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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2659 Design and Development of Natural Composite Material Noamaan Tanvir Shaikh1, Yash Hemraj Patil2, Suraj Pratap Godse3, Pravin Gunderao Irawadkar4 1,3,4Department of Mechanical Engineering, Savitribai Phule Pune University 2Department of Industrial Engineering, Texas Tech University, USA ----------------------------------------------------------------------***--------------------------------------------------------------------- Abstract –The paper describesthedesignanddevelopment of natural composite material which is prepared using epoxy resin as matrix phase and century plant fiber as reinforcing phase which follows the categoryofPolymer matrixcomposite with fiber reinforced. The natural composite plates are prepared according to the ASTM standards (American society for testing and materials). Referring to the ASTM standards, the dimensions of the composite plates are decided. The percentage of fiber and their angle of orientation are varied. Finally, the composite plates are tested for tensile andflexural load and the results are plotted. Key Words: ASTM, Tensile, Flexural, Epoxy & Fibre. 1. INTRODUCTION 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 [2]. 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 thatthere be an integrated effort in design, material, process, tooling, quality assurance, manufacturing, and even program management for composites to become competitive with metals. The composites industry has begun to recognize that the commercial applications of composites promise to offer much larger business opportunities than the aerospace sector due to the sheer size of transportation industry. For certain applications, the use of composites rather than metals has in fact resulted in savings ofbothcostandweight. Some examples are cascades for engines, curved fairing and fillets, replacements for welded metallic parts, cylinders, tubes, ducts, blade containment bands etc. Further, the need of composite for lighter construction materials and more seismic resistant structures has placed highemphasisonthe use of new and advanced materials that not only decreases dead weight but also absorbs the shock & vibration through tailored microstructures. Fig-1: Methodology 1.1 OBJECTIVES To develop a new class of natural fiber-based composite to explore the potential of century plant fiber (Sisal fiber). To fabricate the different composite by varying the fiber fraction and matrix Fraction To study the effect of fiber percentage on mechanical behavior of natural fiber reinforced matrix-based composites. To Evaluate mechanical properties such as Tensile strength and Flexural strength To compare the test results of composite plates of different fiberpercentageandtheiralignmentangle. Selection Calculations Design & Development Testing Results
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2660 1.2 DEFINITIONS A composite material consists of two or more physically and/or chemically distinct, suitably arranged or distributed phases, with an interface separating them. It has characteristics that are not depicted by any of the components in isolation. Most commonly, composite materials have a bulk phase, which is continuous, called the matrix, and one dispersed, non-continuous, phase calledthe reinforcement, which is usually harder and stronger. The function of individual components has been described as: Matrix phase: The primary phase, having a continuous character, is called matrix. Matrix isusuallymoreductileand less hard phase. It holds the dispersed phase and shares a load with it. Reinforcing phase: The second phase (or phases) is embedded in the matrix in a discontinuous form. This secondary phase is called dispersed phase. Dispersed phase is usually stronger than the matrix, therefore itissometimes called reinforcing phase. 1.3 Classification of composites Composites can be grouped into categories based on the nature of the matrix each type possesses and the type of reinforcing material to be used [5]. Methods of fabrication also varyaccordingtophysicalandchemicalpropertiesofthe matrices and reinforcing fibers. Based on the reinforcing fibers they can be grouped into particulate composites, fibrous composites and laminate composites [13]. Fig 2: Reinforced based composites a) Particulate Composites Particulate Composites consist of a matrix reinforced by a dispersed phase in form of particles. These are the cheapest and most widely used. They fall in two categories depending on the size of the particles. Composites with random orientation of particles. Composites with preferred orientation of particles. Dispersed phase of these materials consists of two-dimensional flat platelets (flakes), laid parallel to each other. b) Fibrous Composites The fibrous compositesare again divided into twotypes.One is short fiber reinforced composites which consists of a matrix reinforced by a dispersed phase in form of discontinuous fibers (length < 100*diameter) and long-fiber reinforced composites which consists of a matrix reinforced by a dispersed phase in form of continuous fibers. c) Laminate composite When a fiber reinforced composite consists of several layers with different fiber orientations, it is called multilayer composite [8]. 1.4 Classification of reinforcements Reinforcements for the composites can be fibers, fabrics particles or whiskers.[17],[19] Fibers are essentially characterized by one very long axis with other two axes either often circular or near circular. Particles have no preferred orientation and sodoestheirshape.Whiskershave a preferred shape but are small both in diameter and length as compared to fibers. Figure.3 shows types of reinforcements in composites Fig 3: Types of reinforcement Fiber-reinforced polymer composites have played a dominant role for long time in a variety of applications for their high specific strength and modulus. The fiber– reinforced polymer, usually made of glass, carbon or aramid fibers–reinforced thermoplastic and thermoset resins [5] are considered critical because of environmental problems [6]. Natural fiber composites means a composite material that is reinforced with fibers, particles or platelets from natural or renewable resources, in contrast to for example carbon or aramid fibers that have to be synthesized.
