EFFECT OF FILLER

RIAL ON
WEAR BEHAVIOR
P
Project Members
Satheesh .G 96609114047
Chindu .D. Dev 96609114503
Sajith Suresh 96609114505
Rohit Joseph 96609114504

Guided by :
Professor.R.Satheesh Raja
(Associate professor)

Mechanical Department , PET Engineering college

 Objective
Fabrication of glass fiber reinforced
polyester based composite with or without
filler content.

Dry sliding wear of composite samples

under various operating conditions
INTRODUCTION
Glass fiber reinforced polymer composites find widespread applications in these days
due to their several advantages like
High wear resistance
Strength-to-weight ratio
Low cost
The performance of the composites can further be improved by adding particulate
fillers to them
The present work includes the processing, characterization and study of the sliding
wear behavior of a series of glass-polyester composite which filled with fly ash in
various ratio
systematic experimentation leads to the determination of significant process
parameters and material variables that predominantly influence the wear rate.
 Polymer composite
Composite materials are engineering materials made from two or
more constituent materials that remain separate and distinct on a
macroscopic level while forming a single component
There are two categories of constituent materials: matrix
and reinforcement.
The matrix material surrounds and supports the reinforcement
materials by maintaining their relative positions.
The reinforcements impart their special mechanical and physical
properties to enhance the matrix properties.
The primary functions of the matrix are to transfer stresses
between The reinforcing fibers and to protect them from
mechanical or environmental damage and also it improves its
mechanical properties such as strength, stiffness etc. .
 The objective is to take advantage of the superior properties of both materials
without compromising on the weakness of either
Due to the wide variety of matrix and reinforcement materials available, the
design potentials are incredible
The reasons why composites are selected because of their high :
Strength-to weight ratio High tensile strength at elevated temperatures
High creep resistance And high toughness.

If the composite is designed and fabricated correctly it combines the strength of

the reinforcement with the toughness of the matrix to achieve a combination of
desirable properties not available in any single conventional material.
APPLICATION OF POLYMER COMPOSITE
MATERIAL
Automotive : Drive shaft,cluth plate,engine block.
Air craft : Elevator, bearing
Marine : propeller vanes, gear case
 SCOPE OF THE PROJECT
The basic aim of the present work is to develop and characterize a new class of
composites with a polymer called polyester-filler as the matrix and glass fiber as the
reinforcing material.

Attempt is made to use fly ash as filler in these fiber reinforced polymer matrix
composites.

Wear behavior of this new class of composites is investigated by performing dry

sliding wear test in this project work.

CONSTRUCTION
Polyester Resin
Polyester resins are unsaturated resins formed by the reaction of
dibasic organic acids and polyhydric alcohols.

Wall panels fabricated from polyester resins reinforced with

fiberglass reinforced are typically used in restaurants, kitchens,
restrooms and other areas that require washable low-maintenance
walls.

These resins can be used with any type of fiberglass and carbon fiber
or Kevlar

These resins tend to be fairly rigid when cured and also more brittle
than epoxy resins.
 Glass fiber

Glass fiber is a material consisting of numerous extremely fine fibers

of glass

Glass fiber is commonly used as an insulating material. It is also

used as a reinforcing agent for many polymer products

It is also used as a reinforcing agent for strong and light fiber-

reinforced polymer composite material called glass reinforced
plastic (GRP), popularly known as "fiberglass

We used E-Glass or electrical grade glass that originally developed

for stand off insulators for electrical wiring
FLY ASH
fly ash usually refers to ash produced during combustion of coal

all fly ash includes substantial amounts of silicon dioxide(SiO2) and calcium oxide
(CaO), both being endemic ingredients in many coal-bearing rock strata.

In the past, fly ash was generally released into the atmosphere, but pollution control
equipment mandated in recent decades now require that it be captured prior to release

The ways of fly ash utilization include:

Concrete production Embankments and other

Cement clinkers
Stabilization of soft soils
Mine reclamation
structural fills
Grout and Flowable fill
production
Waste stabilization and solidification
CATALYSTS
The distinction between chemical and catalytic uses is some what blurred. For
purposes of clarification, applications of cobalt salts as driers in paints and inks
and as curing agents for unsaturated polyester resins are treated as chemical rather
than catalytic.

