te A STUDY ON MECHANICAL AND SLIDING WEAR
BEHAVIOUR OF E-GLASS FIBRE REINFORCED
EPOXY COMPOSITES
A
Major Project Report
submitted
in partial fulfillment
for the award of the Degree of
Master of Technology
in
Department of Mechanical Engineering
(With specialization in Manufacturing Technology & Automation)
Supervised By: Submitted By:
Mr. Dharmender Sharma Punit Dhingra
Associate Professor MME-14011
Department of Mechanical Engineering
Advanced Institute Of Technology And Management, Palwal (2016)
Maharshi Dayanand University, Rohtak
Advanced Institute of Technology and Management
Aurangabad, Palwal, Haryana, India
Affiliated to MDU, Rohtak
Department of Mechanical Engineering
CERTIFICATE
This is to certify that the thesis entitled 'A STUDY ON MECHANICAL AND SLIDING
WEAR BEHAVIOUR OF E-GLASS FIBRE REINFORCED EPOXY COMPOSITES',
submitted to the Advanced Institute of Technology and Management, Palwal by Mr. Punit Dhingra, bearing Roll no. MME14011 in partial fulfilment of the requirements for the award of Master of Technology in the Department of Mechanical Engineering, Advanced Institute of Technology and Management, Palwal, is an authentic work carried out by him under my supervision and guidance.
To the best of my knowledge, the matter embodied in the thesis has not been submitted to any other university/institute for the award of any Degree or Diploma.
Date:25/06/2016
Dharmender Sharma
Assistant Professor
Dept. of Mechanical Engineering
Advanced Institute of Technology and Management, Palwal
ii
Advanced Institute of Technology and Management
Aurangabad, Palwal, Haryana, India
Affiliated to MDU, Rohtak
Department of Mechanical Engineering
DECLERATION
I hereby declare that the work, which is being presented in the Major Project, entitled as
'A STUDY ON MECHANICAL AND SLIDING WEAR BEHAVIOUR OF E-GLASS FIBRE REINFORCED EPOXY COMPOSITES ' in partial fulfillment for the award of Degree of 'Master of Technology' in Department of Mechanical Engineering with Specialization in Manufacturing Technology & Automation submitted to the Department of Mechanical Engineering, Advanced Institute Of Technology And Management, Palwal, affiliated to Maharshi Dayanand University, is a record of my own investigations carried under the Guidance of Mr. Dharmender Sharma , Designation: Associate Professor.
I have not submitted the matter presented in this Major Project Report anywhere for the award of any other Degree.
Student Name: Punit Dhingra
(Manufacturing Technology & Automation)
Roll No: MME-14011
AITM, Palwal iii
Advanced Institute of Technology and Management
Aurangabad, Palwal, Haryana, India
Affiliated to MDU, Rohtak
Department of Mechanical Engineering
ACKNOWLEDGEMENT
With deep regards and profound respect, I avail this opportunity to express my deep sense of
gratitude and indebtedness to Prof. Dharmender Sharma, Department of Mechanical
Engineering, A.I.T.M, Palwal for introducing the present research topic and for her inspiring guidance, constructive criticism and valuable suggestion throughout this research work. It would have not been possible for me to bring out this report without her help and constant encouragement.
I express my sincere gratefulness to Prof. Sunil Singh, Mr. Yogesh kumar sharma ,
Mr. Brijesh Chaudhary, Mechanical Engineering, A.I.T.M Palwal for giving me an opportunity to work on this project and allowing me the access to valuable facilities in the department. I also like to thank the entire institute faculty who helped me directly or indirectly to complete my work .
This acknowledgement will remain incomplete if fail to express my deep sense of obligation to my family and God for their consistent blessings and encouragement.
PUNIT DHINGRA
MME14011
iv
Advanced Institute of Technology and Management
Aurangabad, Palwal, Haryana, India
Affiliated to MDU, Rohtak
Department of Mechanical Engineering
ABSTRACT
Due to increasing demand and widespread application of Fibre reinforced polymer
(FRPs) composites, they have been used in a variety of application like aerospace, automotive, sports, ships and constructional work. Because of their several advantages such
as relatively low cost of production light weight, easy to fabricate and superior strength to
weight ratio. In the present work E-glass fibre is used as reinforcing agent with and without
alumina filler. The objective of the present research work is to study the mechanical and
abrasive wear behaviour of coated and uncoated E-glass fibre reinforced epoxy based
composites. The effect of fibre loading and filler content on mechanical properties like
hardness, tensile strength, flexural strength and impact strength of composites are studied. A
robust design technique called Taguchi method is also used to determine the optimal
condition for specific wear rate of the composites by considering different parameters.
ANOVA study is also performed to study the effect of various factors on the sliding wear
behaviour of the composites. Surface morphology of composites was studied by optical
microscope.