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2661 Natural fibers include those made from plant, animal and mineral sources. Natural fibers can be classified according to their origin. Fig 4 shows the classification natural fibers according to their respective types Fig 4: Classification of natural fibers 1.5 MANUFACTURING PROCESSES OF COMPOSITE MATERIAL Manufacturing of a composite material is to combine the polymeric resin system with the fiber reinforcement [3]. Since the orientation of the fibers is critical to the end properties of thecomposite,manufacturingprocessisutmost important to align the fibers in desired direction [9]. A good manufacturing process will produce a higher, uniform fiber volume fraction along with a higher production of a large volume of parts economically and have repeatable dimensional tolerances. In this work, Hand lay-up process is used for manufacturing the composite material. The composite manufacturing techniques can be classified into two categories: A. Open mould process 1. Hand lay-up process 2. Spray up process 3. Vacuum-bag auto clave process 4. Filament winding process B. Closed mould process 1. Compression molding 2. Injection molding 3. Sheet molding compound (SMC) process 4. Continuous pultrusion process 2. MATERIAL The following materials used in this work are as follows: a) Epoxy resin (LY-556) Epoxy LY-556 resin belonging to the epoxide family is chosen as the matrix due to its light weight, easy to fabricate, resists most alkalis and acids and resists stress cracking. b) Hardener (HY-951) Hardener is a curing agent for epoxy or fiberglass. Epoxy resin requires a hardener to initiate curing; it is also called as catalyst, the substance that hardens the adhesive whenmixed with resin. It is the specific selection and combination of the epoxy and hardener components that determines the final characteristics and suitability of the epoxy coating for given environment neededforspecial purposes. c) Century Plant fibre (Sisal) Century plant’s fibre was taken to fill as reinforcement in the polymer composite. Century Plant is Commercially available and it is fully biodegradable and highly renewable resource. Sisal is a natural fiber (Scientific name is Agave sisalana) of Agavaceae (Agave) family yields a stiff fiber traditionally used in making twine and rope. Century Plant fiber is exceptionally durable and a low maintenance with minimal wear and tear. Fig 5: Sisal Fiber 3. CALCULATIONS The samplesare cut to the followingdimensionsasperASTM standards [10], [16],[18] for testing shown in Table 1.
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2662 Table -1: ASTM Standards for sample dimensions S.N ASTM Code Mechanical Test Sample Dimensions (mm) 1. ASTM-D638 Tensile 200 ×25× 4 2. ASTM-D790 Flexural 100 × 15 × 4 1. Tensile: Volume = 4×25×200 mm3 = 20,000 mm3 = 20,000 × 10-9 m3 Density of epoxy = 1.15 gm/ml = 1.15 × 103 kg/m3 Density of hardener = 1 gm/ml = 1 × 103 kg/m3 Total density (Epoxy + Hardener) = 2.15 gm/ml = 2.15 × 103 kg/m3 Mass = Density × Volume = 2.15 × 103 × 20,000 × 10-9 kg = 43 gm OR 0.043 kg Weight fraction method is used for calculations. Sample 1: 0° Specimen with 5% fiber Total weight of the specimen = 43 gm Weight of the fiber = 5% of 43 gm = 2.15 gm Weight of the polymer = 43-2.15 = 40.85 gm 40.85/3 = 13.61 gm Therefore, weight of the epoxy = 27.23 gm Weight of the hardener = 13.61 gm Hardener used in the epoxy-hardener mixture is 1:2. Similar calculations were carried out for different fiber percentages and their orientations. The results of tensiletest specimens after calculations are shown in the table 2 Table -2: Tensile test sample calculations Angle of fiber orientation 00,300 & 450 Percentages offibers 5% 10% 15% 18% Total weight of the specimen (gm) 43 43 43 43 Weight of the fiber (gm) 2.15 4.3 6.45 7.74 Weight of the polymer (gm) 40.85 38.7 36.55 35.26 Weight of the epoxy (gm) 27.23 25.8 24.36 23.53 Weight of the