Design, Fabrication and Characterization of Polymer based Hybrid

Composites for Automotive & Food Processing Machinery

Hemanth G, Apurva Rakesh, Adarsh K M, Anjan Poonacha K M
The National Institute of Engineering, Manandavadi road, Mysore-570008
Project Poster Presentation: 2018-19 Guide: Dr. B. Suresha (Professor & Dean (R&D)

Abstract Methodology
Polyarylether Ketone (PAEK) combined with particulate Boron  Injection molding followed by extrusion is used to fabricate the
Nitride (BN) was investigated for the tribological performance composites.
under multi-pass abrasion wear condition. Composites showed  Multipass tests, pin on disc test (ASTM G99) and three body
increasing specific wear rate with filler loading under both abrasive wear test were conducted (ASTM G65).
tribology tests. The PAEK with 10 wt.% BN loading showcased  For Pin on Disc test, composition, Emery paper grit size and
the decreased specific wear rate of 27.12% when used with sliding distance were varied.
 The wear rate between abrasive wear was compared.
emery paper beyond 320 grit. However, for further increment in
 To study the mechanism of wear the SEM images were taken
BN material experienced more wear. Three body abrasion with
and analyzed.
silica sand showed decreasing specific wear rate with escalating
 Apart from the above tests, density and hardness were
sliding distances. The thermal effects was insignificant as the performed as per ASTM standards.
duration of examination was feeble. Material loss with Three
Materials and Test Parameters
body abrasive wear test was found to vary from 0.8 to 2.4 times
to that of the pin on disc. The diminish in the wear rate ranges • Polyarlyetherketone has shown it’s application not only in
from 27.72% to 39.88%. The wear surface morphology was automotive and aerospace but also in electrical insulation, high
analyzed under the vision of Scanning electron microscope. thermal application and chemical environment. Figure 5. Worn out specimens for 500m sliding distance
Figure 2. Specific wear rate of pin on disc experiment with under three body abrasive wear.
• Boron Nitride has identified itself as anti-wear additive, it also
emery paper
Keywords: Composites, Hardness, Abrasion, Specific Wear imparts the thermal conductivity to the composite prepared.
Rate, Scanning Electron Microscope. Table 2. Variables associated in testing. Summary
Introduction Factors Levels Based on the test results obtained, following conclusions are
1 2 3 derived,
In most of the engineering applications, abrasive wear Filler Content (%) 10 20 30  Density showed increasing trend whereas hardness exhibited
problems arise in the form of three-body wear, while two- Grit size 100 150 320 decreasing trend.
body abrasion occurs primarily in material removal Sliding Distance (m) 175 1487 3600  PAEK and their composites surfaces exhibited relatively high
operations. initial wear rate, when the surfaces are new, which decreases
Table 3. Three body abrasive wear test conditions. gradually to an almost constant value.
Table 1. Litreature Review
Test Sliding Velocity Load Particle
Distance (m/s) (N) size
 The specific wear rate is decreases with increase in the grit
Author Title Conclusions size of the emery paper. 27.12% decrement was observed in
(m) (microns)
Harsha et al. Two-body and three-body abrasive wear Abrasive wear of PAEK and its
behaviour of composite depends upon load and Three Body 250, 500, 750, 2.4 15 425 specific wear rate with 320 grit paper.
polyaryletherketone composites. sliding distances. Abrasion wear 1000  In pin on disc test after a few revolution abrasion ceases and
Harsha et al. Three-body abrasive wear behaviour of Abrasive wear rate is higher in
Results and Discussions sliding prevails because of composite debris formed.
polyaryletherketone composites. composites than the neat Figure 3. Specific wear rate of Three body abrasion with  The specific wear rate decreases with increase in sliding
matrix.
Harsha et al. Tribological studies on polyetherketone Due to repetitive cyclic stress,
Table 4. Density and Hardness test results. varying sliding distances distances was observed. The decrement was found to be vary
composite under reciprocating sliding deterioration of fiber–matrix,
Specimen Density (g/cc) Shore D hardness from 27.72% for P20BN to 39.88% for P0BN.
(a) (b)
condition against steel cylinder. adhesion, and fiber–matrix

 As the sliding distances increases the surface area increases

debonding dominated the wear
mechanisms. P(Neat) 1.29 73.7
P(10BN) 1.33 68.2 where the contact pressure decreases
Geringer et Wear behavior of PAEK, poly (aryl-ether- PAEK materials could
al. ketone), under physiological conditions, be used potentially as implants,
P(20BN) 1.40 64.64  The wear rate in Three body abrasive wear was found to range
from 0.8 to 2.4 times that of the pin on disc.
outlooks for performing these materials in for example, artificial hip joint.
the field of hip prosthesis.
P(30BN) 1.43 55.7
 Higher loading of fillers showed more material loss making it
Laux et al. Wear behavior of polyaryletherketones Greater adhesion between the pin
under multi-directional sliding and fretting and counterface results in not feasible to use in bearing application.
 PAEK based composites can be used as a substitute for
conditions frictional softening which
increases the
magnitude of frictional force and
the wear.
traditional material in the field orthopaedic joint replacement.
Gan et al. Mechanical properties and frictional The frictional behaviour of the
behavior of a mica-filled poly (aryl ether PAEK composites were effected (c) (d) Acknowledgements
ketone) composite. by the content of filler used.

PAEK based composites show exceptional properties due to its We would like to Thank Principal Dr. G .Ravi and Head of the
semi-crystalline character and molecular rigidity of its repeating Department Dr. M. V. Achutha for providing an opportunity to do
units. PAEK based composites can be used as an alternative to project.
traditional UHMWPE (ultra high molecular weight polyethylene) We thank Professor and Dean(R&D) Dr. B. Suresha for guiding
polymer as a bone replacement material. The tribological us throughout this project.
property is affected by parameters like sliding velocity, normal We also thank TEQIP lll for providing us with the required funds
load, contact geometry, and also on the relative movement needed to carry this project.
Figure 1. (a),(b) & (c) Wear mechanism of three body wear and Figure 4. Surface morphology of composite (a) P0BN,
between the two materials in contact. (d) pin on disc wear test. (b) P10BN, (c) P20BN, (d) P30BN
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