GOVERNMENT COLLEGE OF TECHNOLOGY DEPARTMENT OF PRODUCTION ENGINEERING SLIDING WEAR BEHAVIOUR OF GLASS FIBER REINFORCED EPOXY RESIN COMPOSITE AND OPTIMIZATION PROJECT TEAM MEMBERS: R.MITHILESH KUMAR(0715123) NARESH KUMAR SENAPATI(0715125) S.NELSON MANDELA(0715126) M.PRADEEP RAJA(0715130) N.SUBBIAH @ SURESH(0715147) A.KAMALAKKANNAN(0715L03) UNDER THE GUIDANCE OF: Mr. S. SRINIVASA MOORTHY, APPE
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SLIDING WEAR BEHAVIOUR OF GLASS FIBER REINFORCED EPOXY RESIN COMPOSITE AND OPTIMIZATION
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GOVERNMENT COLLEGE OF TECHNOLOGY
DEPARTMENT OF PRODUCTION ENGINEERINGSLIDING WEAR BEHAVIOUR OF
UNDER THE GUIDANCE OF:Mr. S. SRINIVASA MOORTHY, APPE
SYNOPSISThe present work includes the processing, characterization and study of the sliding wear behaviour of a e glass-epoxy composite. The composite with varying fibre length of 1cm, 2cm and 3cm along with different fibre content of 30wt%, 40wt% and 50wt % are used. By volume fraction method, the weight percentage of fiber, unsaturated polyester resin is calculated, and the polymer composite is fabricated by hand layup method.
The experimental investigations are carried out to investigate properties of unsaturated polyester composites under the wear test.
Then Taguchi’s experimental design approach is carried out to make a parametric analysis of sliding wear behaviour.
The systematic experimentation leads to determination of material variables that predominantly influence the wear rate.
The regressive analysis is carried out to determine the non-linear analysis for the prediction of the optimized model.
INTRODUCTION 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. At least one portion of each type is required.
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.
MATERIALS USED FOR FABRICATION OF COMPOSITES
FIBER : FIBER : E GLASS FIBRE E GLASS FIBRE ((ALUMINO-BOROSILICATE GLASS WITH LESS ALUMINO-BOROSILICATE GLASS WITH LESS THAN THAN 11 WT% ALKALI OXIDES, MAINLY USED WT% ALKALI OXIDES, MAINLY USED FOR GLASS-REINFORCED PLASTICS )FOR GLASS-REINFORCED PLASTICS )RESIN :RESIN :UNSATURATED UNSATURATED
FABRICATIONHAND LAY-UP OPERATION:Pattern preparation.Weighing of fibre, resin are made as per calculations.Mixture of (resin + catalyst + accelerator) is made.Wax coating .The fibers are laid in the pattern and the mixture is applied for bonding.After fabrication the composite material is left for curing for 24 hours.After curing process, cutting is done as per required dimensions.
PATTERN WITH WAX COATING
MATERIAL LEFT FOR CURING
FABRICATED PIECE AFTER CUTTING TO REQUIRED DIMENSIONS
WEAR TESTWear is erosion or sideways displacement of
material from its derivative and original position on a solid surface performed by the action of another surface.
The definition of wear may include loss of dimension from plastic deformation if it is originated at the interface between two sliding surfaces.
The wear test is being conducted on the specimens prepared by the hand lay-up method
WEAR TESTING MACHINEThe machine used for conducting the wear test
is DUCOM TRIBOMETER. The DUCOM TRIBOMETER uses a pin-on-disk system to measure wear.
The unit consists of a gimbaled arm to which the pin is attached, a fixture which accommodates discs upto 165mm in diameter and 8mm thick, an electronic force sensor for measuring the friction force, and a computer software (WINDUCOM) for displaying the parameters, printing, or storing data for analysis.
The motor driven turn table produces upto 2000rpm. Wear is quantified by measuring the wear groove with a profilometer and measuring the amount of material removed.