By definition, a catalyst is not consumed in a chemical reaction, but there are

always in process losses as well as losses in the catalyst recovery, recycling and
operations

Cobalt has major uses in the petrochemical and plastic industries, as both a hetero
and homogeneous catalyst
SCANNING ELECTRON MICROSCOPE
A scanning electron microscope ( SEM ) is a type of electron
microscope that produces images of a sample by scanning it with
a focused beam of electrons
For SEM, a specimen is normally required to be completely dry,
since the specimen chamber is at high vacuum

SCANNING PROCESS AND IMAGE FORMATION

In a typical SEM, an electron beam is the rmionically emitted

from an electron gun fitted with a tungsten filament cathode

The most common configuration for an SEM produces a single

value per pixel, with the results usually rendered as black-and-white
images
PREPRATION OF COMPOSITE MATERIALS
Preparation of mould
Cut the fibers suitable measurement
Apply the resin
By using wax fill the gaps
Apply the resin and fiber one by one
Remove the mould
Mould Preparation
First of all the mould for the composite is prepared by
using aluminium as per required measurement

Then clean mould and clear the gaps by using wax

Hand lay-up process
Cut the fibers(E-glass fiber)with suitable measurement
 The resin mix(cobalt & polyester resin ) with suitable ratio

Apply the resin

E-Glass fiber mat was placed and repeated till the required thickness is ach
 A layer of E-glass fiber mat was placed over it and worked by hand
with brushes and rollers ,so the resin fully impregnates the fabric

Again the resin applied and a fiber was placed for two three times
Machining process
After the hand lay up process polymer composite plate shaped to small
square plate on the based on the required measurement

Then small square plates are pasted at the end of bolt by using m- seal.
 Procedure of wear test
Prepare the material with suitable measurement

Connected in a wear test machine

Machine started and apply different loads

loads 5N,10N,15N

Sliding distance 500m,1000m,1500m

CALCULATION OF WEAR
WEIGHT LOSS
(gm

ABRASIVE
WEAR RATE(W)
W= cm3/m

SPECIFIC WEAR RATE(ko)

ko= m3/Nm

the density of the composite

Is
is the weight loss in grams
Sd-is the sliding distance in meter
L-is the applied load in N.

MODEL CALCULATION OF WEAR RATE

Sample G 25.
Change in weight( gm
17.609-17.606
= 0.003gm

Abrasive wear rate(W ) =

=
=2.170767004x10^(-6) cm3/m

Specific wear (ko) =

=
= 4.341534009x10^(-7) m3/Nm
 RESULT

GRAPH( Specimen , Abrasive wear, Specific wear )

LOAD = 5N , SLIDING DISTANCE =1000M LOAD = 5N ,SLIDING DISTANCE = 1000M

 LOAD = 10N, SLIDING DISTANCE=1000M
LOAD = 10N, SLIDING DISTANCE = 1000M

This graph piloted with specimen, abrasive wear and specific wear. In this graph x axis
represent specimen (G25,G30,G35,F25,F30,F35) and Y axis represent wear rate From this
graph can understand wear rate increases with increasing percentages(25%,30%,35%)of fiber.
Wear rate also increases with increasing percentages fly ash (05%,10%,15%).
GRAPH (co-efficient of friction Vs specimen )

LOAD = 5N , SLIDING DISTANCE =1000M LOAD = 5N ,SLIDING DISTANCE = 1000M

 LOAD = 10N, SLIDING DISTANCE = 1000M LOAD = 10N, SLIDING DISTANCE=1000M

This graph piloted with specimen Vs co-efficient of friction . In this graph

xaxisrepresent specimen (G25,G30,G35,F25,F30,F35) and Y axis represent ,co-efficient of
friction . From this graph can understand co-efficient of friction increases with increasing
percentages(25%,30%,35%) of fiber.Co-efficient of friction also increases with increasing
percentages fly ash (05%,10%,15%).
 CONCLUSION
The present investigation of wear rate of fiber reinforced polyster resin composite leads to
the following conclusion . The E-glass/polyster approach has been made use of in order to make
cost effective composites.

In the present the work E- fiber reinforced polyester resin composites have been
successfully fabricate by simple hand lay up process . It has been noticed that wear of the
composite of found out various specimen by varying fiber and filler materials percentages .
The wear rate increases with increasing percentages (25%,30%,35%) of fiber. Wear rate also
increases with increasing percentages fly ash (05%,10%,15%).The co-efficient of friction
increases with increasing percentages (25%,30%,35%) of fiber.Co-efficient of friction also
increases with increasing percentages fly ash (05%,10%,15%).
THANK YOU