PROJECT TASK

Title: Design, Fabricate and Testing Composite Materials Plates

COURSE CODE

BFC 20903

COURSE NAME

MECHANICS OF MATERIALS

FACULTY

FKAAS
1

STUDENT NAMES

SECTION

LECTURER NAME

2
3
4
5
6
7

VIKNHESWAR A/L CHANDIRA SEGARAN

(CF140022)
RHUBENTHIRAAN A/L KELUNDAPYAN (CF140066)
KALPANA SRI A/P UTHAYAVANAN (CF140188)
KOMALA DEVI A/P SUNDARARAJAN (CF140123)
LOGESWUARAN A/L BALOO (CF140179)
NARAIN A/L MUTHUKRISHNAN (CF140008)
THOMBSON A/L DAVID (CF140037)

5
ENCIK AHMAD ZURISMAN BIN MOHD ALI

1.0 INTRODUCTION
Tensile strength is a measurement of the force required to pull something such as rope,
wire, or a structural beam to the point where it breaks. It is very important at breaking stuff.
The tensile strength of a material is the maximum amount of tensile stress that it can take
before failure, for example breaking. The project proposal is mainly about design, fabricated
and testing composite materials plates.
For this project we must use any recycle materials comprising of more than eight piles
(8 layers). As the term composite materials are described ,the composite plate should
comprise of more than two types of materials. In this case we used aluminum and card board.
The thickness of the composite plate should not be larger than 2mm. we use gluing and
heating method to assemble all the plates. The composite plate will be tested to determine its
tensile strength and modulus.
The maximum stress that a material can withstand while being stretched or pulled
before failing or breaking. Tensile strength is not the same as compressive strength and the
values can be quite different. Some materials will break sharply, without plastic deformation,
in what is called a brittle failure. Others, which are more ductile, including most metals, will
experience some plastic deformation and possibly necking before fracture.
The tensile strength is usually found by performing a tensile test and recording the
engineering stress versus strain. The highest point of the stressstrain curve (see point 1 on
the engineering stress/strain diagrams below) is the tensile strength. It is an intensive
property; therefore its value does not depend on the size of the test specimen. However, it is
dependent on other factors, such as the preparation of the specimen, the presence or
otherwise of surface defects, and the temperature of the test environment and material.

2.0 CHOICE OF MATERIALS

The materials that we used are :

Aluminium

Aluminium is a chemical element in the boron group with symbol Al and atomic
number 13. It is a silvery white, soft, ductile metal. Aluminium is the third most abundant
element, and the most abundant metal, in the Earth's crust. It makes up about 8% by weight
of the Earth's solid surface. Aluminium metal is so chemically reactive that native specimens
are rare and limited to extreme reducing environments. Instead, it is found combined in over
270 different minerals.
Aluminium is ductile which permits it to be permanently drawn, bent, or twisted into
various shapes without breaking. This property is essential for metals used in making wire
and tubing. Ductile metals are greatly preferred for aircraft use because of their ease of
forming and resistance to failure under shock loads. For this reason, aluminium alloys are
used for cowl rings; fuselage and wing skin, and formed or extruded parts, such as ribs, spars,
and bulkheads.
Aluminium is remarkable for the metals low density and for its ability to resist
corrosion due to the phenomenon of passivation. Structural components made from
aluminium and its alloys are vital to the aerospace industry and are important in other areas
of transportation and structural materials. The most useful compounds of aluminium, at least
on a weight basis, are the oxides and sulfates.
Tin (Zinc)

Zinc in commerce is also can called as spelter, which is a metallic chemical element
that has the symbol Zn and atomic number 30. It is the first element of group 12 of the
periodic table. Zinc also in some respects, chemically similar to magnesium. It is because
ions is similar of size. For the mean time, it is common oxidation state is only +2. As we
know, zinc has five stable isotopes and it is 24th most abundant element in the Earth's crust.
The strength of Zinc is relatively low, and their tendency to creep makes them
unsuitable for use at temperatures above 100C. It is also has very low wall thicknesses are
achievable and the surface hardly requires any after-treatment. However, zinc offers a good
corrosion resistance, especially against rain. Zinc has the rigidity of metals with modulus of
elasticity characteristics equivalent to other die cast able materials. Stiffness properties are,
therefore, far superior to engineering plastics.

Cardboard

Cardboard is a generic term for a

heavy-duty paper of various strengths,
ranging from a simple arrangement of a single thick sheet of paper to complex configurations
featuring multiple corrugated and uncorrelated layers. Alternatively, the term may simply be
used to refer to corrugated paper, a material commonly used for packaging purposes,
generally in the form of a container.
Despite widespread use in general English and French, the term is deprecated in
business and industry. Material producers, container manufacturers, packaging, and standards
organizations, try to use more specific terminology. There is still no complete and uniform
usage. Often the term "cardboard" is avoided because it does not define any particular
material.
Most types of "cardboard" are recyclable. Boards that are laminates, wax coated, or
treated for wet-strength are often more difficult to recycle. Clean cardboard (cardboard that
has not been subject to chemical coatings) "is usually worth recovering, although often the
difference between the value it realizes and the cost of recovery is marginal. Cardboard can
be recycled industrially, or for home uses. For example, cardboard may be composted or
shredded for animal bedding.

