composites

1. DEVELOPMENT AND
CHARACTERISATION OF POLYMER
HYBRID COMPOSITE WITH
PARTICULATE FILLINGS
GUIDE NAME: MR. PRAMENDRA KUMAR BAJPAI
NAME OF STUDENTS ROLL NO. DEPTT. YEAR
1.AAKASH KUMAR RAJPUT 601/MP/11 MPAE 4TH YEAR
2.AASHISH MOGHA 602/MP/11 MPAE 4TH YEAR
3.DHARMENDER YADAV 621/MP/11 MPAE 4TH YEAR
4.JATIN BADHANA 629/MP/11 MPAE 4TH YEAR
5.NILESH 640/MP/11 MPAE 4TH YEAR

2. Objective of project:
 Fabrication of a polyester based hybrid composites reinforced with glass, carbon fibers
and two different particulate fillers (alumina & silicon carbide).
 Evaluation of mechanical properties and wear characteristics of hybrid composites.
 Analysis by FEM method, to study the difference in output readings.
 Characterization of the composite using SEM and investigation of the effect of
reinforcement volume fraction on UTS and Hardness.
 To find out suitable applications where composite material can replace conventional
material on account of improved properties.

3. Composite material:
1.Substances that are formed by the combination of two or more materials having
different physical and chemical properties is called a composite.
2.Constituents remain separate and distinct, but at the same time work together to
give the composite properties.
3.They do not dissolve or blend into each other.
Hence composites are engineered materials that satisfy the requirement of modern
technology, as they have several advantageous features like high specific strength,
high specific modulus and other desired properties.

4. Metal matrix composite
• Reinforcement: boron;
Borsic;
carbon (graphite); SiC;
alumina (Al2O3)
• Matrix: aluminium;
magnesium; titanium;
copper
• Reinforcements improves
high temp creep; thermal
expansion.
Polymer matrix composite
• Reinforcement:glass
fibers;Aramid fibers
boron; carbon (graphite);
SiC; alumina (Al2O3)
• Matrix:Thermoplastic,
Thermoset
• Reinforcements improves
strength, sp.modulus,
light weight, low density,
low cost.
Ceramic matrix composite
• Reinforcement: SiC;
alumina; SiN
• Matrix: SiC;
alumina;
glass-ceramic;
SiN
• Reinforcement improves
toughness
Classification based on type of matrix

5.  There are five basic types of composite materials: Fiber, particle, flake, laminar or
layered and filled composites.
Classification based on reinforcement

6. Literature survey:
It includes reviews of available research reports:
 On mechanical properties of synthetic fiber composites
 On particulate filled polymer composites
 On wear of polymer composites
1.Moorthy and Manonmani[1] carried out to determine tensile strength and impact strength
on the account of factors fiber length, fiber content and filler content. Strength increases
with fiber & particulate content.
fiber: E glass(3,5,7cm)
filler: Tio2(2,4,6wt%)
Resin: polyester

7. 2.S.C. MISHRA[2] studied the wear behaviour of glass fiber filled epoxy resin matrix
composites. composite shows brittle type failure and maximum wear erosion rate is
observed at 90° impingement angle. Erosion wear rate is decreased with increasing the
glass fiber amount.
different impingement angles(30°,45°,60°,75°,90°)
various impact velocities(34,48,60,78,92m/sec)
erodent : dry silica sand ,size range 200-600μm
3. Yamamoto et al. [3] reported that the structure and shape of silica particle have
significant effects on the mechanical properties such as fatigue resistance, tensile and
fracture properties.
4.Nakamura et al. [4] discussed the effects of size and shape of silica particle on the
strength and fracture toughness based on particle-matrix adhesion and found that increase
in the flexural and tensile strength as specific surface area of particles increased.
5. Nicolais and Nicodemo [5] studied the effect of particle shape on tensile properties of
glass-thermoplastic composites. Strength increases with increases with size of particles.
6. Patnaik et al. [6] reported that the mechanical properties of polyester based hybrid
composites are highly influenced also by the type and content of the filler materials.
7. Harsha et al. [7] reported the influence of impingement angles and impact velocities on
solid particle erosion of poly-ether-ether-ketones and their composites with short FRP.

8. Methodology
Fiber
Glass fiber
Carbon fiber
Particulate
Al2O3 and SIC
Mfg. process
Compression Moulding

9. Methodology(Cont.):
Polymer-Hardener mixture preparation:
For making a good composite, the mixture should be uniform. We take the resin and
hardener in certain ratio(as prescribed by mfg. firm) and the mixture is stirred thoroughly
till it becomes warm and viscous.
Compression Molding:
1.Compression Molding is a Closed Mold process in which a molding charge is squeezed
into a preheated mold taking a shape of the mold cavity and performing curing(cross-
linking) due to heat and pressure applied to the material.
2.The method uses a split mold mounted in a hydraulic press .

