INVESTIGATIONS ON SLIDING WEAR BEHAVIOUR

OF FIBRE REINFORCED EPOXY BASED

HOMOGENOUS AND THEIR FUNCTIONALLY
GRADED COMPOSITES

Presented By
Amit Joshi
M.Tech (Production Engineering )- II year
1

CONTENT
A.
B.
C.
D.
E.
F.
G.
H.
I.

Introduction
What is a composite
FGM- a special class of composite
Types of graded structure
Examples of natural composite
Advantages and challenges of FGM
Application of FGM
Manufacturing FGM
Conventional methods of manufacturing FGM
2

IMPORTANCE OF NEW MATERIALS

More important than any one
new application is the new
materials concept itself
Peter F. Drucker
The Age of Discontinuity , 1969

Human civilization has always tried to create

things as per its own criterion and thus
suiting and soothing their needs from
centuries and thus technological
development of human in all areas step
by step can be seen by EVOLUTION.
One area which is always in the human mind
is the area of materials.
3

WHAT IS A COMPOSITE?

A composite is a structural material

which consists of combining two or
more constituents which have quite
different properties that when
combined offer properties which are
more desirable than the properties
of the individual constituents.
Examples:

Wood with cellular fibers and reinforced

with lignin.
Flesh in leg reinforced with bones
Concrete reinforced with steel
Epoxy reinforced with graphite fibers.

FIBROUS COMPOSITES
Generally there are two phases
i.
ii.

Fiber as a reinforcement
Matrix as a binder

INTRODUCTION TO FGM- A SPECIAL CLASS OF

COMPOSITES
Functionally Graded Material concept was first proposed at Sendai,
Japan in 1984.
FGM on its simplest structure consists of one material on one side
and a second material on the other side and an intermediate layer
whose structure, composition and morphology vary smoothly
from one material to the other at the micron level.
FGM are multifunctional materials used for producing components
that require functional performance which is variable within the
component.
This is basically termed as engineering the transition in micro/nano
structures. Thus enhancing the overall performance of the
component.
6

WHAT IS FGM ?

TYPES OF GRADED STRUCTURES

Stepwise Graded Structures

An example is a spark plug which gradient

is formed by changing its composition
from a refractory ceramic to a metal

Continuous Graded Structures

An example is the human bone which

gradient is formed by its change in
porosity and composition
Change in porosity happens across the
bone because of miniature blood vessels
inside the bone

Note: Desired properties gradients may designed by

controlling crystal structure and crystal
orientation, particulate diameter, bonding state,
etc.
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EXAMPLE OF A FGM IN NATURE

The human bone is a an example

of a FGM. It is a mix of collagen
(ductile protein polymer) and
hydroxyapatite (brittle calcium
phospate ceramic). The yellow
marrow consists of fat which
contributes to the weight and the
red marrow is where the
formation of red blood cells occur.
A gradual increase in the pore
distribution from the interior to
the surface can pass on
properties such as shock
resistance, thermal insulation,
catalytic efficiency, and the
relaxation of the thermal stress.
The distribution of the porosity
affect the tensile strength and the

ADVANTAGES AND CHALLENGES OF FGMS

Advantages of FGMs

Provide multi-functionality
Provide ability to control deformation,
dynamic response, wear, corrosion, etc. and
ability to design for different complex
environments
Provide ability to remove stress
concentrations
Provide opportunities to take the benefits
(pros) of different material systems [e.g.
ceramics and metals such as resistance to
oxidation (rust), toughness, machinability, and
bonding capability]

Challenges of FGMs

Mass production

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APPLICATIONS OF FGMS
ENGINEERING

NUCLEAR
ENERGY

AEROSPACE

FUNCTIONALLY
GRADED
MATERIALS

OPTICS

BIOMATERIALS

ELECTRONIC
S

CHEMICAL
PLANT
ENERGY
CONVERSION
S

COMMODITIES

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MANUFACTURING FGM
Manufacturing process of a FGM can
usually be divided into two steps:(a)Gradation - Building an spatially
inhomogeneous structure.
(b)Consolidation - Transformation of these
structure into bulk material.
Note:- For FGM Development it is essential to have a wide database of
properties of various materials for different chemical compositions say
Youngs Modulus, coefficient of thermal expansion, Poisson's ratio,
thermal conductivity etc. Once this knowledge is available the design
of FGM is proposed keeping in mind the the need and application area.

12

CONVENTIONAL METHODS FOR MANUFACTURING FGM

The various techniques are classified as:(a)

Melt casting process:- gravity casting, centrifugal

casting, sedimentation casting, directional solidification.

