The document discusses the fabrication and characterization of continuous functionally graded materials (FGMs) for a class project. It provides an introduction to FGMs and their applications. The group's objectives are to fabricate a leaf spring using 3D printing with aluminum/glass fiber/epoxy FGM and compare it to conventional leaf springs. The methodology includes a literature review on FGMs and 3D printing techniques, material selection, fabrication using inkjet 3D printing, testing, and results reporting. A Gantt chart outlines the project schedule.

1. Fabrication & Characterization of Continuous Graded FGM
Group No. 46
Under the Guidance of
Mr. Ranjeet Kumar Singh
Name of Student Roll no.
1. Gaurav Pandey 1519240079
2. Md. Shahid Perwez 1519240116
3. Rishabh Ranjan 1519240187
4. Vishwajeet Gaurav 1619240907
G L Bajaj Institute of Technology & Management
Greater Noida
Mechanical Engineering Department
Session 2018-19

2. CONTENT OF PRESENTATION
• Introduction
• Motivation for this project
• Literature Review
• Outcome from Literature
• Objectives
• Gantt Chart
• Methodology

3. • Functionally Graded Material
(FGM) belongs to a class of
advanced material characterized
by variation in properties as the
dimension varies. [1]
• The properties of FGM are
different from any of the
individual materials that make
up the composite. [2]
• FGM are characterized by
variation in composition,
microstructure, as well as
properties across the dimension
of the material. [2]
• The concept of FGM was first
considered in Japan in 1984
during a space plane project. [3]
Figure.1(Sirris Materials Workshop)
INTRODUCTION

4. APPLICATION
 During last decades ,effort were concentrated in development of fatigue resistant material ,which
would keep low weight and good mechanical properties.
 The most successful product in this field was obtained at Delft university of technology
(Netherland),with development of fiber-metal laminates (FML) using armid(having high temp.
resistant & strong synthetic fiber), aluminium 7475-T761 and epoxy resin.
 A patent on Glare (GLAss REinforced) was filed by AKZO in 1987. A partnership between AKZO and
ALCOA started to operate in 1991 to produce and commercialize Glare.
 There are two types of composites falls in the category of FML ,these are polymer composites (CF/E
and GF/E) and the hybrid composites (Glare and Caral).
 Carbon/epoxy and glass/epoxy composites exhibit high specific modulus.
 The combination of high stiffness and strength with good impact property gives to the
carbon/aluminum laminates.
 Studies addressing costs of FML showed that they are five to ten times more expensive per
kilogram than a traditional aluminum alloy used in the aerospace field, but they can exhibit at
least 20% weight savings in the role structure.
INTRODUCTION

5. LITERATURE REVIEW
Author Title Contribution
Syed AM Tofail
et. al.
[8]
Additive
manufacturing :
scientific and
technological
challenge.
(2017)
1. Additive manufacturing is fundamentally different from traditional formation
or subtractive manufacturing in that it is the closest to the bottom up
manufacturing where a structure can be built into its designed shape using a
layer-by-layer approach rather than casting or forming.
2. AM is clear and reassuring that advance in the technology related to the
making are producing object faster and can print these object in much
greater complexities with multiple combinations of materials, colours and
finishes.
Cian Conlan-
Smith
Et. al.
[10]
Optimal design of
complaint
mechanism using
functionally
garaded mateial
(2017)
1. This research applies topology optimization to create feasible functionally
graded complaints mechanism design with the aim of improving structural
performance compared o traditional homogeneous complaints mechanism
design.
2. Results suggests that FGMs can achieved the desired improvements in
mechanical advantage when compared to both homogeneous and two-material
mechanisms.
LITERATURE REVIEW

