Modeling and analysis of hybrid composite

strip with bolted joint using FEM

PRESENTED BY

SHANAWAZ KHAN.M (Reg. No. 312811114042)

SIVA.A (Reg. No. 312811114045)
SURESH.M (Reg. No. 312811114310)

Under the Guidance of,

Mr. RAMESH.R M.E., (Supervisor)
Assistant Professor,

Department of Mechanical Engineering,

Agni College of Technology,

Chennai- 603 130.

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 ABSTRACT

 Composite materials are materials made from two or more constituent materials
with significantly different physical structure and chemical properties.

 In this project, we made a composite plate by mixing three fibres of different

physical and chemical properties. These fibres are held together by epoxy resin
along with little amount of hardener which acts as binding agent.

 The composite plate after manufacturing is cut into rectangular strips in reference
to ASTM standard. Of these ,two rectangular strips are made together as lap joint
which is done by bolt and nut assembly.

 Tensile test and bending moment test are executed in the fiber reinforced strips.

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 ABSTRACT

 By getting the result, we can analyse the strength of this composite joints and can
be applied in the area where conventional metals is used.

 Using this composite joint in place of metals can considerably reduce the weight
and it is free of corrosiveness which is the drawback for most of the metal joints.

 This is can be applied mostly in aero ship manufacturing where the ultimate aim is
to reduce weight and increase the strength of the materials used.FEM analysis is
done in ANSYS version [15,work bench].

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 TYPES OF GLASS FIBERS

LETTER DESIGNATION PROPERTY OR

CHARACTERISTIC
E, electrical Low electrical conductivity
S, strength High strength

C, chemical High chemical durability

M, modulus High stiffness

A, alkali High alkali or soda lime glass

D, dielectric Low dielectric constant

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 LITRATURE REVIEW

S.VENKATESWARLU 1,K.RAJASEKHAR 2“ANALYSIS OF

SINGLE RIVET COMPOSITE JOINT” PUBLISHED IN IOSR
JOURNAL OF MECHANICAL AND CIVIL ENGINEERING, PP 01-
06 concluded that, The shear stress with hybrid joint has less value of
stress and also the glass Fibre reinforced plastic material the cost is less
than other composite material. The stress induced by using ansys is less
than the material allowable stress. It was found that a well designed hybrid
joint is very efficient when compared to bonded, riveted joints in case of
repair situation in aircraft structures. The GFRP strength is less than that of
the CFRP strength .

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 LITRATURE REVIEW

TP.SATHISHKUMAR,J.NAVEEN,S.SATHEESHKUMAR “HYBRID FIBER

REINFORCED POLYMER COMPOSITES” IN JOURNAL OF
REINFORCED PLASTICS AND COMPOSITES reported that ,The polymer
matrix composites have been widely used for many applications. These are light in
weight and easy for manufacturing. The hybrid fiber reinforced composites have
been prepared to enhance the mechanical, thermal, damping properties compared to
single-fiber reinforced composites. The fiber reinforced hybrid composites consist
of two or more fiber in a matrix system. The different fibers were reinforced with
suitable matrix for preparing the hybrid composites using various manufacturing
methodology.

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 A-GLASS FIBER

A-GLASS FIBER:

 It is called as Alkali-lime glass with little or no boron oxide fiber. If SiO 2 is heated
above 1200°C/2192°F then cooled ambient, it crystallizes and becomes quartz.

 Glass is produced by altering the temperature and cool down rates. If pure SiO 2 is
heated to 1720°C/3128°F then cooled quickly, crystallization can be prevented and
the process yields the amorphous or randomly ordered atomic structure we know as
glass.
 Today’s glass fiber manufacturers combine this high heat/quick cool strategy with
other steps in a process

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 E-GLASS FIBER

 E-Glass or electrical grade glass was originally developed for stand off
insulators for electrical wiring.
 It was later found to have excellent fibre forming capabilities and is now
used almost exclusively as the reinforcing phase in the material commonly known
as fibreglasses-Glass.