(b)

Powder metallurgy based techniques:- solid freeform,

powder stacking, sheet lamination, wet powder spraying, slurry
dipping.

(c)

Electromagnetic/electrophoresis based techniques.

(d)

Laser assisted techniques:- 3-D laser cladding, Laser

engineered net shaping (LENS), Selective laser sintering.

(e)

Others:- Chemical vapor deposition (CVD), physical vapor

deposition (PVD), combustion synthesis, spark plasma sintering.

13

POLYMER MATRIX COMPOSITE

Polymer matrix composite is the material consisting of a polymer
matrix combined with a fibrous reinforcing dispersed phase.
FRP
A composite material consisting of a polymer matrix imbedded
with high-strength fibers.
Widely used in rubber products such as tires and conveyor
belts.
Principle fiber materials are: glass, carbon, and Kevlar 49 with
glass (E-glass) the most common fiber material

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POLYMER MATRIX COMPOSITE

Attractive features of FRP:

high strength-to-weight ratio

high modulus-to-weight ratio
low specific gravity
good fatigue strength
good corrosion resistance, although polymers are soluble in various
chemicals
low thermal expansion, leading to good dimensional stability.

15

MATERIALS AND METHODS

Epoxy as matrix material
Epoxies have improved strength and stiffness properties over polyesters.
Epoxies offer excellent corrosion resistance and resistance to solvents and
alkalis. Cure cycles are usually longer than polyesters, however no byproducts are produced.

Flexibility and improved performance is also achieved by the utilization of

additives and fillers.

Due to several advantages over other thermoset polymers as mentioned above,

epoxy resin is chosen as the matrix material for the present research work.

16

EPOXY MATERIAL PROPERTY

Epoxy resin is defined

as a molecule
containing more than
one epoxide groups.
The curing of epoxy is a
chemical reaction in
which the epoxide
groups in epoxy resin
reacts with a curing
agent (hardener) to
form a highly
crosslinked, three

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EPOXY MATERIAL PROPERTY

The typical properties of epoxy are:
Density- 1.16gm/cc
Youngs modulus- 3.42 GPa
Poissons ratio- 0.32
Epoxy resins can be cure quickly and
easily at practically any temperature
from 5-150C depending on the choice
of curing agent.
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FIBER MATERIALS
Kelvar Fiber
Reinforcement

Superior resistance to damage

(Energy Absorber)
Good in tension applications
(Cables, Tendons)
Moderate stiffness
More expensive than glass

Carbon Fiber
Reinforcement

Good modulus high

temperatures
Excellent stiffness
More expensive than glass
Brittle
Low electric insulating
properties

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MECHANICAL PROPERTIES OF FIBERS

Carbon
Fiber
Aramid
Fiber
Boron
Fiber
E- Glass
Fiber
S- Glass
Fiber
Kevlar
49 Fiber

Density
( g/cc)

Tensile
Strength
( GPa)

Tensile
Modulus
( MPa)

Elongation
(%)

Poissons
Ratio

Young
Modulus
( GPa )

1.79

1.80

400

1.8

0.10

70

1.44

2.80

130

2.5

0.20

30

2.54

3.50

400

2.56

3.45

70

4.8

0.20

25

2.46

4.50

86

5.3

0.25

1.44

3.8

131

2.8

0.42

76

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FGM AND HOMOGENEOUS COMPOSITE

FABRICATION

The fibre material Kevlar & Carbon is mixed with epoxy resin in five
different percentages (0wt.-%, 5wt.-% and 10wt.-%, 15wt.-% & 20wt.%) by simple mechanical stirring technique and slowly poured in glass
tubes so as to get cylindrical specimen.

The graded composites with similar weight fraction of Kevlar fibre &
Carbon fibre are cast by vertical centrifugal casting arrangement. The
mixture of resin & fibre is filled in the cylinder mould. taken out of &
centrifugation time is kept constant for 30min( 12 mm). The
container is kept closed & is fitted on the centrifugal arrangement. The
rotation speed is kept constant of 400rpm at room temperature ,
length 120 mm). Then after the mould is removed from the rotating
system & kept for curing at room temperature for almost 24hours &
then hardened composites samples are the in container.

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Exhaust air

Coefficient of friction display

unit

Display unit
Time measuring unit
Glass rod

Test tube
Particles

R.P.M adjustment unit

Wear rate display unit

22

ADVANTAGES (POLYMER MATRIX COMPOSITE)

High

specific stiffness and strength

Parts consolidation
High durability
1.
2.