hardener (gm) 13.61 12.9 12.18 11.76 2. Flexural: Volume = 4×15×100 mm3 = 6000 mm3 = 6000 × 10-9 m3 Density of epoxy = 1.15 gm/ml = 1.15 × 103 kg/m3 Density of hardener = 1 gm/ml = 1 × 103 kg/m3 Total density (Epoxy + Hardener) = 2.15 gm/ml = 2.15 × 103 kg/m3 Mass = Density × Volume = 2.15 × 103 × 6000 × 10-9 kg =12.9 gm OR 0.0129 kg Sample 1: 0° Specimen with 5% fiber Total mass of the specimen = 12.9 gm Weight of the fiber = 5% of 12.9 gm = 0.64 gm Weight of the polymer = 12.9-0.64 = 12.26 gm 12.26/3 = 4.08 gm Therefore, weight of the epoxy = 8.17 gm Weight of the hardener = 4.08 gm Similar calculations were carried out for different fiber percentages and theirorientations.Theresultsofflexuraltest specimens after calculations are shown in the following tables Table -3: Flexural test sample calculations Angle of fiber orientation 00,300 & 450 Percentages offibers 5% 10% 15% 18% Total weight of the specimen (gm) 12.9 12.9 12.9 12.9
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2663 Weight of the fiber (gm) 0.64 1.29 1.93 2.32 Weight of the polymer (gm) 12.26 11.61 10.97 10.58 Weight of the epoxy (gm) 8.17 7.74 7.31 7.05 Weight of the hardener (gm) 4.08 3.87 3.65 3.52 4. PLACING FIBERS INTO THE MOULD It is the one of the simplest methodsofcompositeprocessing. The processing steps are quitesimple.Glassmouldingisused to prepare the specimen. A thick flat glass sheet was chosen as the base on which specimen were prepared. To avoid sticking of the epoxy on the glass plate, aluminium foil paper is used to cover the glass plate as, epoxy resin contains OH group which means epoxy resin is very sticky. Glass plates were used to hold the specimen by providing supportive structureand also used to make the specimen in dimensions. Percentage of epoxy hardener in the specimen were calculated by weight fraction. Hardener used in the epoxy- hardener mixture is 1:2. After calculations of varying fibre % and their alignment angle, hardener and epoxy resin were mixed thoroughlyinsuitableproportionandpouredbetween the space surrounded by the glass plates or glass mould. The mixture is uniformly spreadwith the help of brushes. Needle was used to remove any air trapped on bubble as well as excess polymer present. Thisprocess was separatedforeach fiber percentage and fiber alignment in the specimen. After done with this, aluminium foilsheetwaswrappedaroundthe glass mould to avoid entry of foreign particle and to avoid formation of air bubbleswhichcreatesirregularityonsurface which will lead to poor quality finish and less strength. Fig 6: Glass moulding All the specimen are then kept at room temperature for 15- 20 hours and then mould is opened and the developed composite part is taken out and further processed. The time of curing depends on type of polymer used for composite processing for e.g. for epoxy-based system, normal curing time at room temperature is 20-24 hours. This method is mainly suitable for small scale application, and infrastructural requirementswere less as comparedtoother methods. Production rate is less and high-weight fraction of reinforcement is difficult to achieve in the processed composition. Composite plates after placing the fibers are shown in Fig 7. Fig 7: Natural composite plates after placing of the fibers 5. TESTING Mechanical properties such as Tensile strength, Flexural strength are computed from the test conducted using universal testing machine (UTM) shown in the (Fig 8) in accordance to ASTM standards for specimen preparation. The 10-ton capacity UTM machine used for testing was supplied by PRAJ Metallurgical Laboratory, Pune,India.UTM Specifications are shown in Table 4. Fig 8: Universal testing machine (UTM)