 Low alkali glass with a typical nominal composition of SiO 2 54wt%,

Al2O314wt%, CaO+MgO 22wt%, B2O3 10wt% and Na2O+K2O less then 2wt%.
Some other materials may also be present at impurity levels.

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ACTUAL PICTURE OF E-GLASSFIBER

E- Glass Fiber

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 HYBRID COMPOSITES

 The term hybrid effect has been used to describe the phenomenon of an apparent
synergistic improvement in the properties of a composite containing two or more
types of fibre .
 The selection of the components that make up the hybrid composite is determined
by the purpose of hybridization, requirements imposed on the material or the
construction being designed.
 The problem of selecting the type of compatible fibres and the level of their
properties is of prime importance when designing and producing hybrid
composites..

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 EPOXY RESIN

 Epoxy resins, also known as polyepoxides are a class of

reactive prepolymer and polymers which contain epoxide groups.
 Epoxy resins may be reacted (cross-linked) either with themselves through
catalytic homo polymerisation, or with a wide range of co-reactants including poly
functional amines, acids (and acid anhydrides), phenols, alcohols, and thiols.
 Reaction of polyepoxides with themselves or with poly functional hardeners forms
a thermo setting polymer, often with strong mechanical properties as well as high
temperature and chemical resistance.

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 HARDERNER

Curing may be achieved by reacting an epoxy with itself (homopolymerisation) or by

forming a copolymer with polyfunctional curatives or hardeners.

 In principle, any molecule containing a reactive hydrogen may react with the
epoxide groups of the epoxy resin.

 Applications of these epoxy resin hardeners extend over to casting, impregnation,

lamination and many others.

Harderner used : HY 957

Chemical Name : Triethylene tetra mine
Molecular Formula :  C6H18N4

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 MATERIAL PROPERTIES

For E- glass fiber:

i. Young’s modulus = 75 Gpa
ii. Shear modulus = 33 Gpa
iii. Poisson’s ratio = 0.23

For Epoxy resin:

i. Young’s modulus = 25 Gpa
ii. Shear modulus = 4 Gpa
iii. Poisson’s ratio = 0.20

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HARDNER AND RESIN PICTURES

- LY 556 Epoxy Resin

Epoxy Resin

- HY 957 Hardner

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 FLOW CHART OF MANUFACTURING PROCESS

Material Selection &

Materials Details
Machining process

Volume of Material
Needed
Testing

Hand Layout Method

Result

curing

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 MATERIALS AND QUANTITY

s.no Name of the material Quantity

1 Glass fibre woven rovings- 360 GSM ½ KG

2 Glass fibre woven rowings- 600 GSM 1 KG

3 Glass fibre E-CLASS – 450 GSM 1 KG

4 Epoxy resin 2 lts

5 Hardner 25 ml

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 MANUFACTURING PROCESS

 A die is made with the dimension of length 30cm,breath 30cm and thickness 6 mm
is taken.

 This die is filled with three different layers of fibre mixed with resin by HAND
LAYOUT METHOD without allowing any air bubbles.

 Hardner used acts as a binding agent to hold fibre and resin strongly.

 The epoxy resin and hardner are mixed in the ratio of 100:12

 Then this setup is left at room temperature for 48 hrs – 56 hrs for setting.

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WOVEN ROWINGS 450 E CLASS FIBRE 360 GSM
GSM

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  Die

Hand Layout Process

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HAND LAYOUT METHOD VIDEO

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 ANALYSIS AND TESTING

 According to ASME(American Society of Mechanical Engineering),

the square plate(30*30cm) is cut to the dimensions of length –
30cm,breath-23.5cm.

 A hole is drilled at a distance of 2 cm from any one end exactly at the

centre of the plate and riveted with another plate of similar geometric
structure.

 Thus two composite plate is riveted and executed for following test:
I) Bending Stress & ii) Tensile Stress

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 Manufactured Fiber
Reinforced Plate

Final Assembly Of A
Composite Bolted Join

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RESULTS:

Experimental Result

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Graph For Tensile Load

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Graph For Bending Load

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Since we manufactured the plate in hand layout there will be slight deviation in the
thickness of the plate through out the area of the palte.a graph representing the
variation in the thickness is given below.

