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SYNOPSIS
M.Tech.(Machine Design)
Submitted to
Visvesvaraya Technological University, Belagaum
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Title of the project : ANALYSIS AND CHARACTERIZATION OF HYBRID
COMPOSITES
Name of the student : Hemanth K, 4thsem
M.Tech (Machine Design)
N.C.E.T, Bangalore
University seat number : 1NC10MMD76
Name of the guide : (1) Internal guide: Dr.Keerthi Prasad K.S
Professor Department of Mechanical Engineering
N.C.E.T, Bangalore.
(2) External guide: Mr.Ravikumar M
Lecture in Mechanical Engineering Department
SJCIT, Chickaballapura
Place of work : (1).Nagarjuna College of Engineering and Technology
Mudgurki Venkatagiri kote post, Devanahalli Taluk.
(2).BGS R&D Center, SJCIT, Chickaballapura
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SYNOPSIS
Over the last thirty years composite materials, plastics and ceramics have been the
dominant emerging materials. The volume and number of applications of composite materials
have grown steadily, penetrating and conquering new markets relentlessly. Modern composite
materials constitute a significant proportion of the engineered materials market ranging from
everyday products to sophisticated niche applications. There has been an expanding search for
new material with high performance at affordable costs in recent years. With growing
environmental awareness, this search is particularly focused on eco-friendly materials. Generally
composite is one which is light weight and high strength. The fibers which are currently used in
commercial hybrid composites combinations are glass, sisal, hemp, aramid, boron, carbon and
Kevlar.
The various properties of hybrid composite made of synthetic fiber and natural fibers
have been extensively studied. The main focus of this study will be development of hybrid
composites using glass and hemp fiber made of hand lay-up process. The developed hybrid
composites will subject to physical and mechanical properties using standard procedure.
The most widely used reinforcement is synthetic fiber (Glass fiber) because of its low
cost, high tensile strength and impact strength, light weight and good corrosion resistance. In
addition, glass is eco-friendly, glass as reinforcement has proved its immense potential in
numerous composites. A combination of low density hemp and high stiffness glass is expected to
bring numerous advantages in composite. Very limited work has been reported on mechanical
and environmental properties of hybrid composite made of hemp and glass fiber as composite
with epoxy as matrix.
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INTRODUCTION
Composite Materials
Over the last thirty years composite materials, plastics and ceramics have been the
dominant emerging materials. The volume and number of applications of composite materials
have grown steadily, penetrating and conquering new markets relentlessly. Modern composite
materials constitute a significant proportion of the engineered materials market ranging from
everyday products to sophisticated niche applications. While composites have already proven
their worth as weight-saving materials, the current challenge is to make them cost effective. The
efforts to produce economically attractive composite components have resulted in several
innovative manufacturing techniques currently being used in the composites industry. It is
obvious, especially for composites, that the improvement in manufacturing technology alone is
not enough to overcome the cost hurdle. It is essential that there be an integrated effort in design,
material, process, tooling, quality assurance, manufacturing, and even program management for
composites to become competitive with metals.
A composite material can be defined as the material that is obtained by judicial
combining of two or more dissimilar materials, having different physical and electrical
properties, in such a way that the resultant material properties are superior to any of the parental
one. Composites are usually made of two phases-one is reinforcement phase and other is matrix
phase.
Composites are usually made of two phases-one is reinforcement phase and other is
matrix phase. Development of new composites and new applications of composites is
accelerating due to the requirement of materials with unusual combination of properties that
cannot be met by the conventional monolithic materials. Actually, composite materials are
capable of covering this requirement in all means because of their heterogeneous nature.
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Properties of composites arise as a function of its constituent materials, their distribution, and the
interaction among them and as a result an unusual combination of material properties can be
obtained.
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Objectives:
Study the merits and demerits of extending hybrid composite commercially available inmarket.
Preparation of new hybrid composite using natural fiber and synthetic fiber as rawmaterial with commercially available epoxy matrix for few volume fraction of
reinforcement.
