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IRJET- Analysis and Improvement of Composite Materials
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1559 Analysis and Improvement of Composite Materials Dilip kumar1, Rajneesh Sagar2, Shabnam3, Lavli Devi4 1P.G Student, Department of Mechanical Engineering, KIT Kanpur, AKTU, U.P., India 2Assistant Prof. Department of Mechanical Engineering, KIT Kanpur, AKTU, U.P., India 3Graduate Student, Dept. of B.TC Chhatrapati Shiva ji M.S.B. Sikandra Kanpur Dehat, U.P India. 4Under Graduate Student, Dept, of B. Tech. Bio. Tech. Rama University Kanpur, U.P, India. --------------------------------------------------------------------------------***-------------------------------------------------------------------------------- Abstract – the perforation of materials analysis and improvement of composite materials inmodernworld use full can be utilized from the fact that more of the research in being to the apply the new materials into different components, and different fields of applications. It is the natural for design Engineer to create rely a confidential andadvancetestedmaterials, such that the changing today compositematerialshave converted all the compositematerialsengineering.The improvement of composite materialstheevaluationan opportunity to various designer to use new and batter materials and improving cast reduction, increase to efficiency and goodness utilization of presented resources. The composite materialsanimprovingtheir applications of different fields in an aerospace industries, manufacturing industries, automobile industries, and biomedical industries etc. the paper manly focuses on the importance of composite materials in Mechanical Engineering and civil Engineering technology applying in composite materials .The various definitions and classifications, properties of the analysis and improvements in composite materials in different space of the world. Key Words: Manufacturing, Aerospace, automobile, biomedical, industries analysis improvement, research. INTRODUCTION - The production of new generation materials for in this paper introduces basic concept of density of materials and stiffness, strength weight of the composite materials from renewable sources in an increasing important fields of research and development. The demand for stronger, stiffness and more light weight materials is essential in most industries. The mechanics of fiber reinforced advance composites materials the fibers usedinthecomposites industries can be divided into same categories.Natural fibers and synthetic fibers, natural fibers (can be mostly derived from trees and plants) are considered to be environmentally friendly and therefore,inrecent years, this composite materials technology is same times termed ‘‘ micromechanics’’ the relation between macroscopic engineering propertiesthetwo or more materials chemically different constituents combined macroscopically. Properties of final product should be significantly different than thatofcomposite materials constituents, manly the volume fraction of fiber. The current used of composite materials in the composed of dissimilar subunits if examined at closed detail. 2. Materials: the current used of the composite materials in the composed of dissimilar subunits if examined at closed detail but the ‘’matrix’’ material that is reinforced with fibers. For the (fiber reinforced plastic) ‘‘FRP’’ usually indicates a thermosetting polyester matrix containing glass fibers and the cast reductionsandimprovementsinmaterialperformance. The particular composite has the highly resistant to corrosion and fatigue. Fig.1. Showing non uniform fiber packing and micro-cracking The cross plying unidirectional reinforced layers in a0 – stacking sequence. Their promising characteristics have attracted key players from the industries to support further research on composites increasing of material technology, with performance and airframes and vehicles parts made of composite can be increase the operational range of the aircrafts and reduce the fuel casts. The demand for lightweight and cast effective materials. Table1. That is the fiber used in modern composites havestiffnessandstrength for above those properties of advance composites materials is presented by the table the high strengths of the raw materials of choice to be used by many
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1560 industries in eluding the aerospace, automotive, marine, military and defense industries. Actually according to findings natural fibers were utilizedmore than 3000years ago. Fig.2.volume fraction of fiber materials in this figure different types of fibers materials to different types of volume fractions The glass fibers are due to processing that avoids the internal or surface weaken glass, and the strength and stiffnessofthepolymericaramidfiberisaconsequence of the nearly perfect alignment of the molecular chains with the fiber axis. The matrix materials that acts to transfer loads to the fibers and also to be presents the fibers from abrasion and environmental attract. The most research nowadays emphasizes the development of the new materials fiber based composite that exhibit the best performance in terms of impact strength. Metal and glass are available as matrix materials but these are currently very expensive and largely restricted to DMSRDE Kanpur laboratories. The polymers are much more commonly used, with unsaturated styrene- hard denned polyesters having the majority of low to medium performance applications and epoxy. Thermoplastic matrix composites are increasingly attractive materials with processing difficulties being perhaps their principal and limitations. Nomenclatures Mc Mass of the composite Mf Mass of the fibers materials Mm Mass of the matrix materials Vc Volume of composite Vf Volume of fibers materials Vm Volume of matrix materials Va Volume of air Density of moistures w Density of water ρc Density of composite ρf Density of fibers materials ρm Density of matrix materials εc Strain of composite metal εf Strain of fibers materials εm Strain of matrix materials Ac Area of composite metal Af Area of fibers materials Am Area of matrix materials c Stress of composite metal f Stress of fibers materials m Stress of matrix materials Pc Load of composite metal Pf Load of fibers materials Pm Load of matrix materials Ec Modulus of composite metal Ef Modulus of fibers materials Em Modulus of matrix materials