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2664 Table -4: Specifications of Universal Testing Machine Parameter Specifications Capacity 10 tones Load frame Mild steel C channel with double ball screw mechanismpre-loadedballscrew with zero backlash covered with bellow Mounting Free standing Load range 1 kg-1000 kg using 1-ton load cell 1 kg-10000 kg using 10-ton load cell Length measurements Rotary encoder mounted on to the screw rod Length resolution 0.01 mm Cross head speed 0.1 to 100 mm/min Controls Emergency off, up and down key Input power 220V±10% VAC,50 HZ,1500 VA Net weight 225 kg Grippers Tensile, Compression, Three-point Bending Length accuracy ±0.1 mm 5.1 Tensile Testing of Composites One of the most common testing methods, tensile testing, is used to determine the behavior of a sample while an axial stretching load is applied. These types of tests may be performed under ambient or controlled (heating or cooling) conditions to determine the tensile properties of a material. Tensile testing is performed on a variety of materials including metals, plastics, elastomers, paper, composites, rubbers, fabrics, adhesives, films, etc. Tensile testing is commonly used to determine the maximum load (tensile strength) that a material or a product can withstand. Tensile testing may be based on a load value or elongation value. Here in tensile test ASTM D-638 is used to prepare specimens however, in ASTM D-638 dumble shaped specimens are given in type 1- type 5. However rectangular specimens were used in this testing, because if we make dumble shaped specimen, fiber will break. Hence, the purpose of putting the fiber material will defiet. Hence, rectangular samples are prepared.Tensiletestsampleplaced in the UTM is shown in the Fig 9. Fig 9: Tensile Testing on UTM machine 5.2 Flexural Testing of Composites Flexural testing is used to determine the flex or bending properties of a material [15]. Sometimes referred to as a transverse beam test, it involves placing a sample between two points or supports and initiating a load using a third point or with two points which are respectively call 3-Point Bend testing [13]. Maximum stress and strain are calculated on the incremental load applied. Typical materials tested are plastics, composites, metals and woods. Flexural test sample placed in the UTM is shown in the Fig 10. Fig 10: Flexural Testing on UTM machine
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2665 Load vs Displacement graphsaregeneratedfromtheUTMfor both tensile and flexural tests samples and the readings are recorded. Figure 11 shows one of the(LoadvsDisplacement) of tensile test of 00 orientation with 10% of the reinforced fiber. Fig 11: Load vs Displacement - 0°, 10% Similar graphs are generated for all the remainingsamplesof both tensile and flexural tests samples and the readings are recorded. 6. RESULT The following tests results of both tensile and flexural tests recorded are as follows: 6.1 Tensile Test Results: The readings obtained for tensile tests specimens are shown in table 5. Table -5: Tensile Test Results Sr.No. Sample Identification Tensile strength (MPa) 5% 10% 15% 18% 1. 00 38.87 34.20 34.03 34.70 2. 300 13.60 7.59 7.28 5.44 3. 450 10.92 9.15 10.54 8.44 The graph of Tensile strengthvs FiberPercentageisshownin Chart 1 Chart -1: Tensile strength vs Fiber Percentage 6.2 Flexural Test Results: The readings obtained forflexuraltestsspecimensareshown in table 6. Table -6: Flexural Test Results Sr.No. Sample Identification Flexural strength (MPa) 5% 10% 15% 18% 1. 00 81.29 68.55 67.51 59.38 2. 300 29.22 31.05 20.18 23.38 3. 450 34.05 30.75 27.56 19.31 The graph of Flexural strength vs Fiber Percentage is shown in Chart 2 Chart -2: Flexural strength vs Fiber Percentage 7. CONCLUSIONS From the observationsandresultsofspecimensundertensile and flexural testing, the various conclusions are taken out which are as follows a) The maximum properties (both tensile strengthand flexural strength) are at 5% fiber reinforcement. b) After 5% reinforcement i.e. 10%, 15%, 18% the properties gradually reduce. This maybe because of increase in reinforcement. c) In flexural strength at 30°, the strength marginally increases for 10% as compared to 5%.
