PROJECT

PRESENTATION
DESIGN AND DEVELOPMENT OF PULTRUSION SETUP FOR FRP
COMPOSITE
NAME OF GUIDE
ASSOCIATE PROFESSOR ANURAG GUPTA
BY
SINGH(1102940048)
CHAUDHARY(1102940051)
SINGH(1102940066)

HARENDRA
HIMANSHU
NIKHIL
NISHANT

CONTENTS
INTRODUCTION
PULTRUSION PROCESS
RESINS & REINFOCRCEMENT USED IN PULTRUSION
FRP COMPOSITES
SIX KEY ELEMENT IN PULTRUSION PROCESS
PULTRUSION APPLICATION
ADVANTAGES & DISADVANTAGES OF PULTRUSION
COST
COURSE OF ACTION

PULTRUSION SETUP FOR FRP

INTRODUCTION
composite material is a judicious combination of two or more
materials that produces a synergistic effect. A material system
composed of two or more physically distinct phases whose
combination produces aggregate properties that are different from
those of its constituents.
Pultrusion setup is a machine that creates composites such as FRP
composites.This setup creates composites in a rapid and economical
way.

PULTRUSION PROCESS
Automated process for manufacturing composite materials into
continuous cross-section profiles
In the standard pultrusion process the reinforcement materials
like fibers or woven or braided strands are impregnated with resin,
possibly followed by a separate preforming system, and pulled
through
a
heated
stationary die where
the
resin
undergoes polymerization. The impregnation is either done by pulling
the reinforcement through a bath or by injectiong the resin into an
injection chamber which typically is connected to the die. Many resin
types
may
be
used
in
pultrusion
including polyester, polyurethane, vinylester and epoxy.

FIG: PUTRUSION PROCESS

1
2
3
4
5
6
7

Continuous roll of reinforced fibers/woven fiber mat

Tension roller
Resin Impregnator
Resin soaked fiber
Die and heat source
Pull mechanism
Finished hardened fiber reinforced polymer

RESINS USED IN PULTRUSION

low viscosities (500 cps)
ability to cure quickly
polyester (most common)
control of styrene level critical - must achieve satisfactory cross-link structure without leaving residual (unreacted)
styrene in finished composite
shrinks upon cure facilitating release from die
vinyl ester resin
slower process speed due to slower reaction
epoxy
very slow process speed
reaction rate is very slow - gelation of epoxy resins occurs at a later stage of reaction - critical exotherm must be
contained within die
typically shorter pot life
drip off at die entrance must be discarded rather than recirculated to bath
temp profiles typically hotter
tendency to bond strongly to die wall

REINFORCEMENT USED IN
PULTRUSION
Form
Type
E-glass, S-glass
carbon/graphite
aramid

roving
mat
fabric

FRP COPOSITES
Fibre-reinforced plastic (FRP) (also fibre-reinforced
polymer) is a composite material made of a polymer
matrix reinforced with fibres.
The fibres are usually glass, carbon, basalt or aramid,
although other fibres such as paper or wood or asbestos
have been sometimes used.
The polymer is usually an epoxy, vinylester or polyester
thermosetting plastic, and phenol formaldehyde resins are
still in use. FRPs are commonly used in the aerospace,
automotive, marine, construction industries and ballistic
armor.

FRP COMPOSITES CONTD.

SIX KEY ELEMENT IN PULTRUSION

PROCESS
Three occur prior to pultrusion
machine
reinforcement handling
system (creel)
resin impregnation station
material forming area

Three integral to pultrusion

machine
components that heat and
consolidate
equipment to pull pultrusion
equipment to cut pultrusion

PULTRUSION APPLICATION
selection of pultruded parts not strictly based on price
competitiveness, but other characteristics not found in
traditional materials
non-conductive ladder rails (highest volume application)
applications in the electric utility industry (insulating
properties)
insulators
hot-line maintenance tools
booms for electrical bucket trucks

grating systems (walkways, stairs, ...) in highly corrosive

environments

ADVANTAGES OF PULTRUSION
high throughput rate
finished part
lines can reportedly produce certain profiles at 10 - 15 ft/min
more typical line speeds in the range of 2 - 4 ft/min

high material usage (low process waste, part is net)

able to use wide variety of reinforcement types, forms and styles with many
thermosetting resins and fillers
complex thin walled shapes can be fabricated (traditionally extruded in
aluminum, PVC)
can fabricate extremely large parts
can fabricate any transportable length parts

DISADVANTAGES OF PULTRUSION
cross-sections must generally be uniform
difficult to maintain tight tolerances
shrinkage (commonly 2% - 3%)
difficult to control
cross-section dependent (variation in thickness)

straightness along length

lateral and bowing
may be able to remove with force

quick curing resin systems typically have lower mechanical properties

complexity of process
problems resulting from resin and fibers accumulating and building up at die
entrance
parts are run resin rich to account for fiber anomalies, strength is sacrificed
voids may result in parts if excessive opening given at die entrance

COST
The expected cost of the project will be around Rs
40,000/- because there are some costly parts of the
machine
It is expected that college will provide some economic
help in making of this machine which will be useful for
college in the future

COURSE OF ACTION
MONTHS
SEPTEMBER
OCTOBER
MACHINE
NOVEMBER

FEBRUARY &

MARCH

PROPOSED ACTIONS
SYNOPSIS PRESENTATION
DESIGN AND ANALYSIS OF
ARRANGEMENT OF PARTS OF
MACHINE
INSTALLATION AND TRIALS

THANKS A MILLION