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1561 c Thermal expansion coefficient Of composite metal f Thermal expansion coefficient Of fibers materials m Thermal expansion coefficient Of matrix materials T T.E.C of transfers direction L T.E.C of longitudinal direction c Moisture expansion coefficient of Composite metal m M.E.C of matrix materials T M.E.C. of transfer direction L M.E.C. of longitudinal direction 3. Fibers materials: The purpose of the matrix is to provide shape and form, to protect the fiber from structural damage and adverse chemical attract, to distributed stress, and to provide toughness. Fig. 3 Stress and strain properties of fiber and matrix materials The primary function of the reinforcement in composites reinforced with continuous is to provide strength and stiffness and to support the structural load. The matrix materials also stabilize the composite against buckling in compressive loading situations. Fibers also known as filaments, havefinitelengthsofat least 100 times their of diameter, the fiber are prepared by methods molten bath, by spinning, chemical vapors deposition (CVDs) on substrate such as tungsten or carbon. They are grouped into bundles or strands of 500 to 12000filaments. 3.1 Advanced Fibers: The carbon fibers in covalent bond are the strongestin nature carbon fibers in contains 80 to 95.5% of carbon it is carbon fiber is produced at 1300 . The graphite fiber contains more than 99% carbon graphite fiber is produced in excess of 1900 . The carbon fibers maximum temperature of used of the fibers ranges from 250 to 2000 properties changes with temperature at higher temperature. Fig. 4 advance carbon fiber The glass fibers: a ancient Egyptians made containers from coarse fibers drown from heat softened glass extruding molten glass at 1200 high strain.
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1562 Fig. 5 Properties testing of advance fibers E- glass: high strength and high resistivity. R- glass: enhanced the mechanical properties. S2- glass: high strength, modulus, and stability under extreme temperature, corrosive environment. C- glass: resists corrosion in an acid environment. D- glass: die-electronic properties. 4. Terminology and basic properties of composite metal. 4. 1. Volume and mass fraction of composites. The mass of the composite = mc, mass of the fibers mf, and mass of the matrix material is mm, mass of the composite mc = mf + mm (1) 1 = + (2) 1 = Mf + Mm (3) The mixture of (n metals) in composite 1 = m1 + m2 + ---- + mn (4) 4. 2 Volume of composite Volume of the composite = Vc, volume of the fiberr=Vf, and volume of the matrix materials = Vm the total volume of the composite. Vc = Vf + Vm (5) 1 = Vf + Vm + Va (6) The mixture of (n volume)incompositemetal.thetotal volume of the composite 1 = V1 + V2 + ----- + VnVa (7) 4. 3. Density of the composites Equation (1) in dividing by Equation (5) = + (8) = + (9) = vf + vm (10) Equation (10) is the total density of the composite. 4.4 Load shearing between fiber and matrix in composites. The strain in composite metal = εc, strain of fiber metal is = εf, and εm is the strain of matrix material Total strain of composite εc = εf + εm (11) = = (12) Load sheared by fiber Pf, and load sheared by matrix materials Pm = (13) = . (14) = . (15) = (16)
5.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1563 = (17) Suppose Vf = 0, lower term is = = is very high Fig. 6 load sheared by directional and bidirectional fibers metal. 4. 5 Thermal Expansioncoefficient( ofthefibers composites. The analysis of properties fibers, matrix based compositesthermalexpansioncoefficientoffiberis , and the thermal expansion coefficient matrix material is Thermal expansion coefficient of composites longitudinal direction = [ (19) Thermal expansion coefficientoftransfer’sdirectionof composite = [(1 + If (Vf ) (20) = [ + (1+ Vm ] (21) 3.6 Moisture Expansion Coefficient of composites Now assume there is matrix is absorbing of water there is no avoid in the system longitudinal and transfer direction both sides = is the density of moisture and = is the density of the water. = . (22) Moisture expansion of composite is longitudinal direction should be zero Transverse direction of compositemoistureexpansion is = (1 + (23) The tensile strength, stiffness and the young’s modulus of the kenaf fibers are lower but still comparable to those the composites, properties improvement and analysis of properties by using analytical method and standard formulations of same properties improved before the fibers are finally used in the fabrication of a composite. The size is usually removed by heat cleaning and washing. For PMCs and MMCs fibers are now also available in a pre- impregnated with matrix materials in the uncured state. Fibers are also now becoming. available as mixtures anadvancedproducerofcomposites,Textron specialty materials (TSMs) has slandered to market a continuous fibers epoxy resin prepared tape that contains a mixture of smaller diameter carbon fibers, with a fiber density of 65 to 85% such i.e. the carbon fibers is good in tension. It is lacks good compressive properties. The combination material has batter flexural properties, that the application of the manufacturingasubmersiblestructures,sportinggood and medicals equipments. Several research studies on polymer composites have already been conducted, such as analysis studies onthe hybridizationeffectand resin application fiber may be utilized in composite materials by providing economical and essential solutions for new developments in materials industries.