10. Compression Molding process involves the following
steps:
1.A pre-weighed amount of a polymer (commonly thermosetting resin) mixed with chopped
reinforcing fibers, hardening agent, anti-adhesive agent and pigment (charge) is placed into the lower
half of the mold.
2.The charge may be in form of powders, pellets, putty-like masses or pre-formed sheets.
3.The charge is usually preheated prior to placement into the mold. Preheated polymer becomes softer
resulting in shortening the molding cycle time.
4.The upper half of the mold moves downwards, pressing on the charge and forcing it to fill the mold
cavity.
5.The mold, equipped with a heating system, provides curing (cross-linking) of the polymer matrix (if
thermosetting resin is processed).
6.The mold is opened and the part is removed from it by means of the ejector pin.
7.Compression Molding cycle time is about 1-6 min, which is longer than Injection Molding cycle.
8.The method is suitable for mass production of flat or moderately curved parts.

12. Progress uptil now:
1.We are planning to use a compression moulding machine for fabrication, commutations
with the industry is still in process for the same
2.We had selected the carbon fibre and glass fiber & commutation will be made asap.
3.We are in the process of selecting polyester resin with hardener and communications with
the industry is in progress for the same.
4.We had selected the reinforcements that will be used in our project and necessary
communication be made with the industry.

13. Use of Hardware & Software:
Hardware used:
1.Compression Moulding Machine : for making the sample
2.Tensometer : To find the mechanical properties & wear characteristics of the composites
on Pin-on Disk Setup
3.Saw Cutter/Blade : to cut the sample into smaller one, that used as samples during
mechanical & wear testing.
Software ( to be used):
1.Ansys/Solidworks : To perform the FEM analysis of the composites made
2.Abacus: To perform the SEM analysis of the composites made

14. Expected outcome:
1.We are trying hard to find a new composite with improved mechanical and wear
properties and low cost, so that it would be used as a substituent for other
materials which are currently used widely in industries.
2.We are creating a model through FEM analysis , so as to compare mechanical
properties.

15. Refrences:
1. S. Srinivasa Moorthy, K. Manonmani,Statistical Analysis and Predictive Learning of Mechanical
Parameters for TiO2 Filled GFRP Composite, International Journal of Mechanical, Aerospace,
Industrial and Mechatronics Engineering Vol:8 No:1, 2014
2. S.C. MISHRA, Tribological behavior and mechanical properties of glass fiber reinforced polymer
matrix composites Journal of Metallurgy and Materials Science, Vol. 53, No. 2, April-June 2011, pp.
139-152
3.Yamamoto I, Higashihara T and Kobayashi T, (2003). Effect of silica particle characteristics on
impact/usual fatigue properties and evaluation of mechanical characteristics of silica-particle epoxy
resins, JSME International Journal-Series A: Solid Mechanics and Material Engineering, 46 (2), pp.
145-153.
4. Nakamura Y, Yamaguchi M, Kitayama A, Okubo M and Matsumoto T, (1991). Effect of particle size
on fracture toughness of epoxy resin filled with angular-shaped silica, Polymer, 32(12), pp. 2221-2229.
5. Nicolais L and Nicodemo L, (1974). The Effect of particles shape on tensile properties of glassy
thermoplastic composites, International Journal of Polymeric Materials, 3(3), pp. 229-243.

16. 6. Patnaik A, Satapathy A, Mahapatra S. S and Dash R. R, (2009). A Comparative Study on Different
Ceramic Fillers affecting Mechanical Properties of Glass-Polyester Composites, Journal of Reinforced
Plastics and Composites, 28 (11), 1305-1318.
7. Harsha A. P, Tewari U. S and Venkataraman B, (2003). Solid particle erosion behaviour of various
polyaryletherketone composites, Wear, 254(7-8), pp. 693-712.
8. El-Tayeb N. S., and Gadelrab R. M., Friction and Wear Properties of E-Glass Fiber Reinforced
Epoxy Composites under Different Sliding Contact Conditions, Wear, 192 (1996), pp.112-117
9. Lu Z. P., and Friedrich K., On Sliding Friction and Wear of PEEK and its Composites, Wear, 181
(1995), pp. 624-631.
10. Ramesh C. S., Keshavamurthy R., Channabasappa B. H., and Pramod S., Friction and Wear
Behavior of Ni–P Coated Si3N4 Reinforced Al6061 Composites, Tribology International, 43 (2010),
pp. 623-634.