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COMPUTATIONAL ANALYSIS OF FEM:

2-D Diagram

Convert into IGES file

3-D modelling in solid
works
Import IGES file and
apply mesh
Assembly
Load constrain and
solve for result
Material property

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Properties of E-glass fiber

S.no Properties unit

1 Tensile strength 3445 Mpa

2 Compressive strength 1080 Mpa

3 density 2.58 g/cm3

4 Thermal expansion 5.4 µm/moc

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LOAD CONSTRAIN FOR BENDING MOMENT:
we are going to find 3 point bending moment,so select the load point over the joint of two strips. Here
point A and B are fixed support and point C is load point.

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Load constrain for tensile load:
For finding ultimate strength for tensile load,keep the end A as fixed and applying
loaat end B. Then maximum tesile load is given in opposite direction till we get the
break event point.

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ANSYS RESULTS:
FOR FLUCTURAL LOAD:

Equivalent elastic strain is maximum at the edges and

decreases towards the center.

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We get uneven stress value throughout the lentgh of the strips which is shown in figure.

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Strain energy for bending load is shown in figure which is maximum at the edges and minimum
at the center areas.

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Directional deformation is maximum towards the bolded joint towards negative x-direction.

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FOR TENSILE LOAD:

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Equivalent stress for tensile is small throughout the
area of the strip which is shown in figure.

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 CONCLUSION

 Thus we conclude that,the ultimate strength of hybrid composite joint is greater

than normal composite joint. From the analysis,the break even point for tensile
load is 4.34 KN and break even point for fluctural load is 1.27KN.
 The replacement of composite materials has resulted in considerable amount
of weight reduction about 60 % when compared to conventional mild steel plates.
the same geometry, plates with E-Glass Fiber have better strength.
 The life the joint is increased because of high resistance to corrosion,
resistance to chemical attack, high stiffness to weight ratio and high strength to
weight ratio of E-Glass fiber.
 The shear stress with hybrid joint has less value of stress and also the glass
Fibre reinforced plastic material the cost is less than other composite material.
 It was found that a well designed hybrid joint is very efficient when
compared to bonded, riveted joints in case of repair situation in aircraft structures.

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 REFERENCES

[1]. Noah M. Salih1, Mahesh J. Patil 2, Hybrid (Bonded/Bolted) Composite Single-

Lap Joints And Its Load Transfer Analysis, International Journal of Advanced
Engineering Technology E-ISSN 0976-3945 IJAET/Vol.III/ Issue I/January-March,
2012/213-216.
[2]. Ch. Aswini Kumar1, G. Pattabhi2, S.Santosh3, I. Bhanu Latha4, Analysis of
Adhesively Bonded Double Lap Joint in Laminated FRP Composites Subjected To
Longitudinal Loading, international journal of engineering science & advanced
technology volume-2, issue-2, 307 – 316 ijesat | Mar-Apr 2012.
[3]. Vincentcaccesse, Richard newer, until s. vel detection of bolt load loss in hybrid
composite.metalboltedconnectionselseiver engineering structures 26(2004) 895-
906.

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[4]. W. Hufenbach a, L.A. Dobrzański b, M. Gude a, J. Konieczny b, A. Czulak a, Optimisation of the
rivet joints of the CFRP Composite material and aluminum alloy, Journal of Achievements in
Materials and Manufacturing Engineering, volume 20 issues 1-2 January- February 2007.

[5]. M.A. McCarthy*, C.T. McCarthy, Finite Element Analysis Of The Effects Of clearance On Single-
Shear, Composite Bolted Joints, Journal of Plastics, Rubber and Composites, The Institute of
Materials, London, UK, Vol. 32, No. 2, in-press.

[6]. Proceedings of the “National Conference on Emerging Trends In Mechanical Engineering 2k13” 122
NCETIME – 2k13 Design Of Hybrid Composite Joints For Research Area S. Lokesha and H. Mohita
a Student, Refrigeration and Air Conditioning Division, Department of Mechanical Engineering,
College of Engineering, Anna University, Chennai-28

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