6. 20-04-2019
Author Title Contribution
Luiz Claudio
pardini
Et. al.
[15]
A review on the
development and
properties of
continuous Fiber
/epoxy/aluminium
Hybrid composites
for aircraft
structures.
(2006)
1. Aiming this objective, a new lightweight Fiber/Metal Laminate (FML)
has been developed. The combination of metal and polymer
composite laminates can create a synergistic effect on many
properties.
2. One of the advantages of FML when compared with conventional
carbon fiber/epoxy composites is the low moisture absorption. The
moisture absorption in FML composites is slower when compared
with polymer composites.
3. Titanium seems to be the next hybrid fiber metal laminate to be
introduced in the market since it has a high stiffness, high yield
strength, good fatigue and good impact properties at room and
elevated temperatures.
Kevin
Garanger
Et. al.
[16]
3D printing of leaf spring
: Demonstration of
closed loop in AM
(2018)
1. This paper presents the integration of a feedback control loop during
the printing of leaf spring using additive manufacturing.
2. In order to achieve a desired objective stiffness, measurements are
taken after each part is completed and the infill density is adjusted
accordingly in a closed-loop framework. The absolute error in the
stiffness at the end of printing is reduced from 11.63% to 1.34% by
using a closed-loop instead of an open-loop control.

7. OBJECTIVES
 Leaf spring is one of the major weighted component. It accounts for 10% to 20% unsprung weight
of the vehicle. For this reason it has been it has been a component of interest for reduction of
weight from few years. To achieve desired weight reduction and conserve natural resources it has
become necessary for automobile industries to study materials like composite as alternative
materials for leaf spring. By reducing the weight of vehicle fuel efficiency can also be increased.
 Strain energy of spring is inversely proportional to density and young's modulus it is better to use
material having low density and modulus of elasticity.
 Composite materials are commonly made from carbon, glass and these fibers are stack together
with the help of resins such as epoxy, polyester, vinyl ester.
 Use of composite material increases load carrying capacity under static loading.
 Some major properties of material which are required to fabricated leaf spring are : tensile
behavior, compressive behavior, shear strength behavior, light weighted.
 On the behalf of desired properties of leaf spring discussed above , Al/Glass Fiber/Epoxy is chosen
for fabrication of leaf spring.
 Glare has better elastic property than the glass fiber /epoxy composite. (fig. 1)
Selection of material for leaf spring

8. NOTE : E= Young Modulus, G = Shear modulus & v = poission’s ratio
Figure:1

9. TENSILE BEHAVIOR :-
Table 4 shows results for the tensile strength of carbon fiber/epoxy, glass fiber/epoxy, Glare and Caral
composites.
 The tensile strength for glass fiber and carbon fiber are 3.45 GPa and 3.65 GPa, respectively.
 At a same fiber volume fraction the CF/E composite tensile strength would be higher than GF/E composite tensile
strength.
COMPRESSIVE BEHAVIOR :-
 The compressive strength of composites dependents on the way the loading is applied.
 In particular, the axial compressive strength for unidirectional polymer composites is mainly controlled by
the buckling modes of the fibers.
 For compressive strength of polymer composites (CF/E and GF/E) and the hybrid composites (Glare and
Caral) are shown in Table 5

11.  In compression, the shape of the curve has additional meaning, because it shows if there is an
opportunity for modifying the materials’ properties by means of cold working on aluminum, such as
stretching.
 The compressive strength value was higher for carbon fiber/epoxy composite, as expected. Therefore,
the fiber/metal laminates presented the lowest values, due to the weak interface between the
composite layer and the aluminum alloy.
 Figures 9a and 9c show a bucking failure of the aluminum layer which is associated to the damage in the
polymeric composite laminae. This is the reason for the low compressive strength found for fiber/metal
laminates when compared to polymeric composites.

12.  The Figures 9b and 9d shows delamination failures under compressive load which are mainly located
inside the composite laminae.
SHEAR STRESS BEHAVIOUR :-
 The short beam shear test has been used to measure the apparent interlaminar shear strength of a composite
materials. Data generated from this test method is still used to obtain design allowables, primarily because of
the lack of any alternative test methods for measuring interlaminar strength.
 Table 6 presents the interlaminar shear strength (ILSS) results for polymer composite materials and for FML
composites.

