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COMPOSITES: A WONDER MATERIAL  FOR THE FUTURE Sreekumar P.A
 
COMPOSITE: ? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Composite materials Fibre reinforced composites Particle reinforced composites Single layer Multi layered Composites (Angle ply) Laminate Hybrid Continuous fibre Discontinuous fibre Unidirectional Bi-directional Random orientation Preferred Orientation Random Preferred
Fibre Natural Man Made Regenerated  Synthetic Mineral Plant Animal Leaf Bast Fruit Wool Mohair Silk
Natural fiber classification
REASONS FOR THE USE OF NATURAL FIBERS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
LIMITS OF NATURAL FIBERS Natural fibers vs glass, carbon, etc .  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Factors influencing the mechanical properties of the composite Strength, modulus and chemical stability of the fibre and the resin matrix ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Factors influencing the mechanical properties of the composite
Factors influencing the mechanical properties of the composite Critical Fiber Length The minimum length per given fiber diameter essential for  high tensile fracture stress.When the length of the fibre is  below critical fibre length, the maximum fibre stress may never reach the ultimate fiber strength         f  l              l< l c   l = l c     l > l c
How to calculate critical fibre length? Consider an infinitesimal length distance dx at a distance x form one of the fibre ends the force equilibrium for this length is  (  /4.d 2 f ) (  f  + d  f ) – (  /4. d 2 f  f ) -    d f  dx.   =  0   (1) Which on simplification gives d  f /dx = 4  / d f  (2) Where   f = longitudinal stress in the fibre at a distance x from one of its ends.  =  Shear stress at the fibre/matrix interface. d f = Fibre diameter. Factors influencing the mechanical properties of the composite
Assuming no stress transfer at the fibre ends, i.e   f  =0 at x=0, and integrating  equation (2)  the normal stress distribution in the fibre ends as   f For simple analysis, it is assumed that interfacial strength is constant. Then equation becomes  f  = (4  I  / d f  ) x Where  = interfacial shear stress. The maximum fibre stress that can be achieved at a given load is   (  f  )  max  = 2  I  (l t  / d f  ) Where x= l t  /2 = load transfer length at each fibre end . Factors influencing the mechanical properties of the composite 3 4 5
l c  = (  f  / 2  I  )d f ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Factors influencing the mechanical properties of the composite Where  l c  = minimum fibre length required for the fibre stress   to be equal to the fibre ultimate strength    f  =  ultimate fibre strength
Factors influencing the mechanical properties of the composite Fibre content ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
How to calculate fibre content and  composite density? Factors influencing the mechanical properties of the composite Where  R is the resin content in composite,  r is the sisal fibre vol%, D is the density of the resin d is the density of sisal fibre. T d =100/(R/D + r/d) V f  =    W f  /  f W f  /  f  + (1-W f ) /  m   Where  W f  is the fibre weight fraction  ( 1-W f )  is the matrix weight fraction   m  is the resin density   f  is the fibre density
Interfacial Adhesion   How to improve interfacial adhesion? By Chemical Methods By Physical methods By using Coupling agents Factors influencing the mechanical properties of the composite fibre matrix interface
Treatment Methods ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Treatment Methods ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Proposed Reaction Mechanism During treatment ,[object Object],[object Object]
Proposed Reaction Mechanism During treatment ,[object Object]
Proposed Reaction Mechanism During treatment ,[object Object],[object Object]
  Influence Of Fibre Orientation   Longitudinal Transverse ,[object Object],[object Object],[object Object],[object Object],[object Object],Factors influencing the mechanical properties of the composite
Continuous and aligned fibre composites Longitudinal loading There are composites in which the fibers are aligned in the direction of  applied stress.Assume that all the filaments are perfectly bonded to the matrix.  Where   c   = composite strain    f  =  fibre strain    m  = Matrix strain Factors influencing the mechanical properties of the composite  f  =   m  =   c   The total tensile force applied on the composite lamina is hared by the fiber and matrix P =P f  +P m Since load  = stress x area: then
Rule of mixtures Factors influencing the mechanical properties of the composite  c .   A c =   f . A f  +   m . A m   c . =   f  (A f /A c ) +   m (A m /A c ) Where   c . = Average tensile strength A f  = Area of the fibre A m  =  Area of the matrix A c =  A f  +  A m  Since V f  =  A f /A c  and V m  = Am/A c  c . =   f  V f   +   m  V m This equation is known as rule of mixtures
For transverse loading In this type the load is applied at 90 0  angle. Under this situation  Stress to both phases are exposed in the same time E c  = E m .E f /V m .E f  + V f . E m Factors influencing the mechanical properties of the composite E c  = elastic moduli of the composite E f =  elastic moduli of the fibre E m =  elastic moduli of the matrix V f =  elastic moduli of the fibre V M =  elastic moduli of the matrix
For randomly oriented fibre composites are composed short and  discontinuous fibre. Under these circumstance the expression for the elastic modulus K= Fibre efficiency parameter which value is lees than unity Modified rule of mixture Factors influencing the mechanical properties of the composite E c  = KE f V f +E m V m
  Voids   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],How to calculate void content? Factors influencing the mechanical properties of the composite where T d  is the theoretical composite density,  M d  is the measured composite density . V= 100(T d -M d )/T d
