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B.HARINDRAN (Reg.No:112915114031)
M.KARTHIKEYAN (Reg.No:112915114047)
S.MAREESWARAN (Reg.No:112915114061)
D.SELVAMANI (Reg.No:112915114097)
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
APRIL 2019
BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND ANALYSIS OF ARTIFICIAL LIMB
USING FIBER REINFORCED POLYMERIC COMPOSITES”is the bonafide work
B.HARINDRAN,M.KARTHIKEYAN, S.MAREESWARAN,D.SELVAMANI who
carried out the project work under my supervision.
SIGNATURE SIGNATURE
Dr.G.PAULRAJ,Ph.D., Mr. B.MURALI, M.E.,
HEAD OF THE DEPARTMENT INTERNAL SUPERVISOR
Assistant Professor, Assistant Professor,
Department of Mechanical Department of Mechanical
Engineering Engineering,
Vel tech owned by R S Trust, Vel tech owned by R S Trust,
Avadi Avadi
Chennai-600 062. Chennai-600 062.
Trust.
We would like to express our heartfelt gratitude to all the faculty and
supporting staff of Mechanical Engineering Department for the help they
extended for completion of project.
This project is dedicated to our parents and friends who were with us
during the tough times by extending their full support to us.
i
ABSTRACT
Composites made with natural fibers are finding applications in a wide variety
of engineering fields due to their low cost and eco-friendly nature. The
fabricated composite samples are tested to investigate the various mechanical
and wear properties.This project deals with hybrid composite materials made of
natural fibres namely kenaf and flax fibres. Glass fibre reinforcement polymer
(GFRP) is used for lamination on both sides. The test result shows that hybrid
composite has far better properties than single fibre glass reinforced composite.
The mechanical and wear properties of the fibers are evaluated under different
combinations as per ASTM standards, and the analysis are compared with a
software analysis using ANSYS software.
LIST OF CONTENTS
1.5.2. Fibers 8
iv
LIST OF FIGURES
LIST OF TABLES
1
competitive with metals.
The composites industry has begun to recognize that the
commercial applications of composites promise to offer much larger
business opportunities than the aerospace sector due to the sheer size of
transportation industry. Thus the shift of composite applications from
aircraft to other commercial uses has become prominent in recent years.
Increasingly enabled by the introduction of newer polymer resin matrix
materials and high performance reinforcement fibers of glass, carbon and
aramid, the penetration of these advanced materials has witnessed a
steady expansion in uses and volume. The increased volume has resulted
in an expected reduction in costs. High performance FRP can now be
found in such diverse applications as composite armoring designed to
resist explosive impacts, fuel cylinders for natural gas vehicles, windmill
blades, industrial drive shafts, support beams of highway bridges and
even paper making rollers.
For certain applications, the use of composites rather than metals
has in fact resulted in savings of both cost and weight. Some examples
are cascades for engines, curved fairing and fillets, replacements for
welded metallic parts, cylinders, tubes, ducts, blade containment bands
etc. Further, the need of composite for lighter construction materials and
more seismic resistant structures has placed high emphasis on the use of
new and advanced materials that not only decreases dead weight but also
absorbs the shock & vibration through tailored microstructures.
Composites are now extensively being used for rehabilitation/
strengthening of pre-existing structures that have to be retrofitted to make
them seismic resistant, or to repair damage caused by seismic activity.
Unlike conventional materials (e.g., steel), the properties of the composite
material can be designed considering the structural aspects.
Composite properties (e.g. stiffness, thermal expansion etc.) can be
varied continuously over a broad range of values under the control of the
designer. Careful selection of reinforcement type enables finished product
characteristics to be tailored to almost any specific engineering
requirement. Whilst the use of composites will be a clear choice in many
instances, material selection in others will depend on factors such as
working lifetime requirements, number of items to be produced (run
length), complexity of product shape, possible savings in assembly costs
and on the experience & skills the designer in tapping the optimum
potential of composites. In some instances, best results may be achieved
through the use of composites in conjunction with traditional materials.