Dunlop Contact Adhesive Glue

Dunlop

CA

are

used

primarily

for

fabricating high performance composites

with

superior mechanical properties, resistance

to

corrosive

liquids

and

environments,

superior electrical properties, good performance at elevated temperatures, good adhesion to a

substrate, or a combination of these benefits. It has good UV resistance. Since the viscosity
of epoxy is much higher than most polyester resin, requires a post-cure(elevated heat) to
obtain ultimate mechanical properties making epoxies more difficult to use. However,
epoxies emit little odor as compared to polyester.
Dunlop CA resins are used with a number of fibrous reinforcing materials, including
glass, carbon and aramid. This latter group is of small in volume, comparatively high cost
than vinyl esters and is usually used to meet high strength or high stiffness requirements.
Besides it, the disadvantages of resin are critical mixing and corrosive handling.

EQUIPMENTS
NO.
1

EQUIPMENTS
Vernier Caliper

PICTURES

Aluminium Cutter

Scissors

Marker Pen

Ruler

3.0 CONCEPT OF COMPOSITE PLATE FABRICATED

Composite Material
Composite materials are formed by combining two or more materials that have quite
different properties. The different materials work together to give the composite unique
properties, but within the composite you can easily tell the different materials apart. They
do not dissolve or blend into each other.
Composite material is also combination or mixture of more than two materials,
different in composition, chemical and physical properties. When combined they retain

their constituent identities, that is, they do not lose their individual identities. The materials
may be classed as base, binder, and filler.
Composite materials also can be defined as materials made from two or more
constituent materials with significantly different physical or chemical properties, that when
combined, produce a material with characteristics different from the individual
components. The individual components remain separate and distinct within the finished
structure. The new material may be preferred for many reasons: common examples include
materials which are stronger, lighter or less expensive when compared to traditional
materials.
Composites exist in nature. A piece of wood is a composite, with long fibres of
cellulose held together by a much weaker substance called lignin. Cellulose is also found in
cotton and linen, but it is the binding power of the lignin that makes a piece of timber much
stronger than a bundle of cotton fibers.

Importance of Composite Material

The greatest advantage of composite materials is strength and stiffness combined with lightness.
By choosing an appropriate combination of reinforcement and matrix material, manufacturers
can produce properties that exactly fit the requirements for a particular structure for a particular
purpose.
The right composites also stand up well to heat and corrosion. This makes them ideal for use in
products that are exposed to extreme environments such as boats, chemical-handling equipment
and spacecraft. In general, composite materials are very durable.
Advantage of Composite Material

High Strength-to-weight ratio

Corrosion Resistance

Wear Resistance

Stiffness

Fatigue Life

Temperature Dependent Behaviour

Thermal Insulation

Thermal Conductivity

Acoustical Insulation

Low-Electrical Conductivity

Visual Attractiveness

Radio Translucent

Disadvantage of Composite Material

High Manufacturing Costs

Lack of The Visual Proof of Damage

Lack of Mechanical Versatility

Production Difficulty

Application of Composite Material

Composites are one of the most widely used materials because of their adaptability to
different situations and the relative ease of combination with other materials to serve specific
purposes and exhibit desirable properties.
In surface transportation, reinforced plastics are the kind of composites used because
of their huge size. They provide ample scope and receptiveness to design changes, materials
and processes. The strength-weight ratio is higher than other materials. Their stiffness and
cost effectiveness offered, apart from easy availability of raw materials, make them the
obvious choice for applications in surface transportation.
In manufacturing of automobile parts, glass and sisal fibers usually find the maximum
use. Sisal costs very less and this alone has prompted extensive research to come up with
applications in which sisal is the dominant reinforcing material in filled polyester resin, in
parts where specific mechanical properties are required and appearance is not very important.
Heater housings, which find uses for sisal, are produced by compression moulding. Since a
variety of glass fibers are available, it is used as reinforcement for a large range of parts of
different types. Rovings, non-woven mats are the commonly used low cost versions. Woven
cloth is applied in special cases, where particular properties are required as cloth is not
known to be amenable to large quantity production methods.
Since the automobile industry is replete with models, options and changes in trends,
the material selection and combinations offered by the materials is also wide-ranging. Along
with a measure of conservation, the choice is also dictated by the demands of the competitive
market for new and alternate materials.
Commercial aircraft applications are the most important uses of composites. Aircraft,
unlike other vehicles, need to lay greater stress on safety and weight. They are achieved by
using materials with high specific properties. A modern civil aircraft must be so designed as
to meet the numerous criteria of power and safety.