Processing techniques ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
HAND LAY UP Processing stages ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
FEATURES OF HAND LAY UP ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
SPRAY LAY UP ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
COMPRESSION MOULDING Moulding through the force of compression is another very  common industrial process. The materials used are melamine, phenol and urea formaldehyde, Polyesters etc. Process Description The mould is held between the heated platens. A 'slug' or piece of the plastic is placed into the mould . The hydraulic press closes with sufficient pressure. The Compound softens and flows to shape. If necessary cooling is done. The press is opened and the moulding removed
Classification of Moulds Positive Mould Semi-positive mould Flash Moul d
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],FILAMENT WINDING
The filament winding process was originally invented to produce missile casings, nose cones and fuselage structures, but with the passage of time industries other than defense  and aerospace have discovered the strength and versatility  of filament winding. Picture
Advantages ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Disadvantages ,[object Object],[object Object],[object Object],[object Object]
Characteristics of resin ,[object Object],[object Object],[object Object],[object Object],Resin Provides ,[object Object],[object Object],[object Object],[object Object],[object Object]
Impregnation method Prepreg: Wet Rerolled ,[object Object],[object Object],[object Object],Wet winding ,[object Object],[object Object],[object Object],[object Object]
Winding Patterns Helical ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Picture
Polar  The fibre passes tangentially in the polar opening at one end of the chamber.Reverses direction, and passes tangentially to the opposite side of the polar.It is simple and winding speed can be maintained Hoop patterns High angle helical winding that approaches an angle of 90 o. They are generally combined with longitudinal windings to produce a balance structure
Surface Considerations ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],How to avoid slipping? ,[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],PULTRUSION
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Precautions to be taken
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Advantages ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Desired resin characteristics and Matrix used ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],RESIN TRANSFER MOULDING
Preform Tool Injection Cure Demould SCHEMATIC REPRESENTATION
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Factors affecting the RTM Process
Different Aspects Of Mold Filling Process? ,[object Object],[object Object],[object Object],[object Object],[object Object]
Is fibre washing is related to injection pressure ? How? Fibre washing increases when pressure is increased
Is fibre washing is related to fibre content? How? ,[object Object],[object Object],[object Object]
Schematic diagram of edge flow
Factors governing the edge flow? Injection pressure Only a marginal increase for mould filling at the edge with increasing edge pressure
Preform permeability ,[object Object],[object Object]
Proper mold designing what it means? ,[object Object],[object Object],[object Object],[object Object],[object Object]
What is “Dry Spot”? How it forms ? ,[object Object],[object Object],[object Object],[object Object],[object Object],Voids can form in RTM process ,[object Object],[object Object],[object Object],[object Object]
Importance of Dry spot…. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Is there any way to prevent dry spot? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Advantages of RTM ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
CALENDERING It is employed to produce continuous film and sheets . ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
SHEET MOULDING COMPOUNDS The material is composed of a filled , thermoset resin and a chopped or continuous strand of glass fibre. Advantages ,[object Object],[object Object],[object Object],[object Object],[object Object]
FILM CASTING Used to produce polymeric films ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
INJECTION MOULDING It involves forcing or injecting a fluid plastic material into a closed mould where it solidifies to give the product  Two basic categories: Thermoplastic; Thermosetting In former material is melted and force through an orifice  or gate into a cool mould . In later a reacting material is injected into  a warm mould  in which the material further  polymerizes into a solid part
Schematic Diagram
Process ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Screw move back and check valve opens Stage 4 Stage 1 Stage 3 Stage 2 Mould open Mould clamped cavities filling with melt. Mould clamped cavities full, melt freezing. Screw almost stationary Screw move forward and check valve closed Reservoir full Frozen moulding in clamped mould. MOULDING  STAGES
EXTRUSION MOULDING
Blow Moulding ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Rotational Moulding It is used t o produce small to large hollow items with very uniform wall thickness Heating while rotating Cooling while rotating Part removal
Processing stages ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Rotational Moulding Three arm indexing machine
VACUUM FORMING ,[object Object],[object Object],[object Object],[object Object]
THE STAGES INVOLVED IN VACUUM FORMING ,[object Object],[object Object],[object Object],[object Object],The former is placed in a vacuum former
A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould. The heater is then turned on and the  plastic slowly becomes soft and pliable  as it heats up. The plastic can be seen to  'warp' and 'distort' as the surface expands . After a few minutes the plastic is ready for ‘ forming’ as it becomes very flexible.