1.2Classification of Composites
Broadly, composite materials can be classified into three groups on the
basis of matrix material. They are:
a) Metal Matrix Composites (MMC)
b) Ceramic Matrix Composites (CMC)
c) Polymer Matrix Composites (PMC)
A) METAL MATRIX COMPOSITES
1.5.2 Fibers
Fibers are the principal constituent in a fiber reinforced composites. They
occupy the largest volume fraction in a composite structure and share the
major load acting on it. Proper selection of the fiber type, fiber volume
fraction, fiber length, and fiber orientation is very important in
composites.
Fiber influence the following characteristics of composite structure
1. Density
2. Tensile strength and modulus
3. Compressive strength and modulus
4. Fatigue strength and as well as fatigue failure mechanisms
5. Electrical and thermal conductivities
1.5.2.1SYNTHETIC FIBERS
Glass Fibers
Glass fibers are the most common of all reinforcing fibers for
polymeric (plastic) matrix composites (PMCs). The principal advantages
of glass fiber are low cost, high tensile strength, high chemical resistance
and excellent insulating properties. The two types of glass fibers
commonly used in the fiber reinforced plastics industries are E-glass and
S-glass. Another type known as C-glass is used in chemical applications
requiring greater corrosion resistance to acids than is provided by E-glass.
Carbon Fibers
Carbon fibers are used for reinforcing certain matrix materials to
form composites. The physical properties of carbon fiber reinforced
composite materials depend considerably on the nature of the matrix, the
fiber alignment, the volume fraction of the fiber and matrix, and on the
molding conditions. Carbon fiber composites, particularly those with
polymer matrices, have become the dominant advanced composite
materials for aerospace, automobile and other applications due to their
high strength, high modulus, low density, and reasonable cost for
application requiring high temperature resistance as in the case of
spacecrafts
Kevlar Fibers
Kevlar belongs to a group of highly crystalline aramid (aromatic
amide) fibers that have the lowest specific gravity and the highest tensile
strength to weight ratio among the current reinforcing fibers. They are
being used as reinforcement in many marine and aerospace applications.
1.5.2.2 NATURAL FIBERS
The interest in natural fiber-reinforced polymer composite
materials is rapidly growing both in terms of their industrial applications
and fundamental research. They are renewable, cheap, completely or
partially recyclable, and biodegradable. Plants, such as flax, cotton,
hemp, jute, sisal, kenaf, pineapple, ramie, bamboo, banana, etc., as well
as wood, used from time immemorial as a source of lignocelluloses
fibers, more often applied in reinforcement of composites.
Their availability, renewability, low density, and price as well as
satisfactory mechanical properties make them an attractive ecological
alternative to glass, carbon and man-made fibers used for the
manufacturing of composites. The natural fiber-containing composites are
more environmentally friendly, and are used in transportation
(automobiles, railway coaches, aerospace), military applications, building
and construction industries (ceiling paneling, partition boards),
packaging, consumer products, etc.
Natural fibers include those made from plant, animal and mineral
sources. Natural fibers can be classified according to their origin.
Natural Fibers
The natural fiber composites can be very cost effective material for
following applications:
Building and construction industry:
panels for partition and false ceiling, partition boards, wall, floor,
window and door frames, roof tiles, mobile or pre-fabricated
buildings which can be used in times of natural calamities such as
floods, cyclones, earthquakes, etc.
Storage devices: Post-boxes, grain storage silos, bio-gas
containers, etc.
Furniture: chair, table, shower, bath units, etc.
Electric devices: Electrical appliances, pipes, etc.
Everyday applications: Lampshades, suitcases, helmets, etc.
Transportation: Automobile and railway coach interior, boat, etc.
CHAPTER 2
LITERATURE SURVEY
Bast fibers are defined as those obtained from the outer cell layers
of the stems of various plants and comprises one-third of the weight. Bast
fibers are made up of bundles of fibers. These bundles are broken down
mechanically or chemically to achieve the fineness required.The
filaments are made of cellulose and hemicellulose, bonded together by a
matrix, which can be lignin or pectin. Natural Bast Fibers are strong,
cellulosic fibers obtained from the phloem or outer bark of jute, kenaf,
flax and hemp plants [7].