6.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1564 4. Composite system and productions 4. 1. Composites with matrices materials: This is the very important matrices materials, metal matrix composites are currently the focus of intense world- wide research and production these materials are fabricated by liquid-infiltration techniques, such as high pressure infiltration casting and pressure less materials. Power metallurgical techniques, plasma spraying of matrix material. The over properly laid fibers, physical vapors deposition, hot pressing, and self propagating high temperature synthesis or reactive synthesis. Fig. 7metal matrix material The matrix materials in nickel- coated and carbon- fiber paper (Ashland carbon flex) has been used in the fabrication of aluminum based MMCs directionally reinforced aluminum composite using AL2O3 and Sic fibers are rapidly emerging as commercial materials for in proving fuel economic and recyclability in the automotive industry. An estimate of the trade-off between weight and fueleconomyisthatareductionin weight of 91kg increasing the fuel efficiency by approximately 0.4 . Fig. 8 carbon fiber matrix materials The infiltration of these porous fiber performs composed of these ours ceramic fibers (such as AL2O3or AL2O3 + SiO2 commercially known as SAFFTVID and KAOWOOLrespectively)inthislowcast of approach to the manufacture of high performance MMCs. the waiting and spontaneous infiltration of a particulate on fibers perform by a molten metal alloy are effected by a novel proprietarytechniqueinvolving the use do pant to the properties elements to rise the melt temperature. Table 1: properties of composite fibers (Axial properties) Materials Density ρ Modulus E (GPa) Passion ratio µ Strength (MPa) Specific Stiffness E/ Specific Strength Thermal expansion coefficient AS4 1.80 235 0.20 3599 5.1 11.1 -0.8 T300 1.76 231 0.20 3654 5.1 11.5 -0.5 P100S 2.15 724 0.20 2199 13.2 5.5 -1.4 IMB 1.8 310 0.20 5171 6.7 16.1 ---- Boron 2.6 385 0.21 3799 5.8 8.3 8.3 Kevlar49 1.44 124 0.34 3620 3.5 14 -2.0 Nicalon 2.55 180 0.25 2000 2.8 4.4 Aluminum 3.95 379 0.25 1585 3.9 1.9 7.6 S-2Glass 2.46 86.8 0.23 4585 1.5 10.6 1.7 E-Glass 2.59 69 0.22 3450 1.06 7.6 5.5 Sapphire 3.98 435 0.28 3600 4.3 5.1 8.8
7.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1565 Table 2 properties of matrix materials Materials Density Modulus E GPa Poison’s ratio Strength MPa Specific stiffness ) Specific strength Epoxy 1.38 4.6 0.36 58.6 0.08 0.4 polyimide 1.46 3.5 0.35 103 0.03 0.4 carbon 8.9 117 0.33 400 0.5 0.3 Silicon carbide 3.2 400 0.25 310 4.9 0.5 Fig.9 testing of the matrix material set- up The unique properties of MMCs (wear resistance, strength and stiffness) the matrix material properties have already led to more than the laboratory scale manufacture of automotive components such as brake calipers , pump housings, gears, valves pulleys, drive shafts, barons, engine, rotors connecting rods and pistons systemsreinforcedwithcontinuousfiberssuch as aluminum fibers. 4.2 Polymer matrix materials Composites (PMMCs): The matrix materials in polymers(a)thermoplastic(b) thermosetting both are plastics soften upon heating and can be reshaped with heat and pressure become cross linked during fabrication and do not soften upon reheating of the thermosetting plastic. Thermoplastics are the high toughness high volume and low cast processing and temperature range 225 . Processing is faster than thermo set composites since no curing reaction is required only heating, shaping and cooling. Improvement of matrix materials of polyesters Low cast high strength andlow viscosity, versatility and application of electrical industries high heat resistance cold and hot molding curing temperature is 120 the polymer matrix materials based on thermoplastic, polypropylene, polyvinyl Chloride (PVCs), nylon, polyurethane, poly-ethe ether keton (PEEK), Fig. 10 polymer matrix material (PMMCs) Chloride (PVCs), nylon, polyurethane, poly- ether- ether keton (PEEK), poly-phenylene Sulfide (PPS) and poly-sup one. Fig. 11 testing of polymer matrix materials set-up