The heater is turned off and the mould is  moved upwards by lifting the lever until it  locks in position. The 'vacuum' is turned on and this pumps  out all the air beneath the plastic sheet. Atmospheric pressure above the plastic  sheet pushes it down on the mould. At  this stage the shape of the mould can  be clearly seen through the plastic sheet.  When the plastic has cooled sufficiently the vacuum pump is switched off.

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Composites m sc new class

  • 1. COMPOSITES: A WONDER MATERIAL FOR THE FUTURE Sreekumar P.A
  • 2.  
  • 3.
  • 4. Composite materials Fibre reinforced composites Particle reinforced composites Single layer Multi layered Composites (Angle ply) Laminate Hybrid Continuous fibre Discontinuous fibre Unidirectional Bi-directional Random orientation Preferred Orientation Random Preferred
  • 5. Fibre Natural Man Made Regenerated Synthetic Mineral Plant Animal Leaf Bast Fruit Wool Mohair Silk
  • 7.
  • 8.
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  • 11. Factors influencing the mechanical properties of the composite Critical Fiber Length The minimum length per given fiber diameter essential for high tensile fracture stress.When the length of the fibre is below critical fibre length, the maximum fibre stress may never reach the ultimate fiber strength      f l           l< l c l = l c l > l c
  • 12. How to calculate critical fibre length? Consider an infinitesimal length distance dx at a distance x form one of the fibre ends the force equilibrium for this length is (  /4.d 2 f ) (  f + d  f ) – (  /4. d 2 f  f ) -  d f dx.  = 0 (1) Which on simplification gives d  f /dx = 4  / d f (2) Where  f = longitudinal stress in the fibre at a distance x from one of its ends.  = Shear stress at the fibre/matrix interface. d f = Fibre diameter. Factors influencing the mechanical properties of the composite
  • 13. Assuming no stress transfer at the fibre ends, i.e  f =0 at x=0, and integrating equation (2) the normal stress distribution in the fibre ends as  f For simple analysis, it is assumed that interfacial strength is constant. Then equation becomes  f = (4  I / d f ) x Where = interfacial shear stress. The maximum fibre stress that can be achieved at a given load is (  f ) max = 2  I (l t / d f ) Where x= l t /2 = load transfer length at each fibre end . Factors influencing the mechanical properties of the composite 3 4 5
  • 14.
  • 15.
  • 16. How to calculate fibre content and composite density? Factors influencing the mechanical properties of the composite Where R is the resin content in composite, r is the sisal fibre vol%, D is the density of the resin d is the density of sisal fibre. T d =100/(R/D + r/d) V f = W f /  f W f /  f + (1-W f ) /  m Where W f is the fibre weight fraction ( 1-W f ) is the matrix weight fraction  m is the resin density  f is the fibre density
  • 17. Interfacial Adhesion How to improve interfacial adhesion? By Chemical Methods By Physical methods By using Coupling agents Factors influencing the mechanical properties of the composite fibre matrix interface
  • 18.