Fatigue
Corrosion

Efficient damping materials

23

WEAR
The

progressive loss of material due to

the dynamic interactions of two
surfaces in relative motion contact is
known as wear.
The wear can be of many types:

surface damage
Abrasive wear
Fretting wear
Sliding and adhesive wear
Rolling contact wear
Impact wear
Corrosive wear

Oxidation wear.

o
o
o
o
o
o

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SLIDING AND ADHESIVE WEAR

Generated

by the sliding of one solid surface

along another surface.
Adhesive wear can be described as plastic
deformation of very small fragments within the
surface layer when two surfaces slides against
each other.
Adhesion is most clearly demonstrated in sliding
systems when, for example, a shaft seizes in a
bearing.
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26

RESEARCH GAP
Less work done on fiber reinforced polymer
based FGM
The general overview of literature does not
indicate relevant work for finding the properties
of hybrid composites i.e. combination of epoxy
matrix with carbon fiber and Kevlar fiber.
No work done on the combination of epoxy with
Kevlar fiber & Caron fiber

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OBJECTIVES

Fabrication and characterization of functionally graded fiber

(carbon fibre and kevlar fibre) reinforced epoxy resin composites.
Determining the Physical & Mechanical properties of FGM
composites
Conduct a tribological characterization of FGMs composites
through wear volume and wear coefficient measurements obtained
from pin on disk wear performance as a fraction of various
operating variables.
Statistical analysis of the experimental results and identification of
significantly influential factors (control factors) using tagucchi
technique in combination with analysis of variance (ANOVA)
approach.
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PROPERTIES OF GLASS FIBER, CARBON FIBER AND ITS

COMPATIBILITY WITH EPOXY MATRIX IS SHOWN AS UNDER
Kevlar Fiber Kevlar Fiber is a common name of Polymer Matrix composite materials reinforced with
Kevlar fibers. The most popular matrix materials for manufacturing Kevlar fibre are thermo sets such
as unsaturated polyesters (UP) and epoxies (EP).
Kevlar fiber are characterized by following properties

High toughness

High modulus of elasticity to weight ratio.

Good chemical and flame resistance

Excellent dimensional stability.

Low thermal conductivity(compared to metals and ceramics).

Carbon Fiber Carbon fiber is a polymer matrix composite material reinforced by carbon fibers.
The most popular matrix materials for manufacturing carbon fiber are thermo sets such as epoxy
and polyesters.
Carbon Fiber are characterized by following properties

Very high modulus of elasticity exceeding that of steel.

High tensile strength, which may reach 1000Ksi

Low density; 114lb/ft3

High chemical inertness

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Designations and Detailed compositions of the FGMs & Composites

Designation

Composition

Manual

epoxy (100 wt% )

MK1

epoxy + Kevlar fibre (0.25wt%)

MK2

epoxy + Kevlar fibre (0.5wt%)

MK3

epoxy + Kevlar fibre (0.75wt%)

MK4

epoxy + Kevlar fibre (1.0wt%)

GK1

epoxy + Kevlar fibre (0.25wt%)

GK2

epoxy + Kevlar fibre (0.5wt%)

GK3

epoxy + Kevlar fibre (0.75wt%)

GK4

epoxy + Kevlar fibre (1.0wt%)

MC1

epoxy + Carbon fibre (0.25wt%)

MC2

epoxy + Carbon fibre (0.5wt%)

MC3

epoxy + Carbon fibre (0.75wt%)

MC4

epoxy + Carbon fibre (1.0wt%)

GC1

epoxy + Carbon fibre (0.25wt%)

GC2

epoxy + Carbon fibre (0.5wt%)

GC3

epoxy + Carbon fibre (0.75wt%)

GC4

epoxy + Carbon fibre (1.0wt%)

MECHANICAL CHARACTERIZATION
Density and Void of fraction:
Density of composite
by the Agarwal & Broutman Expression
Wf
Wm is calculated
1/

m f
th =
Where
Wm= weight of matrix, Wf = weight of fiber, m= density of matrix, f = density of fiber, th=
theoretical density of composites

Void fraction:

( th ce )
Vv
ct

th = Theoretical density of composites

ce=Experimental density of composites

PRESENTATION, NIT HAMIRPUR

01/11/2010

FUTURE PLAN
SELECTED MATERIAL:
Epoxy resin selected is of grade LY250.
Hardener of grade HY840 mixed in the ratio of 10:1
by weight.
Kevlar fiber is Kevlar-49 fiber
Carbon fiber selected is bidirectional met carbon fiber.

After selection of desired composition composites are

than prepared and tested on dry sliding tester.

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QUESTIONS PLEASE

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THANK-YOU

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