8.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1566 The polymer matrix materials susceptibility to environmental degradation due to moisture reduction atomic oxygen (in space) they are therefore used for the interior panels of aircraft, where combustion requirement justify lower properties. Also these materials and the newly developed thermoplastic polyether sulphone (PESs) contain additivesthatreact to fiber by emitting contained water vapors, the thermoplastic materials exhibit higher strain to the failure, and are ideally suitable for use as matrix materials combinedwithhighstrengthandhigh-strain carbon fibers. These Materials include resins such as (PEEK),withamelting point of 334 Fig. 11 stress strain properties of composites materials These materials and the newly improvement of the polymer matrix material composites in polyether sulphone (PESs), contain additives that react to fire by emitting contained water vapors, the thermoplastic materials exhibit high strain to failure, and are ideally suitable for use as matrix materials combined with high strength and high- strain carbon-fibers. The (PMMCs) susceptibility to environmental degradation Due to moisture, radiation, atomic oxygen in space lower transverse strength of the (PMCs), materials high-residual due to large mismatch in coefficients of thermal expansion both fiber and matrix. Polymer matrix cannot be used near or above the glass transition temperature. 5. Conclusions New fibers, polymers and processing technique for all classes of the composites are constantly being improved and developed the composites have attractive mechanical and physical properties that are now being utilized in industries and aerospace on a grand scale world- wide. Research in also going to improve repair techniques, and recyclability, and the bonding between fiber and matrix materials. Table 3 Properties Comparison of matrix material composites. Properties Polyester Epoxy Steel Specific gravity 1.1 To 1.4 1.2 To 1.3 7.8 T. modulus MP a 2000 To 4400 2500 To 4500 200000 T. strength MP a 33 To 104 50 To 150 300 To 1000 T.E.C 55 To 100 45 To 70 12 W. absorption % 0.15 To 0.65 0.05 To 0.15 0
9.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 08 | Aug 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1567 The standards are being set-up for the testing and computerization of mechanical, physical and chemical properties data banks. The PMCs are being utilized more in structural and wear- resistant applications in mining and industrial environments. The new application that are being found on an almost daily basis and the continuous reporting of company investment and new ventures into the manufacture of MMCs and CMC, PMMC parts, the important progress has been made to worlds the reduction of processing and manufacturing casts. This emails knowledge of the structural efficiency of the material. Its homogeneous or heterogeneous and isotropic or anisotropic behavior, environmental effects, and its manufacturing requirements, assembly and repair. References [1] Muhammad F. Ismaila, Mohamed T.H,a Sultan,a b c Ahmad Hamdana, Ain U.M.Shan a b, Mohammad. Jawaid b ‘‘Low velocity impact behavior and post- impact characteristicsofkenaf/glasshybridcomposite with various weight university putra Malaysia 43400, UPM Serdany. [2] Lakhwinder Singh 1, Geetesh Goga 2, Mukesh Kumar Rathi 3 ‘‘Latest Developments in Composite Materials’’ pp 152-158. [3] AE-681 Composite Materials Office: AE, Aerospace Engineering. [4] Carter, F.C. and paul. D.E .Material science and Engineering. Ohio, ASM International,1991 351 pp.. [5] Harris S, B.A perspective view of composite materials. Mat & Design , vol 12, 5. 1991. PP. 259-271. [6] Ashby, M.F, and Jones D.R.H. Engineering materials – an introduction to their properties and applications oxford pergamon press.1985. 277 pp. [7] F.P.Gerstle, composite, ‘Encyclopdia of polymer science and Engineering, Wiley, New, York.1991 IOGRAPHIES DILIP KUMAR: P.G Student, Department of Mechanical Engineering, KIT Kanpur, AKTU, U.P., India RAJNEESH SAGAR: Assistant Prof. Department of Mechanical Engineering, KIT Kanpur, AKTU ,U.P., India SHABNAM: Graduate Student, Dept. of B.TC Chhatrapati Shiva jiM.S.B.SikandraKanpurDehat, U.P India. LAVLI DEVI: Under Graduate Student, Dept, of B. Tech. Bio. Tech. Rama University Kanpur, U.P, India.
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