The fibers find use in textile applications and are increasingly
being considered as reinforcements for polymer–matrix composites as
they are perceived to be ‘‘sustainable’’. The fibers are composed
primarily of cellulose which potentially has a Young’s modulus of 140
GPa (being a value comparable with manmade aramid [Kevlar/Twaron]
fibers). The plants which are currently attracting most interest are flax
and hemp (in temperate climates) or jute and kenaf (in tropical climates)
[8].
20
the highest tensile strength and flexural strength for both kenaf bast and
core fiber composites were 20%wt. The optimal value to obtain the
highest impact strength for kenaf bast and core fiber composites was
10%wt and 5%wt respectively. The elongation at break for both
composites decreased as the fibers content increased [36].
Kenaf fiber can be a good reinforcement candidate for high
performance polymer composites. The alkalization treatment has
improved the mechanical properties of the composites. Kenaf provides an
opportunity of replacing existing materials with a higher strength, low
cost alternative that is environmentally friendly [37].
The Arengapinnata fibers were mixed with epoxy resin at the
various fiber weight percentages of 10, 15 and 20% Arengapinnata fiber
and with different fiber orientations such as long random, chopped
random and woven roving. Results from the flexural tests of
Arengapinnata fiber reinforced epoxy composite are that the 10 wt %
woven roving Arengapinnata fiber showed the highest value for
maximum flexural properties. The flexural strength and flexural modulus
values for 10 wt % of woven roving Arengapinnata fiber composite are
108.157 MPa and 4421.782 MPa respectively [38].
In flexural stress test, flexural modulus decreased with the
increasing of volume fraction of pseudo-stem banana fiber in the matrix.
Pseudo-stem banana fiber improved the impact strength properties of the
epoxy material. Higher impact strength value leads to the higher
toughness properties of the material [39].
Okra woven FRP composites showed the highest tensile strength
and modulus of 64.41 MPa and 946.44 MPa respectively. Specific tensile
strength and modulus of untreated and treated okra FRP composites is
34.31% and 39.84% higher than pure polyester specimen respectively
[40].
Uniaxial tensile behavior of Kenaf bast fiber bundles (KBFB) and
Kenaf fiber epoxy composite strands were evaluated at various loading
rates. Statistical elastic properties are presented based on a relatively
large testing sample set due to a large scatter in tensile properties caused
by the random arrangement of single fibers in the KBFB. The KBFB is
fairly brittle and demonstrated a rate-dependency in the strain rate range
of 10-4 ~10-2/s. No significant variations in tensile modulus were observed
after these high temperature treatments [41].
Banana and pandanus woven reinforced unsaturated polyester
composites werefabricated. Improvement in flexural and impact
properties of the resin was obtainedwith the use of these two woven
fabrics. Banana woven composites effectively reinforcedpolyester resin
and the flexural and impact performances are maximum at 10 and 15 vol
%loadings, respectively. Pandanus woven composites exhibits lower
flexural and impactproperties than those of banana composites. Water
absorption studies indicates pandanusfiber composites shows higher
water absorption when compared to banana fiber composites,and as
expected higher water up-take was observed at higher fiber content. This
isdue to poor fiber–matrix adhesion and the existence of defect such as
voids at high fibercontent. The present work is still preliminary because
of limited testing used to comparethe properties of these two fiber
composites [42].
There are a quite few research studies on the effects of operating
conditions on tribological performance,such as applied load, sliding
distance and sliding speed. However, studies on the effects of temperature
and fibercomposition are limited in exploring tribological behaviour.
Thus, the aim of this work was to explore the influenceof temperature and
fiber composition on the coefficient of friction (COF) and the wear rate
of oil palm fiber/epoxycomposite (OPF/E) and kenaf fiber/epoxy (KF/E)
composites. To date, several wear mechanisms have beenproposed for
different natural fiber composites. These include micro-cracks,
debonding, deformation, delamination,detachment, pull-out, breakage of
fibers, and torn fibers. Studies have demonstrated that wearmechanisms
change with the severity of contact conditions. Therefore, a wear
mapping approach was alsoundertaken to represent mild to severe wear
transition and predominant wear mechanisms in these two regimes as
afunction of temperature and fiber composition factors. Hence, this paper
as well explored the possibility of using thisnatural fiber reinforce epoxy
as a new candidate tribo-material for bearing applications related to the
previousstudy’s aim by Chin and Yousif that using kenaf fibers as
reinforcement for tribo-composite. Hereby, it isdesired to have a low
friction coefficient with low specific wear rate [43].
