1. Modeling and analysis of hybrid composite
strip with bolted joint using FEM
PRESENTED BY
SHANAWAZ KHAN.M (Reg. No. 312811114042)
SIVA.A (Reg. No. 312811114045)
SURESH.M (Reg. No. 312811114310)
Under the Guidance of,
Mr. RAMESH.R M.E., (Supervisor)
Assistant Professor,
Department of Mechanical Engineering,
Agni College of Technology,
Chennai- 603 130.
1
2. Composite materials are materials made from two or more constituent materials
with significantly different physical structure and chemical properties.
In this project, we made a composite plate by mixing three fibres of different
physical and chemical properties. These fibres are held together by epoxy resin
along with little amount of hardener which acts as binding agent.
The composite plate after manufacturing is cut into rectangular strips in reference to
ASTM standard. Of these ,two rectangular strips are made together as lap joint
which is done by bolt and nut assembly.
Tensile test and bending moment test are executed in the fiber reinforced strips.
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ABSTRACT
3. By getting the result, we can analyse the strength of this composite joints and can
be applied in the area where conventional metals is used.
Using this composite joint in place of metals can considerably reduce the weight
and it is free of corrosiveness which is the drawback for most of the metal joints.
This is can be applied mostly in aero ship manufacturing where the ultimate aim is
to reduce weight and increase the strength of the materials used.FEM analysis is
done in ANSYS version [15,work bench].
3
ABSTRACT
4. 4
LETTER DESIGNATION PROPERTY OR
CHARACTERISTIC
E, electrical Low electrical conductivity
S, strength High strength
C, chemical High chemical durability
M, modulus High stiffness
A, alkali High alkali or soda lime glass
D, dielectric Low dielectric constant
TYPES OF GLASS FIBERS
5. LITRATURE REVIEW
S.VENKATESWARLU 1,K.RAJASEKHAR 2“ANALYSIS OF
SINGLE RIVET COMPOSITE JOINT” PUBLISHED IN IOSR
JOURNAL OF MECHANICALAND CIVIL ENGINEERING, PP 01-
06 concluded that, The shear stress with hybrid joint has less value of
stress and also the glass Fibre reinforced plastic material the cost is less
than other composite material. The stress induced by using ansys is less
than the material allowable stress. It was found that a well designed hybrid
joint is very efficient when compared to bonded, riveted joints in case of
repair situation in aircraft structures. The GFRP strength is less than that of
the CFRP strength .
5
6. TP.SATHISHKUMAR,J.NAVEEN,S.SATHEESHKUMAR “HYBRID FIBER
REINFORCED POLYMER COMPOSITES” IN JOURNAL OF
REINFORCED PLASTICS AND COMPOSITES reported that ,The polymer
matrix composites have been widely used for many applications. These are light in
weight and easy for manufacturing. The hybrid fiber reinforced composites have
been prepared to enhance the mechanical, thermal, damping properties compared to
single-fiber reinforced composites. The fiber reinforced hybrid composites consist
of two or more fiber in a matrix system. The different fibers were reinforced with
suitable matrix for preparing the hybrid composites using various manufacturing
methodology.
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LITRATURE REVIEW
7. A-GLASS FIBER:
It is called as Alkali-lime glass with little or no boron oxide fiber. If SiO2 is heated
above 1200°C/2192°F then cooled ambient, it crystallizes and becomes quartz.
Glass is produced by altering the temperature and cool down rates. If pure SiO2 is
heated to 1720°C/3128°F then cooled quickly, crystallization can be prevented and
the process yields the amorphous or randomly ordered atomic structure we know as
glass.
Today’s glass fiber manufacturers combine this high heat/quick cool strategy with
other steps in a process
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A-GLASS FIBER
8. E-Glass or electrical grade glass was originally developed for stand off
insulators for electrical wiring.
It was later found to have excellent fibre forming capabilities and is now used
almost exclusively as the reinforcing phase in the material commonly known as
fibreglasses-Glass.