13.  The interlaminar shear strength for CF/E and GF/E composites is more than twice the value for FML
composites (Caral and Glare), approx. 85 MPa and approx. 40 MPa, respectively.
DAMPING BEHAVIOUR:-
 The Glass fiber/epoxy dissipates less energy per cycle of damping than the CF-E composite.

14. 3D printing (Solid-freeform technique) is a process in which material is joined or solidified under computer
control to create a three-dimensional object, with material (such as liquid molecules or powder grains)
typically being added layer by layer.
3D printed objects can have a very complex shape and are always produced from a digital 3D model or a CAD
file.
In 3D Printing, a three-dimensional object is built from computer-aided design (CAD) model, usually by
successively adding material layer by layer.
This process has been used to fabricate numerous metal, ceramic, and polymeric components of any geometry
for a wide array of applications.
 Inkjet 3D printing method is more helpful as tool less manufacturing method.
 Inkjet three-dimensional (3D) Printing is a fast, flexible and cost-effective technology which enables the
construction of both simple and complicated 3D objects directly from Computer-Aided Design (CAD) data
without the need for tooling.
FABRICATION METHOD

15. Activity by Weeks from the start of the project
Task
August-18 September-18 October-18 November-18 December-18 January-19 February-19 March-19
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Selection of
Topic
Final selection of
Project
Study of
research paper
Week on hold
due to certain
reasons
Methodology &
material
selection
Work on hold
due to exam
Fabrication
Work on hold
due to exam
Testing of
Sample
Final Result
Report writing
Report
submission
GANTT CHART

16. FLOW DIAGRAM
START
Aim
To fabricate leaf
spring using 3DP
Required properties
for leaf spring
Material Selection on
the basis of required
properties
Study of different types of
method used for fabrication
of leaf spring
Suitable Method Selection
Fabrication of leaf spring
using selected method
Testing for fabricated leaf
spring using binder jetting or
Inkjet 3DP
Make a comparison between
conventional and 3DP leaf spring
using test report
END

17. REFERENCE
[1] Rasheedat M. Mahamood, Esther T. Akinlabi Member, IAENG, Mukul Shukla and Sisa Pityana.
[2] https://link.springer.com/chapter/10.1007/978-3-319-53756-6_1
[3] https://en.wikipedia.org/wiki/Functionally_graded_material
[4] https://www.google.com/search?q=application+of+functionally+graded+materials&source=lnms&tbm=isch&sa=X&ved=0
[5] eprints.uthm.edu.my/2698/1/saifulnizan_jamian_1.pdf
[6] Koizumi M (1993) The concept of FGM. Ceram Trans Funct Grad Mater 34: 3-10.
[7] S. S. Wang “Fracture mechanics for delamination problems in composite materials,” Journal of Composite Materials
[8] SK Boid, Y. Inaguma, H. Sato, and E. A. Miura-Fujiwara, “Novel fabrication method for functionally graded materials .
[9] AB Sannudin, and Ganeshan N, (2006) Thermoelastic buckling and vibration behavior of a functionally graded sandwich beam.
[10] F. Tarloch, X., Hu, Y., Liu, J., Tio, B., Cheang, P., Khor, K.A.: Highly interconnected and functionally graded porous bioceramics. Key Eng. Mater.
240–242, 595–598 (2003)
[11] https://www.sciencedirect.com/science/article/pii/S2211812814008074
[12] https://www.scirp.org/journal/articles.aspx?searchCode=+Functionally+Graded+Material+(FGM)&searchField=keyword&page=1
[13] https://ieeexplore.ieee.org/document/5459096
[14] https://www.google.com/search?q=centrifugal+casting&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiKjPymx5LfAhUB4o
[15] A Review on the Development and Properties of Continuous Fiber/epoxy/aluminum Hybrid Composites for Aircraft Structures
[16] 3D printing of a leaf spring: A demonstration of closed-loop control in additive manufacturing
REFERENCE