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Abstract
In the dissertation work an attempt is made to study the Mechanical properties of Glass Fibre Reinforced
Epoxy Composite and Wear Resistance of the material using Design of Experiments (DOE) approach. The composite is
fabricated using Epoxy Resin and woven Glass Fibre mats of different Grams/Square Meter (GSM) values. Hand lay-up
technique is used for fabrication of the composite. The composite is tested as per ASTM standards for various mechanical
properties such as Tensile Strength, Impact Strength and Bending Strength. The composite is also tested for Wear Resistance by varying the process parameters during the test such as load applied, loading time and glass fibre GSM. As per
the Design of Experiments approach, the three parameters are varied in two levels and single replicates i.e. L8 array. The
specified number of experiments is conducted to obtain the optimum condition for Wear Resistance by the composite.
Keywords GFRP, Tensile strength, Impact Strength, Bending Strength, Wear Resistance, DOE
1. Introduction
The unique and diverse characteristics of composite materials have increased in their utilisation worldwide. From featherweight fly fishing rods to high performance airplane parts, the use of fiber reinforced composite materials is becoming
more popular due to their high strength to weight ratio combined with easy manufacturing methods. Fiber reinforced polymer matrix consists of reinforcing fibers and polymer resin. The fibers are considered as principal load carrying constituent
of the composite, while the role of polymer matrix is to transfer the load between fibers as well as provide corrosion resistance damage tolerance and thermal environmental stability.
Fillers are used along with various commodity as well as engineering polymers to improve the properties and reduce the
cost. Incorporating inorganic mineral fillers into plastic resin improves various physical properties of the materials such as
mechanical strength, modulus etc. In general the mechanical properties of particulate filled polymer composites depend
strongly on size, shape and distribution of filler particles in the polymer matrix and extend of interfacial adhesion between
filler and matrix.
At present, epoxy resins are widely used in various engineering and structural applications such as electrical industries, and
commercial and military aircrafts industries. In order to improve their processing and product performances, and to reduce
cost, various fillers are introduced into the resins during processing. However polymeric composites are susceptible to mechanical damage, when subjected to tension, wear and flexural loads resulting in interlayer delamination. Over the past
several decades enormous efforts have been made to study the mechanical characteristics of composites.
1.1 Overview
The dissertation work deals with determining the mechanical properties and wear resistance of glass fibre reinforced epoxy
composite. The composite is manufactured by hand-layup process. Specimens were cut and tested according to ASTM
standards. The mechanical properties like Tensile Strength, Bending Strength and Impact Strength of the material were
studied. Wear resistance of the composite was checked using the Design of Experiment (DOE) approach by varying the
Load, Speed and Loading time on the specimen.
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i) Investigation of the mechanical properties such as Tensile Strength, Bend Strength and Impact Strength of the GFRP.
ii) Investigation of the Wear resistance of the composite.
iii) Using Design of Experiments approach to analyze the Wear resistance of the composite.
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The impact behavior of the composite is experimentally investigated using the notched Charpy Impact test specimen. For this
purpose, Impact Testing Machine (AIT- 300 N) was used which has a maximum energy of pendulum of 300 J. The specimens
were carefully cut to the required dimensions of the impact test according to ASTM D256. The notched Charpy impact
specimen dimensions were (55*12.5 mm) having U notch of 450 with a depth of 0.5 mm prepared by milling machine. The
notch allows for a predetermined crack initiation location. The Charpy impact test method works by placing a notched
specimen (with the notch facing away from the point of contact) into a large machine with a pendulum of a known weight.
The pendulum is raised to a known height and allowed to fall. As the pendulum swings, it impacts and breaks the specimen,
rising to a measured height. A digital attachment for recording the energy absorption was used to perform the tests. The
difference in the initial and final heights is directly proportional to the amount of energy lost due to fracturing the specimen.
2.4. Wear Test
Abrasion testing is used to test the abrasive resistance of solid materials. Materials such as composites can be tested with this
method. The intent of this test method is to produce data that will rank materials in their resistance to sliding abrasion under a
specified set of conditions and can help to predict the life time of a material. Abrasive wear tests were conducted on the
composite specimen according to ASTM standards i.e. ASTM G 65. The wear tests were conducted on a pin-on-drum
abrasive wear tester, designed for standard wear tests described in ASTM standards. In this method, the test specimen
translates over the surface of an abrasive paper, which is mounted on a revolving drum, with the resulting wear of the material
expressed as volume loss. An alumina (Al2O3) abrasive which is substantially harder than either the matrix or the reinforcement was used. The specimen is continuously in contact with new abrasive surface. A static normal load, L, was applied
directly on the specimen to press it against the center of the drum that caused wear. Design of Experiments approach (DOE)
was used to conduct this test. By Taguchi method, L8 array was used containing 3 parameters and 2 levels. Load, Loading
time and Speed are the three parameters that were varied. All tests were carried out in dry ambient air laboratory conditions.