Low alkali glass with a typical nominal composition of SiO2 54wt%,
Al2O314wt%, CaO+MgO 22wt%, B2O3 10wt% and Na2O+K2O less then 2wt%.
Some other materials may also be present at impurity levels.
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E-GLASS FIBER
10. The term hybrid effect has been used to describe the phenomenon of an apparent
synergistic improvement in the properties of a composite containing two or more
types of fibre .
The selection of the components that make up the hybrid composite is determined
by the purpose of hybridization, requirements imposed on the material or the
construction being designed.
The problem of selecting the type of compatible fibres and the level of their
properties is of prime importance when designing and producing hybrid
composites..
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HYBRID COMPOSITES
11. Epoxy resins, also known as polyepoxides are a class of
reactive prepolymer and polymers which contain epoxide groups.
Epoxy resins may be reacted (cross-linked) either with themselves through
catalytic homo polymerisation, or with a wide range of co-reactants including poly
functional amines, acids (and acid anhydrides), phenols, alcohols, and thiols.
Reaction of polyepoxides with themselves or with poly functional hardeners forms
a thermo setting polymer, often with strong mechanical properties as well as high
temperature and chemical resistance.
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EPOXY RESIN
12. Curing may be achieved by reacting an epoxy with itself (homopolymerisation) or by
forming a copolymer with polyfunctional curatives or hardeners.
In principle, any molecule containing a reactive hydrogen may react with the
epoxide groups of the epoxy resin.
Applications of these epoxy resin hardeners extend over to casting, impregnation,
lamination and many others.
Harderner used : HY 957
Chemical Name : Triethylene tetra mine
Molecular Formula : C6H18N4
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HARDERNER
13. For E- glass fiber:
i. Young’s modulus = 75 Gpa
ii. Shear modulus = 33 Gpa
iii. Poisson’s ratio = 0.23
For Epoxy resin:
i. Young’s modulus = 25 Gpa
ii. Shear modulus = 4 Gpa
iii. Poisson’s ratio = 0.20
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MATERIAL PROPERTIES
14. 14
Epoxy Resin
- LY 556 Epoxy Resin
- HY 957 Hardner
HARDNER AND RESIN PICTURES
15. 15
Material Selection &
Materials Details
Volume of Material
Needed
Hand Layout Method
curing
Machining process
Testing
Result
FLOW CHART OF MANUFACTURING PROCESS
16. 16
s.no Name of the material Quantity
1 Glass fibre woven rovings- 360 GSM ½ KG
2 Glass fibre woven rowings- 600 GSM 1 KG
3 Glass fibre E-CLASS – 450 GSM 1 KG
4 Epoxy resin 2 lts
5 Hardner 25 ml
MATERIALS AND QUANTITY
17. A die is made with the dimension of length 30cm,breath 30cm and thickness 6 mm
is taken.
This die is filled with three different layers of fibre mixed with resin by HAND
LAYOUT METHOD without allowing any air bubbles.
Hardner used acts as a binding agent to hold fibre and resin strongly.
The epoxy resin and hardner are mixed in the ratio of 100:12
Then this setup is left at room temperature for 48 hrs – 56 hrs for setting.
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MANUFACTURING PROCESS
21. According to ASME(American Society of Mechanical Engineering),
the square plate(30*30cm) is cut to the dimensions of length –
30cm,breath-23.5cm.
A hole is drilled at a distance of 2 cm from any one end exactly at the
centre of the plate and riveted with another plate of similar geometric
structure.
Thus two composite plate is riveted and executed for following test:
I) Bending Stress & ii) Tensile Stress
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ANALYSIS AND TESTING
22. 22
Final Assembly Of A
Composite Bolted Join
Manufactured Fiber
Reinforced Plate
26. Since we manufactured the plate in hand layout there will be slight deviation in the
thickness of the plate through out the area of the palte.a graph representing the
variation in the thickness is given below.
