ROAD MAP Abstract of the Research area Problem Definition Research Methodology Process Technology Research Tools to be used

used Conclusion

References

BROAD AREA OF RESEARCH

Mechanical Engineering Material science Composite materials with 3D Fabric fiber reinforcement polymer.

ABSTRACT OF THE RESEARCH AREA

The objective of the research project is to develop a bumper using 3D fabric FRP in Vaccum assisted resin infusion moulding (VARIM) process.

Why 3D fabric FRP? Various types of composite materials with threedimensional (3D) fibre structure (incorporating z-direction fibres) have been developed to overcome the shortcomings of 2D laminates.
They have, High strength and modulus in all three directions No delamination Good structural integrity (not many broken fiber ends) To reduce fabrication cost Light Weight Excellent thermal insulation Acoustic damping

3D FABRIC FIBER

3D fiberglass woven fabric construction is a newly developed concept. The fabric surfaces are strongly connected to each other by the vertical pile fibers which are interwoven with the skins. Therefore, the 3D fiber fabric can provide good skin-core debonding resistance, excellent durability and superior integrity.

In addition, the interstitial space of the construction can be filled up with foams to provide synergistic support with vertical piles. These products have broad application prospects in automobile, Locomotives, aerospace, marine, windmills, building and other industries.

SOLID 3D WOVEN FABRICS

MULTILAYER ORTHOGONAL ANGLE-INTERLOCK

 PERFECT 3D ORTHOGONAL WEAVE

Top view

Side view

SOLID 3D WOVEN FABRICS

Woven beams with different cross sections

Dry 3D woven preform

RESEARCH METHODOLOGY
The first phase of this project deals with the selection of 3D fabric fiber /resin will include processing parameters. 3D glass woven fabric and unsaturated polyester resin are used to make composite specimen by hand lay up process and finally VARIM process. Volume fraction , Fiber - Matrix interface and processing techniques were studied. Automobile bumper to be moulded using the selected fibre/resin. The purpose of this study is to assess the mechanical performance of this new type of composite material. Tensile, compressive, out-of-plane, shear and flexural properties of the composite flat beam specimens were tested.

PROCESS TECHNOLOGY 1.HAND LAY UP PROCESS

Apply 40% of the resin even brushed on the surface of the mould , after preparation the resin. Apply 3D glass fabric into the resin layer and roll it firmly but gentle. Apply the remaining 60% of the recommended resin quantity on top of the 3D glass fabric and distribute it evenly by rolling. Roll resin gently into the 3D glass fabric .Smooth surface and maximum height is achieved by finishing with gently rolling in weft direction against the pile direction.

PROCESS TECHNOLOGY

2.VACCUM ASSISTED RESIN INFUSION MOLDING PROCESS[VARIM]

Fig.1. A sample image of composite production by VARIM system.

PROCESS TECHNOLOGY
In this process, dry, net shape fibrous textile reinforcements are infused with a liquid resin and cured in a single step to produce a structural part Fig.1.

Fig.2.Vacuum assisted resin infusion molding(VARIM) process setup

VARIM uses vacuum pressure to draw resin into the mold to saturate the reinforcements. Because of the minimal pressure involved, and the fact that it is done at ambient temperature.

 In the VARIM process, There are many variables such as vacuum pressure , temperature , viscosity and density of resin, flow velocity, time of curing etc. that can dramatically change the outcome of the composite piece(dimensional stability, residual stress, distortion and cracks) especially with contours and profiles Fig.2. setting the process up is the most important stage. Based upon the changes that will be made and the variables of the VARIM process it will be determined that the process could be made more reliable and stable.

PROCESS STEPS OF VACUUM ASSISTED INFUSION MOLDING PROCESS

RESEARCH TOOLS TO BE USED Design model to be verified by Flow analysis for polymer flow Mat Lab for Design of Experiments and Optimisation

Physical model to be manufactured by VARIM set up and to be verified by the following equipments, NDT(Non Destructive testing) equipment UTM for material characterisation

CONCLUSION
The final phase of this project is testing and inspection of composite components manufactured for the desired mechanical properties such as strength, stiffness, etc., and dimensional stability, voids, cracks, etc., Various testing techniques(UTM and ultrasonic inspection) will be developed to test and inspect the components.

REFERENCES
1) A. Goren and C. Atas ,2008, Manufacturing of polymer matrix composites using vacuum assisted resin infusion molding, Journal of Archives of Materials Science and Engineering ,Vol. 34, No.2 Dec/2008, pp. 117-120. 2) Gerald G. Trantina and Joseph T woods, 2000, Standard test procedure for relevant material properties for structural analysis, Journal of Reinforced plastics and Composites, Vol. 10, No.13 Jan/2000, pp. 233-240. 3) R.T.DuraiPrabhakaran,2011,Attribute Based Selection of Thermoplastic Resin for Vacuum Infusion Process: A Decision Making Methodology,Journal of International Journal of Manufacturing, Materials and Mechanical Engineering, Vol.1,No.3, July-Sep/2011, pp. 31-52. 4) Dong, C.S., 2008, "A modified rule of mixture for the vacuum-assisted resin transfer moulding process simulation" ,Journal of Composites Science and Technology, Vol. 68, No. 9, pp. 2125-2133. 5) Kleisner.V and Zemcik.R .,2009,Analysis of composite car bumper reinforcement, Journal of Applied and Computational Mechanics ,Vol. 3 Aug 30/2009, pp.287-296