To evaluate the mechanical properties of hybrid composite. Analysis of hybrid composite using software.
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LITERATURE REVIEW
Types of fibers
Fibers are class of hair-like materials that are in discrete elongated pieces, similar to pieces of
thread (Natural, 2007). They can be spun into filaments, thread or rope. They can be used as a
component of composite materials. Fiber can be classified in to two main groups, which are
man-made fiber and natural fiber. In general, natural fibers can be subdivided as to their origin
such as plants, animals, or minerals; while man-made fibers can be subdivided to synthetic and
natural polymers.
The first fibers used by man were natural fibers such as cotton, wool, silk, flax, hemp and sisal.
The first man-made fiber was probably glass (Cooke, 1989). Both natural and synthetic fibers
(commonly known as man-made fibers) are now available and always being used as fillers in
making a good properties of composites. The major fibers used till now can be classified into the
groups given in Figure
Classification of Fibers (Cooke, 1989)
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Reinforcing fibers in a single-layer composite may be short or long compared to its overall
dimensions.The long fibers and short fibers are called continuous fibers and discontinuous fibers,
respectively (Agarwal and Broutman, 1990). The continuous fibers in a single-layer composite
may be all aligned in one direction to form a unidirectional composite. The unidirectional
composites are very strong in the fiber direction but are generally weak in the direction
perpendicular to the fibers. The continuous reinforcement in a single layer may also be provided
in a second direction to provide more balanced properties [1].
Synthetic fibers
Synthetic fibers are the result of extensive research by scientists to improve upon naturally
occurring animal and plant fibers used in making cloth and rope (Synthetic, 2007). A large
number of synthetic fibers with a variety of properties have been produced from polymers by
various spinning techniques, including melt, dry, wet and emulsion spinning. Before synthetic
fibers were developed, artificial (manufactured) fibers were made from cellulose, which comes
from plants. At the beginning of the twentieth century, synthetic fibers started supplementing and
replacing natural fibers. The first trulysynthetic fiber was nylon, followed by polyesters,
polyacrylics and polyolefins. Also synthetic elastomeric, glass and aramid fibers became
important commercial products (Cooke, 1989).
Synthetic fibers are now available, ranging in properties from the high-elongation and
low-modulus elastomeric fibers, through the medium-elongation and medium-modulus fibers
such as polyamides and polyesters, to the low-elongation, high-modulus carbon, aramid and
inorganic fibers (Hannant, 1989). With such a wide variety of synthetic fibers available, the
volume of synthetic fibers consumed in worldwide is now greater than that of natural fibers.
Most synthetic fibers have relatively smooth surfaces and they are frequently subjected to
various mechanical and heat-setting processes to provide crimp (Cooke, 1989).
The modern synthetic fiber that was made from older artificial materials and become the most
common of all reinforcing fibers for polymer matrix composites is glass fiber (Agarwal and
Broutman, 1990). Glass fiber is the dominant fiber and is used in 95 % of cases to reinforce
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thermoplastic and thermoset composites (Mohanty et al., 2005). The principal advantages of
glass fibers are low cost and high strength compared with others synthetic fibers. The
disadvantages are low modulus and poor adhesion to Polymer matrix resins, particularly in the
presence of moisture.
Natural fibers
Natural fibers are subdivided based on their origins, for example vegetable/plants, animals, or
minerals. Vegetable or plant fibers include bast or stem fibers, leaf or hard fibers, seed, fruit,
wood, cereal straw and other grass fibers (Alexander et al., 2005). According to Jeronimidis
(1989), plants can stand up because of cellulose and lignin. Structural materialsin animals are
mainly made of proteins such as collagen, elastin and keratin in combination with various
polysaccharides, calcium minerals (in bone and teeth) or complex phenolic compounds (in hard
insect cuticles). Mineral fibers are naturally occurring fiber or slightly modified fiber procured
from minerals. Mineral fibers such as asbestos fibers had been used historically for insulating
houses. However, since January 1997, to provide protection of workers and consumers, the
manufacture and transformation of asbestos fibers became forbidden (Bilba et al., 2007).