It can be concluded that epoxy composites reinforced with basal
fiber and modifiedwith basalt powder indicate good thermomechanical
properties. Hybrid effect, caused by anintroduction of both powder and
fibrous filler into epoxy matrix, was obtained. Theintroduction of basalt
powder improves stiffness and thermal resistance of the
compositesTherefore, both elastic modulus values and storage modulus
values of these materialsincreased. Complex modification of mechanical
properties caused by hybridization of basaltfiber reinforced composites
was observed. The most advantageous mechanical andthermomechanical
properties for the sample containing 2.5 wt% of basalt powder
wereobtained, due to sufficient dispersion of basalt powder particles in
epoxy matrix. Moreover, itwas found that incorporation of low amounts
(2.5 wt%) of basalt powder led to a decrease incomposites’ brittleness in
comparison to unmodified epoxy composites. Introduction of
higheramounts of the powder may cause formation of agglomerates
(defects) in epoxy matrix [44].
The wear properties of all the form of composites mentioned
hereinbefore was analysed, wherein the SN composite had shown severe
abrasion loss of 0.3991g. S15 composite had shown the least abrasion
loss of 0.2729g among all the form of composites, which is 31.62% less
than that of SN composite. This indicates that the addition of
molybdenum sulphide to the resin matrix had considerably increased the
wear properties of the composites. The tensile properties of the S15
composites were found to be better, which shows that the rigidity of the
composite was increased with increase in the addition of molybdenum
disulphide. The tensile strength and tensile modulus of S15 composite
was found to be 32.47MPa and 1623MPa, respectively. In analogous to
the tensile properties, flexural properties too was found to be better in the
case of S15 composites because of the increase in stiffness of the
composite on addition of molybdenum disulphide. The flexural strength
of the S15 composites was 21.9% more than that of SN composites [45].
CHAPTER 3
MATERIALS AND METHODS
3.1.6 Hardener
The hand layup technique is one of the oldest and most commonly
used methods for manufacture of the composite parts. The infrastructural
requirement for this method is less. The processing steps are quite simple.
In the beginning a liquid paraffin is sprayed on the mould surface to
avoid the sticking of fiber to the mould surface. Thin plastic sheets are
used at the top and bottom of the mould to get good surface finish of the
product. The fibers which are in the form of woven mats are cut as per the
mould size and placed at the surface of mould. Then the liquid form
epoxy resin and the prescribed hardner (polymer) is mixed thoroughly in
suitable proportion with a ratio of 10:1 and it is poured on to the mould
surface where the fiber is placed. The polymer is uniformly spread with
the help of roller. Second layer of the fiber is then placed on the polymer
surface and a roller is moved with a mild pressure on the fiber-polymer
layer to remove any air trapped as well as the excess polymer present.
The process is repeated for each layer of polymer and fiber, till the
required layers. After placing the plastic sheet, liquid paraffin is sprayed
on the inner surface of the top mould plate which is then kept on the
stacked layers and the pressure is applied.
Then the finished product is kept at room temperature or at some
specific temperature, mould is opened and the developed composite part
is taken out and further processed. The time of curing depends on type of
polymer used for composite processing. It is lead to a normal curing time
of room temperature of 24-48 hours. This method is mainly suitable for
thermosetting polymer based composites. Capital and infrastructural
requirement is less as compared to other methods. Production rate is less
and high volume fraction of reinforcement is difficult to achieve in the
processed composites. Hand lay-up method finds application in many
areas like aircraft components, automotive parts, boat hulls, diase board,
deck etc. Curing the part can be cured at elevated temperatures using an
oven (usually somewhere around 160 degrees F) or at room temperature.