Average E = 1.86
Maximum E = 2.27
Average E = 2.183
Average ILSS
(N/mm)
413.39
581.60
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The result obtained at the end of the impact test in the form of Impact Energy is used to find the Impact Strength. The Impact
Strength was plotted on a graph to conclude on the Final Average Impact Strength of both the GFRP specimens using three
trials each. The results obtained are as follows:
Composite Specimen
415 GSM
600 GSM
Initial Weight
(gms)
2.9761
2.6096
2.9739
3.0520
2.7963
3.0232
2.5965
2.5009
Speed
(rpm)
Load
(kgs)
Time
(min.)
Final Weight
(gms)
Weight
(mg)
Wear Coefficient
(m2/N)
300
300
300
300
600
600
600
600
1.5
1.5
3
3
1.5
1.5
3
3
2
4
2
4
2
4
2
4
2.9742
2.6054
2.9694
3.0465
2.7933
3.0192
2.5924
2.4952
1.9
4.2
4.5
5.5
3.0
4.0
4.1
5.7
6.55 * 10-14
7.25 * 10-14
7.76 * 10-14
4.74 * 10-14
5.16 * 10-14
3.44 * 10-14
3.53 * 10-14
2.45 * 10-14
Table 4.
Initial Weight
(gms)
5.2134
4.5458
4.5547
4.7545
5.2576
4.3962
4.4765
5.0737
Speed
(rpm)
Load
(kgs)
Time
(min.)
Final Weight
(gms)
Weight
(mg)
Wear Coefficient
(m2/N)
300
300
300
300
600
600
600
600
1.5
1.5
3
3
1.5
1.5
3
3
2
4
2
4
2
4
2
4
5.2099
4.5399
4.5510
4.7477
5.2537
4.3910
4.4723
5.0683
3.5
5.9
3.7
6.8
3.9
5.0
4.2
5.4
1.21 * 10-13
2.04 * 10-13
6.38 * 10-14
5.86 * 10-14
6.71 * 10-14
4.30 * 10-14
3.61 * 10-14
2.32 * 10-14
Table 5.
The results were then analysed using the Minitab software. Anova & Response Table for Means & Signal to Noise Ratios for
both the GFRP specimens was obtained as shown below.
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4. Conclusion
From the Tensile tests conducted on the GFRP composite specimens it can be concluded that as the GSM value of the glass
fibre in the composite increases, the tensile strength too increases for the given percentage (40: 60) of glass fibre and resin.
The 3-Point Bend Test conducted on the GFRP gave the responses in terms of Bend load and change in height (CHT)
through which the Flexural strength was calculated. The higher flexural strength for 415 GSM than 600 GSM can be due to
inclusions and voids in the microstructure of the composite specimen. Impact test conducted on the GFRP specimens
yielded results in terms of impact load that the specimens could bear before fracture. The impact energy of the composite
increases with an increase in the GSM value of the glass fibre reinforcement.
The results obtained from Wear tests were used to analyse and interpret the results using Design of Experiments (DOE)
approach and Minitab software. The results show the Mean values, Signal to Noise (SN) ratio values and the rank of the
different parameters that varied. It is observed that as the GSM values of the GFRP specimens and the load increase, the
wear observed on the specimen increases i.e. the wear resistance of the specimen decreases.
ACKNOWLEDGEMENT
I am greatly indebted to Prof. Nikhil R. & Prof. G. S. Guggari (I.P.E., G.I.T., Belagavi), for their guidance & unending
support throughout the course of the work. I deeply thank Dr. Shivkumar S., Professor (I.P.E., G.I.T., Belagavi), for his
guidance and also for being a great source of knowledge.
I would like to express my sincere gratitude to Mr. Suhas P. Chandak (Director), Mr. Uttam S. Gurjar (Production Manager)
and supporting staff, Vega Industries Pvt, Ltd., Belagavi, for providing me with an opportunity to carry out the dissertation
work in their esteemed organization and for training/guiding me.
I would also like to express my deep gratitude to Prof. D. B. Patil, H.O.D. & all the staff members, Mechanical Engineering
Department, J.C.E., Belagavi, for being a constant source of encouragement.
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