Mechanical properties of natural fibers
The mechanical properties and physical properties of natural fi bers vary considerably
depending on the chemical and structural composition, fi ber type and growth conditions.
Mechanical properties [2] of plant fibers are much lower when compared to those of the most
widely used competing reinforcing glass fibers. However, because of their low density, the
specifi c properties (property-to-density ratio), strength, and stiffness of plant fibers are
comparable to the values of glass fibers [7].
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FABRICATION OF COMPOSITE
Basic Raw materials
1. Reinforcing material2. Matrix material
REINFORCEMENTS
These are fibrous materials, when introduced into polymer matrix produce a dramatic
improvement in physical properties of a composite. Reinforcement improves overall mechanical
properties of the matrix. The reinforcing filler usually takes the form of fiber but particles (for
e.g. Glass spheres) are also used. A wide range of amorphous and crystalline materials can be
used as reinforcing fibers. These include glass, carbon, boron and silicon. In recent years, fibers
have been produced from synthetic polymers for e.g. Kevlar fibers Glass in the form of fibers is
relatively inexpensive and is the principal form of reinforcement used in plastics. Drawing of
continuous stands of glass from an orifice in the base of an electrically heated platinum crucible,
which contains molten glass, produces the fibers. The earliest successful glass reinforcement had
a calcium-alumina borosilicate composition developed specifically for insulation purpose (E-
glass).
The use of reinforcement fibers can result in the following changes.
Increase in modulus of elasticity and stiffness Lower shrinkage Low temperature dependency of mechanical and physical properties Increase in tensile, compressive and flexural strength.
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Fiber reinforced composites
Glass fiber
Fiberglass or glass fiber is material made from extremely fine fibers of glass. It is used as
a reinforcing agent for many polymer products, the resulting composite material, properly known
as Fiber-Reinforced Polymer (FRP) or Glass-Reinforced plastic (GRP), is called fiberglass in
popular usage. Fiberglass is shown in fig. 2.3.
Glass fiber
Unidirectional Bi-directional
Discontinuous FiberWoven
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Hemp fiber
Hemp fiber is one of the important lignocellulosic bast fiber and has been used as
reinforcement for industrial applications. It is one of the inexpensive and readily available best
natural fibers and hemp-fiber reinforced polymer composite products have gained considerable
attraction for automotive interior products.
Hemp Fiber
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MATRIX
The matrix is the material that gives body and grips or holds the reinforcements of the
composites together, and is usually of lower strength than the reinforcement. The matrix must be
capable of being forced around the reinforcement during some state in manufacture of
composite. Typically, composite material is formed by reinforcing fibers in matrix resin is shown
in fig Resign is organic polymer used as a matrix to contain fibrous reinforcement in composite
material or as an adhesive.
Formation of composite material using fibers and resin
The purpose of matrix is to provide:
Load transfer to fibers Dimensional stability Fiber support Protection Good surface finish quality
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Lapox L-12(Epoxy)
Lapox L-12 is a liquid, unmodified epoxy resin of medium viscosity which can be used
with various hardeners for making reinforced composite and laminates. The choice of hardener
depends upon the processing method to be used and on the properties required of the cured
composite.
Hardener K-6
Hardener K-6 is a low viscosity room temperature curing aliphatic amine curing agent. It
is commonly employed for civil engineering system where low viscosity and fast setting at
ambient temperature is desired.