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  • 24. Continuous and aligned fibre composites Longitudinal loading There are composites in which the fibers are aligned in the direction of applied stress.Assume that all the filaments are perfectly bonded to the matrix. Where  c = composite strain  f = fibre strain  m = Matrix strain Factors influencing the mechanical properties of the composite  f =  m =  c The total tensile force applied on the composite lamina is hared by the fiber and matrix P =P f +P m Since load = stress x area: then
  • 25. Rule of mixtures Factors influencing the mechanical properties of the composite  c . A c =  f . A f +  m . A m  c . =  f (A f /A c ) +  m (A m /A c ) Where  c . = Average tensile strength A f = Area of the fibre A m = Area of the matrix A c = A f + A m Since V f = A f /A c and V m = Am/A c  c . =  f V f +  m V m This equation is known as rule of mixtures
  • 26. For transverse loading In this type the load is applied at 90 0 angle. Under this situation Stress to both phases are exposed in the same time E c = E m .E f /V m .E f + V f . E m Factors influencing the mechanical properties of the composite E c = elastic moduli of the composite E f = elastic moduli of the fibre E m = elastic moduli of the matrix V f = elastic moduli of the fibre V M = elastic moduli of the matrix
  • 27. For randomly oriented fibre composites are composed short and discontinuous fibre. Under these circumstance the expression for the elastic modulus K= Fibre efficiency parameter which value is lees than unity Modified rule of mixture Factors influencing the mechanical properties of the composite E c = KE f V f +E m V m
  • 28.
  • 29.
  • 30.
  • 31.
  • 32.
  • 33. COMPRESSION MOULDING Moulding through the force of compression is another very common industrial process. The materials used are melamine, phenol and urea formaldehyde, Polyesters etc. Process Description The mould is held between the heated platens. A 'slug' or piece of the plastic is placed into the mould . The hydraulic press closes with sufficient pressure. The Compound softens and flows to shape. If necessary cooling is done. The press is opened and the moulding removed
  • 34. Classification of Moulds Positive Mould Semi-positive mould Flash Moul d
  • 35.
  • 36. The filament winding process was originally invented to produce missile casings, nose cones and fuselage structures, but with the passage of time industries other than defense and aerospace have discovered the strength and versatility of filament winding. Picture
  • 37.
  • 38.
  • 39.
  • 40.
  • 41. Polar The fibre passes tangentially in the polar opening at one end of the chamber.Reverses direction, and passes tangentially to the opposite side of the polar.It is simple and winding speed can be maintained Hoop patterns High angle helical winding that approaches an angle of 90 o. They are generally combined with longitudinal windings to produce a balance structure
  • 42.
  • 43.
  • 44.
  • 45.
  • 46.
  • 47. Preform Tool Injection Cure Demould SCHEMATIC REPRESENTATION
  • 48.
  • 49.
  • 50. Is fibre washing is related to injection pressure ? How? Fibre washing increases when pressure is increased
  • 51.
  • 52. Schematic diagram of edge flow
  • 53. Factors governing the edge flow? Injection pressure Only a marginal increase for mould filling at the edge with increasing edge pressure
  • 54.
  • 55.
  • 56.
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  • 58.
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  • 60.
  • 61.
  • 62. INJECTION MOULDING It involves forcing or injecting a fluid plastic material into a closed mould where it solidifies to give the product Two basic categories: Thermoplastic; Thermosetting In former material is melted and force through an orifice or gate into a cool mould . In later a reacting material is injected into a warm mould in which the material further polymerizes into a solid part
  • 64.
  • 65. Screw move back and check valve opens Stage 4 Stage 1 Stage 3 Stage 2 Mould open Mould clamped cavities filling with melt. Mould clamped cavities full, melt freezing. Screw almost stationary Screw move forward and check valve closed Reservoir full Frozen moulding in clamped mould. MOULDING STAGES
  • 67.
  • 68. Rotational Moulding It is used t o produce small to large hollow items with very uniform wall thickness Heating while rotating Cooling while rotating Part removal
  • 69.
  • 70. Rotational Moulding Three arm indexing machine
  • 71.
  • 72.
  • 73. A sheet of plastic (for example, compressed polystyrene) is clamped in position above the mould. The heater is then turned on and the plastic slowly becomes soft and pliable as it heats up. The plastic can be seen to 'warp' and 'distort' as the surface expands . After a few minutes the plastic is ready for ‘ forming’ as it becomes very flexible.
  • 74. The heater is turned off and the mould is moved upwards by lifting the lever until it locks in position. The 'vacuum' is turned on and this pumps out all the air beneath the plastic sheet. Atmospheric pressure above the plastic sheet pushes it down on the mould. At this stage the shape of the mould can be clearly seen through the plastic sheet. When the plastic has cooled sufficiently the vacuum pump is switched off.