. The sliding distance is set as 50cm for the entire tests. All tests are

carried out in dry ambient laboratory conditions.



Figure 7 Drum type Abarder

A counter records the number of revolutions. Since the relative size of the

reinforcement is small in particulate reinforced composites, the effect of the

interfacial toughness on the wear rate can be significant. For example, when the

interface is weak, the reinforcement can be readily removed during abrasive wear

situations, such that a negative reinforcement effect is observed.

To estimate the abrasion resistance, wear rate could be computed by using the

following equation:

Kc = Δm/ (ρc.Vc.T).

Where

Δm = m₁-m₂

m₁ = Weight of specimen before test (g).

m₂ = Weight of specimen after test (g).

ρc = density of the specimen (g/mm).

Vs =sliding speed (mm/s).

T = sliding time.

4.3.2. Compressive strength

The ability of a material to resist breaking under compressive stress is an important

property of materials and used in engineering applications. The value of the uniaxial

compressive strength reached when the material fails completely is designed as the

compressive strength of that material. The compressive strength is usually obtained

experimentally by means of a compressive set.

Compressive strength is determined by finding compression set for the specimens.

Cylindrical samples are used for the purpose. The equipment is shown in the figure.

The differences between the original and the deformed heights obtained after keeping

the samples for 24hrs under a constant load of 80kg.

Compression Set = [(Original length- Deformed length)/ Original length] x 100

%.

4.3.3. Hardness test

The hardness of the cured composites is measured in Shore A; using Durometer,

model 5019. The measurement is accordance with ASTM-D2240.

5. RESULTS AND DISCUSSIONS

The alkali treatment removed the pectin, wax, oil and other soluble carbohydrates like

hemicelluloses etc., leaving only alkali resistant cellulose. This exposes the hydroxyl

groups of the fibre and increases bonding sites in the fibre interface.




Table 4 Test results

Specim

en No. Nomenclature

Hardness

(Shore A)

Relative

Abrasion

(mm³)

Compressi

on Set (%)

1 Rubber only 25 - -

2 Alkalised fib. Comp. 52 410.62 12.5

3 Benzoylated fib comp. 39 489.94 12

4 Permanganate fib comp. 42 306.55 12

5 Impreg. fib comp. 62 310.07 15.11

6 Untreated fib comp. 61 253.69 7.17

5.1. Wear resistance

It is a common practice to increase the wear resistance of elastomers by adding fibres

and fillers to the elastomer matrix. The theory is that the sliding of the abrasive on

solid surface results in volume removal and the wear mechanism depends on the

hardness of a material. The presence of hard and inelastic fibres in a composite

increase the effective hardness of the composite which acts to reduce the amount of

material removal [26].

The results (Fig.8) shows that the rubber reinforced with untreated fibre has a

lower wear rate (higher abrasion resistance) followed by rubber filled with alkali-

potassium permanganate treated fibres. This may be due to the high level of rigidity

offered by the dry-untreated raw banana fibre embedded in the rubber matrix.

Mechanical properties of the reinforcement (Banana fibres) are harder than rubber in

nature. Due to this stiffness and rigidity offered by the untreated fibre along with the

fibre-matrix bonding, a higher abrasion resistance is offered by the composite.

Figure 8 Abrasion Resistance

0

100

200

300

400

500

Relative Abrasion (mm³)

Relative Abrasion (mm³)



In the case of permanganate composite, the better fibre-matrix mechanical and

chemical interlocking is the reason for the good abrasion resistance offered. In other

cases, a low wear resistance is observed compared to the previous samples due to the

failure at the matrix-reinforcement interface or in the reinforcement itself.

Furthermore, two distinct wear mechanisms can be seen operating on the

composite surface. In some areas, fatigue failure associated with micro cracking is

clearly observed, whereas in other areas micro cutting is observed. The micro

cracking areas can be associated with hard fibre rich regions.

5.2. Compressive strength

From the compression set graph (Fig.9), it can be seen that the least compression set

value is for untreated fibre-rubber composite. Only a deformation of 7.17% from the

original length, exhibiting a maximum compressive strength. This is due to the high

level of stiffness and rigidity offered by the raw fibre and their resistance to

deformation and bending, thus giving the composite a high level of hardness. Banana

fibres have less elasticity and higher rigidity than the matrix rubber. Other samples

didn’t show any significant improvement in compressive strength.

Figure 9 Compression Set

5.3. Hardness

The hardness results of the different samples are shown in Figure 10. The maximum

hardness is obtained for the rubber impregnated fibres. An improvement of 148%

compared to rubber composite without reinforcement. This is due to the better and

rich fibre-rubber interphase and hence a close packing of the material. This is in line

with the reduced elasticity as a result of the reinforcement in the molecules. This

increase in rigidity decreases the elasticity of the virgin rubber. The next better

hardness is shown is shown by rubber reinforced with untreated fibre. This is because

of the fact that untreated banana fibre has more rigidity than the chemically treated

other samples.

0 2 4 6 8

10 12 14 16

Compression Set (%)

Compression Set (%)




Figure 10 Hardness

Banana fibres have large surface area, which can form a strong physical bond with

the rubber matrix. Composites with strong bonds make it harder by impeding matrix

motion along the stress direction.

6. MANAGERIAL IMPLICATIONS

Wear of rubber and its components is of great importance because rubber parts are

wi9dely used in a lot of engineering applications. But their industrial applications are

limited by incomplete understanding of their abrasion resistance and the methods by

which this can be controlled and improved.

Enhanced properties of rubber-like, hardness, wear resistance and compressive

strength finds applications in the development of products like load bearing bushes in

automobiles, aerospace, vibration damping devices etc.

7. CONCLUSION

Four different treatments (alkali, permanganate, benzoylation and fibre impregnation

with rubber) are carried out on Banana cellulose fibre and the treated, as well as

untreated fibres are used for the making of natural rubber composites. The effect of

different fibre treatments on the hardness, wear and compressive strength of rubber

are analysed. The mechanical properties such as wear resistance, compressive strength

and hardness of composites are found to increase with an increase in better interphase

properties. These results suggest that Banana fibre has immense potential in the

making of natural fibre reinforced rubber composites. Such a material can find a lot of

engineering and industrial applications.

The use of banana fibres as filler for natural rubber is of economical value and

their consumption as filler would help in the disposal of agricultural waste. The

hardness of rubber composites increases with the better interfacial bonding of

reinforcing fibres and reaches a maximum value (62 Shore A) for rubber composite

reinforced with rubber impregnated fibre. The hardness of this composite is higher

than that of alkalized fibre at the same fibre v/v and loading level. The wear rate

decreased with the surface modification of reinforcing fibres and better fibre-matrix

interfacial bonding.

0 10 20 30 40 50 60 70

Hardness Shore A

Hardness Shore A



ACKNOWLEDGEMENTS

The authors would like to express the support given by the Department of Mechanical

Engineering, Noorul Islam University, Thuckalai, TN.,India.

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