3.5.3 Typical Properties
Epoxy Resin( Lapox L-12)
Appearance ------- Clear pale yellow liquid
Epoxy Value eq/kg 5.25-5.4
Hydrolysable chlorine % .1max
Viscosity at 25
mPas 10,000-12,000
Volatile content % .55max
Hardener K-6
Appearance -------- Clear pale yellow liquid
Viscosity at 250
mPas 10-23
Refractive Index 1.4940-1.5000
Water content % 1max
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FABRICATION BY HAND LAY-UP TECHNIQUE
In this process resins are impregnated by hand into fibers which are in the form of woven
or bonded fabrics. Hand layup process usually accomplished by rollers or brushes.
The composite plates from which the test specimens were fabricated by employing the
traditional Hand layup technique. This is a very popular method of composite fabrication, limited
by its ability to produce simple shapes.
Initially, a plate consisting of epoxy resin with glass and hemp fiber reinforcement was
fabricated. The plate was made up of 55% fiber and 45% Resin by weight.
FABRICATION STEPS:
1) The bottom slab of the mould (granite slabs) is thoroughly cleaned with acetone andrelease film is spread on it.
2) Initially, a plate consisting of Epoxy resin with glass and hemp fiber reinforcement isfabricated. This plate consists of 55% glass and hemp fiber and 45% epoxy by
weight.
3) The initial material preparation includes getting the glass and hemp fabric cut to thedesired size.
4) The weight of fabrics is determined, in accordance with which the quantity of resinto be used is decided in such a way that the final plate is made up of 45% resin and
55% reinforcement by weight
5) The resin is taken in two separate bowls (because of the relatively short gelling timeof epoxy which was 20mins.), each bowl containing half the total weight.
6) The curing additives(hardener) are added in the specified proportions, stirredthoroughly and the first resin coat is applied on the release film as per the size of the
fabric.
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7) The first layer of fabric is carefully placed over the resin coat in and thoroughcompaction is achieved to prevent air bubble entrapment.
8) This is followed by the application of alternate layers of resin and reinforcement upto desired thickness is achieved. After the final resin coat is applied, the lay- up is
covered by another release film. The mould is closed by placing the top slab.
9) The top slab on account of its weight (18 kg) compresses the lay-up to the desiredthickness of 3.5mm, which is maintained using appropriate stoppers and the lay- up
is allowed to cure for 6-8 hours before it is retrieved from the mould.
10)The above steps are repeated to fabricate composite plates of different orientation.
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Granite Slabs forming the mold. Affixation of Release Film
Application of first resin coat. Placement of fabrics.
Placing release film over the lay-up Curing Stage
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Reference
1. Knothe, J., Flster, Th., Naturfaserverstrkte Fahrzeugteile, Kunststoffe 87 (1997),Carl Hanser Verlag, Germany, pages 1148-1152
2. Amar, K.M., Manjusri, M. and Lawrence, T.D. 2005. Natural Fibers, Biopolymers,and Bio-composites. CRC Press, Tailor & Francis.
3. Maiti, S.N. and Singh, K. 1986. Influence of wood flour on the mechanical propertiesof polyethylene. J. Appl. Poym. Sci. 32:4285-4289.
4. Devi, L., Bhagawan, S. and Thomas, S. 1997. Mechanical properties of pineappleleaf fi ber-reinforced polyester composites. J. Appl. Polym. Sci. 64:1739-1748.
5. Chen, X., Gao, Q. and Mi, Y. 1998. Bamboo Fiber-reinforced polypropylenecomposites: a study of the mechanical properties. J. Appl. Polym. Sci. 69:1891-1899.
6. Thwe, M.M. and Liao, K. 2002. Effects of environmental aging on the mechanicalproperties of bamboo-glass fiber reinforced polymer matrix hybrid composites.
Composites Part A. 33:43-52.
7. Wambua, P., Ivens, U. and Verpoest, I. 2003. Natural fibers: can they replace glassin fi ber-reinforced plastics? Compos. Sci. Technol. 63:12591264.
8. Herrera-Franco, P.J. and Valadez-Gonzalez, A. 2005. A study of the mechanicalproperties of short natural-fiber reinforced composites. Composites B 36:597-608.
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