Keywords: coating, e-glass fibre, epoxy, filler, surface morphology, taguchi method
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TABLE OF CONTENTS
INTRODUCTION ……………………………………………………………………………………………………… 1
1.1 Background and Motivation ………………………………………………………………………………… 1
1.2 Thesis Outline …………………………………………………………………………………………………… 5
LITERATURE SURVEY ……………………………………………………………………………………………. 6
2.1 On mechanical properties of E-glass reinforced epoxy composites …………………………… 6
2.2 On sliding wear behaviour of fibre reinforced polymer composites ………………………….. 7
2.3 Effect of coating on wear behaviour of fibre reinforced polymer composite …………….. 11
2.4 Objective of the Present Research Work ……………………………………………………………… 13
MATERIALS AND METHODS ………………………………………………………………………………… 14
3.1 Materials ………………………………………………………………………………………………………. 14
3.1.1 Matrix ……………………………………………………………………………………………………….. 14
3.1.2 Fibre material …………………………………………………………………………………………….. 15
3.1.3 Filler material …………………………………………………………………………………………….. 16
3.1.4 Coating material …………………………………………………………………………………………. 16
3.2 Composite Fabrication ……………………………………………………………………………………. 16
3.2.1 For Mechanical Testing ……………………………………………………………………………….. 16
3.2.2 For Wear Test …………………………………………………………………………………………….. 17
3.2.3 Coating of Composite ………………………………………………………………………………….. 17
3.3 Physical property of composite …………………………………………………………………………… 18
3.4 Mechanical testing of composites ……………………………………………………………………….. 18
3.5 Sliding wear test of composite ……………………………………………………………………………. 21
3.6 Optical microscope ……………………………………………………………………………………………. 23
3.7 Taguchi method ……………………………………………………………………………………………….. 24
RESULT AND DISCUSSIONS …………………………………………………………………………………. 26
4.1 Physical property of composites …………………………………………………………………………. 26
4.2Part-1Mechanical properties of composites without filler at different fibre loading ……. 27
4.2 part-2 Mechanical properties of composites with filler at different fibre loading ………. 28
4.3 Surface morphology of composites before and after tensile test ……………………………… 29
SLIDING WEAR BEHAVIOUR OF E-GLASS FIBRE REINFORCED EPOXY
COMPOSITES ………………………………………………………………………………………………………….. 31
5.1 Sliding wear behaviour of E-glass-epoxy composites …………………………………………….. 31
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5.1.1 Effect of fibre loading on sliding wear behaviour of uncoated and unfilled
composites ………………………………………………………………………………………………………… 31
5.1.2 Effect of fibre loading on sliding wear of uncoated and filled composites ………… 32
5.1.3 Effect of fibre loading on sliding wear behaviour of coated and unfilled composites
………………………………………………………………………………………………………………………… 33
5.2 Taguchi experimental result ………………………………………………………………………………. 34
5.3 Surface Morphology of Composite before and after wear test ……………………………….. 37
CONCLUSIONS………………………………………………………………………………………………………. 38
REFERENCES ………………………………………………………………………………………………………… 40
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LIST OF FIGURES
Figure 1.1 Classification of composite based on the type of reinforcement
Figure 3.1 The epoxide group
Figure 3.2 Chemical structure of diglycidyl ether of bisphenol-A
Figure 3.3 Short E-glass fibres
Figure 3.4 Schematic diagram of vacuum evaporation
Figure 3.5 Experimental set up for tensile test
Figure 3.6 Experimental set up for flexural test
Figure 3.7 Experimental set up for Hardness test
Figure 3.8 Block diagram of 'Pin-on-Disc' set up
Figure 3.9 Pin on disc set up
Figure 3.10 Optical microscope setup
Figure 4.6 (a) Optical images of glass fibre epoxy composite before tensile test
Figure 4.6 (b) Optical images of glass fibre epoxy composite after tensile test
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15
15
17
19
20
21
22
23
24
30
30
Figure 5.1 Wear rate of uncoated and unfilled composite at different fibre loading and test
conditions
32
Figure 5.2 Wear rate of uncoated and filled composite at different fibre loading and test
conditions
33
Figure 5.3 Wear rate of coated and unfilled composite at different fibre loading and test
conditions
Figure 5.4 Effect of control factors on specific wear rate for glass-epoxy composites
Figure 5.5 (a) Optical microscope images of glass-epoxy composite before wear test
Figure 5.5 (b) Optical microscope images of glass-epoxy composite after wear test
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36
37
37
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LIST OF TABLES
Table 1.1 Different types of glass fibres
Table 1.2 Composition and properties of glass fibres
Table 3.1 Designation of composite
Table 3.2 Experimental details of control factors and their level
Table 4.1 Theoretical and measured densities with void fractions in composites
Table 4.2 Mechanical properties of composites without filler at different loading
Table 4.3 Mechanical properties of composites with filler at different fibre loading
Table 5.1 Test conditions with output results using mixed type L36 orthogonal array
Table 5.2 ANOVA table for wear rate
xt in here…