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6.2
6.5
6.6 6.6
6.7
6.9
6.6
6.5 6.5
6.4
5.8
6
6.2
6.4
6.6
6.8
7
1 2 3 4 5 6 7 8 9 10
Thickness vs Design points
thickness
27. COMPUTATIONALANALYSIS OF FEM:
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2-D Diagram
Material property
3-D modelling in solid
works
Assembly
Load constrain and
solve for result
Import IGES file and
apply mesh
Convert into IGES file
28. S.no Properties unit
1 Tensile strength 3445 Mpa
2 Compressive strength 1080 Mpa
3 density 2.58 g/cm3
4 Thermal expansion 5.4 µm/moc
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Properties of E-glass fiber
29. 29
LOAD CONSTRAIN FOR BENDING MOMENT:
we are going to find 3 point bending moment,so select the load point over the joint of two strips. Here
point A and B are fixed support and point C is load point.
30. 30
Load constrain for tensile load:
For finding ultimate strength for tensile load,keep the end A as fixed and applying
loaat end B. Then maximum tesile load is given in opposite direction till we get the
break event point.
31. ANSYS RESULTS:
FOR FLUCTURAL LOAD:
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Equivalent elastic strain is maximum at the edges and
decreases towards the center.
32. 32
We get uneven stress value throughout the lentgh of the strips which is shown in figure.
33. 33
Strain energy for bending load is shown in figure which is maximum at the edges and minimum
at the center areas.
36. 36
Equivalent stress for tensile is small throughout the
area of the strip which is shown in figure.
37. CONCLUSION
Thus we conclude that,the ultimate strength of hybrid composite joint is greater
than normal composite joint. From the analysis,the break even point for tensile
load is 4.34 KN and break even point for fluctural load is 1.27KN.
The replacement of composite materials has resulted in considerable amount
of weight reduction about 60 % when compared to conventional mild steel plates.
the same geometry, plates with E-Glass Fiber have better strength.
The life the joint is increased because of high resistance to corrosion,
resistance to chemical attack, high stiffness to weight ratio and high strength to
weight ratio of E-Glass fiber.
The shear stress with hybrid joint has less value of stress and also the glass
Fibre reinforced plastic material the cost is less than other composite material.
It was found that a well designed hybrid joint is very efficient when
compared to bonded, riveted joints in case of repair situation in aircraft structures.
37
38. [1]. Noah M. Salih1, Mahesh J. Patil 2, Hybrid (Bonded/Bolted) Composite Single-
Lap Joints And Its Load Transfer Analysis, International Journal of Advanced
Engineering Technology E-ISSN 0976-3945 IJAET/Vol.III/ Issue I/January-March,
2012/213-216.
[2]. Ch. Aswini Kumar1, G. Pattabhi2, S.Santosh3, I. Bhanu Latha4, Analysis of
Adhesively Bonded Double Lap Joint in Laminated FRP Composites Subjected To
Longitudinal Loading, international journal of engineering science & advanced
technology volume-2, issue-2, 307 – 316 ijesat | Mar-Apr 2012.
[3]. Vincentcaccesse, Richard newer, until s. vel detection of bolt load loss in hybrid
composite.metalboltedconnectionselseiver engineering structures 26(2004) 895-
906.
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REFERENCES
39. [4]. W. Hufenbach a, L.A. Dobrzański b, M. Gude a, J. Konieczny b, A. Czulak a,
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alloy, Journal of Achievements in Materials and Manufacturing Engineering,
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[5]. M.A. McCarthy*, C.T. McCarthy, Finite Element Analysis Of The Effects Of
clearance On Single-Shear, Composite Bolted Joints, Journal of Plastics, Rubber
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[6]. Proceedings of the “National Conference on Emerging Trends In Mechanical
Engineering 2k13” 122 NCETIME – 2k13 Design Of Hybrid Composite Joints For
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Engineering, Anna University, Chennai-28
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