Generally, the proper curing time of each type of resin-hardener, as well
as the working time, is given by the supplier on the back of the
containers.Most plastic sheet available from hardware stores
(polyethylene) may melt. If planning the layup part is going to be moved
to a curing oven, then layup should be done on a caul plate- generally a
sheet of aluminum or steel >1/8” thick .
Fig. 3.7 Hand-layup technique
COMBINATIONS OF FIBERS
S.NO SEQUENCE OF S1 S2
LAMINATES
The impact test is a method for evaluating the toughness and notch sensitivity
of engineering materials. It is usually used to test the toughness of metals, but
similar tests are used for polymers, ceramics and composites. Metal industry
sectors include Oil and Gas, Aerospace, Power Generation, Automotive, and
Nuclear. The notched test specimen is broken by the impact of a heavy pendulum
or hammer, falling at a predetermined velocity through a fixed distance. The test
measures the energy absorbed by the fractured specimen.
The test specimen is machined to a square or round section, with either one ,
two or three notches. The specimen is clamped vertically on the anvil with the
notch facing the Hammer.
38
Fig 3.9 IMPACT TEST
Procasting Process
A metal mold of rectangular shape is taken with a size of 30x30x5 mm
width, length, and depth. The fiber mat that has been prepared is taken with equal
ratio of two mixtures (hybrid fibers). The matrix of epoxy resin is poured in to the
ingredient with 1:1 ratio of hardner and resin and mix up gradually to get as free of
air gaps. The fine mixture of fiber and matrix is filled in the rectangular wooden
mold and dry it under room temperature
3.5 ANSYS
The first commercial version of Ansys software was labeled version 2.0 and
released in 1971. At the time, the software was made up of boxes of punch cards,
and the program was typically run overnight to get results the following morning.
In 1975, non-linear and thermo-electric features were added. The software was
exclusively used on mainframes, until version 3.0 (the second release) was
introduced for the VAXstation in 1979. Version 3 had a command line interface
like DOS.
The combination of s1fibre is kenaf and flax with e-glass gives the more
tensile strength compared to s2 fibre which is combination of s1fibre is kenaf and flax
with s-glass.
Laminate s1=Kenaf+Flax+E-glass
Laminate s2=Kenaf+Flax+S-glass
s1s2
The combination of s1fibre is kenaf and flax with e-glass gives the more
impact strength compared to s2 fibre which is combination of s1fibre is kenaf and flax
with s-glass.
Laminate s1=Kenaf+Flax+E-glass
Laminate s2=Kenaf+Flax+S-glass
Impact
1.5
1
0.5
0
s1 s2
The combination of s1fibre is kenaf and flax with e-glass gives the more
flextural strength compared to s2 fibre which is combination of s1fibre is kenaf and
flax with s-glass.
Laminate s1=Kenaf+Flax+E-glass
Laminate s2=Kenaf+Flax+S-glass
s1s2
0
13 17 20
Co-Efficient of Friction 6.548 6.548 6.4014
Specific Wear Rate 0.5036 0.3851 0.32007
Wear Loss 0.1025 0.0784 0.0651
0
13 17 20
Co-Efficient of Friction 6.4009 6.3142 6.3138
Specific Wear Rate 0.4923 0.3714 0.3156
Wear Loss 0.1002 0.0756 0.0642
0
13 17 20
Co-Efficient of Friction 6.5394 6.5391 6.5391
Specific Wear Rate 0.503 0.3846 0.3269
Wear Loss 0.1024 0.0783 0.0665
13 17 20
Co-Efficient of Friction 6.0918 6.6605 6.6593
Specific Wear Rate 0.4686 0.3917 0.3329
Wear Loss 0.0954 0.0797 0.0678
0
13 17 20
Co-Efficient of Friction 6.0841 6.0818 6.4334
Specific Wear Rate 0.468 0.3577 0.3217
Wear Loss 0.0953 0.0728 0.0655
0
13 17 20
Co-Efficient of Friction 6.4307 6.4398 6.4874
Specific Wear Rate 0.4946 0.3788 0.3243
Wear Loss 0.1007 0.0771 0.066
Using ANSYS APDL , we are analyzing the acting on the different fiber
combinations , a constant load of 981N is applied at on the product and the
stresses acting on them is evaluated
Modelling
Deformation
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