4.0 PROCEDURE

Design
1) Firstly, the equipments and materials were checked to ensure that they are safe to use.
2) Firstly, we measured the thickness of the material which is aluminium and cardboard by
using vernier caliper and make sure that the thickness of the material is 0.25mm.
3) Secondly, we marked the area of the material by marker pen according to the length and
the width that had been given which is 200mm and 20mm.

4) Then, we cut the materials carefully by using scissors according to the marked to
prevent the area of the material obey to the specimen requirement.

5) After we cut the materials, we glued to the material alternating until it has 8 layers by
using Dunlop CA glue.

6) During

we

make sure that

glued

the

material;

the glue covers all the

area of the material to prevent porosity on the material which can reduce the strength of
the materials.
7) After we finished glue it, let it dry for 8 hours to ensure that the material is truly strong
bond enough before we test it.

Testing of the Specimen

1) The technical assistant of the laboratory was loosening the tensile machine to put the
composite material in it.

2) We put the composite materials in the Universal Tensile Machine and tighten it.

3) Next, we test the tensile

strength of the composite material and

with it until it comes to

break.
4) The data was collected and we analysis the data according to the graph shown below.

5.0 STRENGTH ANALYSIS CALCULATIONS METHOD OF FABRICATIONS

Results and Discussions

SAMPLE 1

SAMPLE 2

SAMPLE 3

RESULT AND CALCULATION

Based on the experiment, there were two types of formula used to identify the value of
modulus of elasticity and the value of tensile strength.
Modulus of Elasticity , =

load force
area

stress ,
strain ,

Tensile Strength=

Max load , P
Original Area , A
SPECIMEN 1

Modulus of Elasticity,
=

13120 Mpa
1000

=1312 GPa

Tensile Strength
I.
II.

Maximum Load Specimen 1 0.7452 kN

Tensile stress
0.7452 103

200 20

745.2
4000

0.1863

N
Pa
2
mm
SPECIMEN 2

Modulus of Elasticity,
=

7423 Mpa
1000

=7.423 GPa

Tensile Strength
I.
II.

Maximum Load Specimen 2 0.7452 kN

Tensile stress

1.648 10
200 20

1648
4000

0.412

N
Pa
2
mm
SPECIMEN 3

Modulus of Elasticity,
=

10200 Mpa
1000

=10.2 GPa

Tensile Strength

I.
II.

Maximum Load Specimen 3 1.640 kN

Tensile stress
1.640 10 3

200 20

1640
4000

0.41

N
Pa
2
mm

6.0 DISCUSSION
We had designed a composite plate by using three different materials comprising of 5
layers as followed the Classical Laminate Plate Theory (CLPT). The three materials we had
used in this project with difference of ratios which is Dunlop CA glue, sample of aluminum,
and some pieces sectional taken from biscuit tin (zinc). Based on this project, we can
describe that the smaller the area of the object, the higher the stress loaded to it.
Composites have properties, which could not be achieved by either of the constituent
materials alone. We can see that composites are becoming more and more important as it can
help to improve our quality of life.
Besides that, we also learnt how to identify the problems that limit the performance
and propose solutions that lead to innovation in design and the successful exploitation and
commercialization of composite materials across the widest spectrum of engineering uses.
We also used totally recycle materials .Even with this we can reduce pollution that
would happen.

7.0 CONCLUSION
We learnt how to applied Composite Materials into different materials and how to
identify the problems that limit the performance and reliability of the composite material and
composite part; and propose solutions that lead to innovation in design and the successful
exploitation and commercialization of composite materials across the widest spectrum of
engineering uses. The main focus is on the quantitative descriptions of material systems and
processing routes. Coverage includes management of time
Composites have properties, which could not be achieved by either of the constituent
materials alone. We can see that composites are becoming more and more important as it can
help to improve our quality of life. Composites are put into service in flight vehicles,
automobiles, boats, pipelines, buildings, roads, bridges, and dozens of other products.
Researchers are finding ways to improve other qualities of composites so they may be strong,
lightweight, long-lived, and inexpensive to produce
Although composite materials have certain advantages over conventional materials,
composites also have some disadvantages. The common one is the high manufacturing costs.
However, as improved manufacturing techniques are developed, it will become possible to
produce composite materials at higher volumes and at a lower cost than is now possible.
Another advantage of composite materials is that they provide design flexibility.
Composites can be moulded into complex shapes, a great asset when producing something like a
surfboard or a boat hull.

Also we learnt that the right composites also stand up well to heat and corrosion. This
makes them ideal for use in products that are exposed to extreme environments such as boats,
chemical-handling equipment and spacecraft. In general, composite materials are very durable.
The downside of composites is usually the cost. Although manufacturing processes are
often more efficient when composites are used, the raw materials are expensive. Composites will
never totally replace traditional materials like steel, but in many cases they are just what we
need. And no doubt new uses will be found as the technology evolves. We havent yet seen all
that composites can do.
8.0 DRAWING

Side view

Front view