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2666 d) From the above results, we got to know as we increase the fiber percentage the brittleness of the specimen also increases with it. e) Hence, to conclude the5%reinforcementisbetteras compared to 10%, 15% and 18%. 8. FUTURE SCOPE Presently, the main markets for bio composites are in the construction and automotive sectors. With further developments and improvements in performance, however, new opportunities [19] and applications will likely arise. In addition to this, improvements in the mechanical performance of existingbiocompositesthrough,forexample, the introduction of new fiber types, processing and additives may well result in an expansion in their use into more diverse,and technically demanding, application areas. There are also good prospects for using reclaimed fiber from products such as MDF (medium density fiberboard) or other waste streams from the pulp and paper industry to manufacture a range of cost-effective and environmentally effective materials and products [9]. While there is ample opportunity forthese productstoenternewmarketsandfind new application, it is essential that benefit in terms of cost saving be highlighted and a stronger commercial case for these materials be made. Acknowledgements The authors would like to thank Mrs. C.G. Nalawade (Project coordinator) for her continuous guidance and Mr. A.M. Bhagat proprietorofPRAJMetallurgical Laboratory,Punefor his support and testing the specimens. REFERENCES [1] Asim Shahzad, R.S. Choudhary “Design and manufacturing of natural fiber reinforced polymer hybrid composites.” Handbook of composites from renewable materials, volume 2,(411-448)[2017]. [2] Olusegun David Samuel, Stephen Agbo, Timothy Adesoye Adekanye “Assesing mechanical properties of natural fiber reinforced composites for Engineering applications” Journal of minerals and materials characterization and Engineering(780-784)[2012] [3] Asim Shahzad, R.S. Choudhary “Design and manufacturing of natural fiber reinforced polymer hybrid composite.” Handbook of composites from renewable materials, volume 2,(411-448)[2017] [4] Elammaran Jayamani, Sinin Hamdan, Md Rezaur Rahman and Muhammad Khusairy Bin Bakri ”Comparative study o fdielectric properties of hybrid natural fiber composites.” Procedia Engineering, (536- 544) [2014] [5] D. Nabi Saheb, J.P Jog e “Natural fiber polymer composites: A Review.” Advance in polymer Technology.vol.18.no.4,(351-363)[1999] [6] Arpitha.G.R, B. Yogesha “An overview on mechanical property evaluation of natural fiberreinforcedpolymer” Materials today proceeding 4 (2755-2760)[2017] [7] MP Westman, SG Laddha, LS Fifield, TA Kafentzis, KL Simmons.“Natural fibercomposites:AReview”Prepared for U.S Department of energy under contract DE-AC05- 76RL01830[2010] [8] J.P.Torres, L-J. Vandi, M. Veidt, M.T. Heitzmann “Statistical data for the tensilepropertiesof natural fiber composites” Data in brief (222-226)[2017] [9] K.P.Ashik, Ramesh S. Sharma “A Review on mechanical properties of natural fiber composites” Journals of materials and minerals characterization and Engineering 3,(420-426)[2015] [10] D. Chandramohan, A. John Presin Kumar “Experimental data on properties of natural fiber particle reinforced polymer composite material” Data in brief 13 (460- 468)[2017] [11] M.R. Bambach, “Compression strength of natural fiber composite plates and sections of flax, jute and hemp.” Thin walled structures 119(103-113) [2017] [12] Z. Leman, Z. Leman, S.M. Sapuan, A.M.M. Edeerozy and I.S. Othman. “Mechanical properties of kenafbast and core fiber reinforced unsaturatedpolyestercomposites” IOP Conf. Series: Materials science and Engineering 11 (012006)[2010] [13] F.AO, Fernandes, T.P Talvres, R.J. Alves desouza. A.B. Perecia, J.L. Esteves “Manufacturing and testing composed on natural materials” Manufacturing Engineering society International conference 2017, MESIC 2017, 28-30 June 2017, Vigo, Spain. [14] Willam Jordon, Patrick Chester, “Improving the properties of Banana fiber reinforced polymer composite by treating the fibers.” 3rd International conference on natural fiber 2017, 21-23 June 2017, Braga, Portugal. [15] Carlos Mota, Fernando Cunha, Raul Fargueiro, “Influence of various thermoplastic polymers ratios on the mechanical and thermal properties of composite materials.” 3rd International conference on natural fibers: Advantages materials for a greener world INCF 2017, 21-23 June 2017, Portugal. [16] C. Elanchezhian, B. Vijaya Ramnath, M.Rajendra kumar, V. Naveenkumar “Review on mechanical properties of
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 12 | Dec 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2667 natural fiber composites.” Materials today: Preecedings 6-5 (2018) [1785-1790] [17] Ganesh. R. Kalagi, Rajshekhar Patil, Narayan Nayak “Experimental study on mechanical properties of natural fiber reinforced polymer composite materials for wind turbine blades.” , Materials today: Proceedings 5 (2018) [2588-2596] [18] Sakshi. S. Kamath, Dhanlaxmi Sampatkumar, “A review on natural areca fiber reinforced polymer composite materials.” Cliencia and technologia dos materials 29 (2017) [106-128] [19] M. R. Sanjay, P. Madhu, Mohammad Jawaid, S.Senthil, S.Pradeep “ Characterization and properties of natural fiber polymer composites; A Comprehensive review” 9 October 2017 [JCLP-10893]
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