FEATURES AND SPECIFICATIONPARAMETER MINIMUM MAXIMUM UNIT
PIN SIZE 3 12 mm
DISC SIZE 165*8 mm thick mm
SLIDING SPEED 0.05 10 m/s
DISC ROTATION 200 2000 rpm
NORMAL LOAD 0 200 N
FRICTIONAL
FORCE
0 200 N
WEAR 0 2 mm
TRACK RADIUS TO BE SET MANUALLY mm
WEAR TESTING MACHINE
TESTING PROCEDUREThe specimen to be tested is placed on the
turn table fixture. The test variables sliding velocity, normal load, distance and time duration are specified.
The normal load is applied to the pin using a system of weights. Rotating the turntable while applying this force to the pin includes sliding wear as well as friction force.
TEST RESULTSAPPLIED FORCE FIBER CONTENT VELOCITY
WEAR RATE
20 30 1 0.00519
20 40 3 0.01745
20 50 5 0.003638
30 30 3 0.004299
30 40 5 0.003768
30 50 1 0.005574
40 30 5 0.00797
40 40 1 0.02955
40 50 3 0.004256
TAGUCHI METHODTaguchi defines the quality of a product, in
terms of the loss imparted by the product to the society from the time the product shipped to the customer.
Taguchi method uses a special design of orthogonal arrays to study the entire parameter space with a small number of experiments only.
The experimental results are then transformed into a signal-to-noise (S/N) ratio.
STEPS INVOLVED IN TAGUCHI METHODDetermination of the number of levels for the
design.Selection of the appropriate orthogonal array and
assignment of design parameters to the orthogonal array.
Conducting of the experiments based on the arrangement ofthe orthogonal array.
Analysis of the experimental results using the S/N and ANOVA analyses.
Selection of the optimal levels of design parameters.
CATEGORIES OF QUALITY CHARACTERISTICNormal is bestSmaller is betterLarger is better
For wear test smaller the better quality characteristic is preferred for analysis.
Smaller the better characteristic equation: S/N= −10 log (1/n) (∑y2)
ORTHOGONAL ARRAYAn orthogonal array is a type of experiment
where the columns for the independent variables are orthogonal to one another.
LEVELS AND FACTORS
Code Factor
Levels
1 2
3
AApplied force in
N20 30 40
BFiber content in
wt%30 40 50
C Velocity in m/s 1 3 5
L9 ORTHOGONAL ARRAY AND VALUESTrial Levels
1 2
3
Wear rate
1 20 30 1 0.00519
2 20 40 3 0.01745
3 20 50 5 0.003638
4 30 30 3 0.004299
5 30 40 5 0.003768
6 30 50 1 0.005574
7 40 30 5 0.00797
8 40 40 1 0.02955
9 40 50 30.004256
S-N RESPONSE FOR WEAR
Mean S/N ratio
Parameter Level1 Level 2 Level 3 Delta Rank
Applied
Force45.000 38.077 47.094 124.632 3
Fibre
content (wt
%)
43.215
46.962
39.994
133.499
1
Velocity
40.454
43.306
46.411
128.345
2
The following table shows the signal to noise response for wear
ANALYSIS OF VARIANCEThe purpose of the analysis of variance
(ANOVA) is to investigate the design parameters significantly affect the quality characteristic of a product or process.
ANOVA can be useful for determining influence of any given input parameter from a series of experimental results by design of experiments for machining process and it can be used to interpret experimental data.
ANOVA TABLE
SymbolCutting
Parameter D.O.F S.S. M.S. F Contribution
1 AF 2 72.981 36.491 1.064 22.218
2 FC 2 133.618 66.809 1.947 40.678
3 V 2 53.260 26.630 0.776 16.214
Error 2 68.622 34.311 20.891
Total 8 328.482 164.241 100.000
FACTORS INFLUENCING WEAR
RESULTS FROM TAGUCHI ANALYSISFrom the Taguchi result fibre content is most
significant factor for wear.The results of ANOVA revealed that fibre
content is the main parameter which has greater influence on wear.
The wear resistance increases with the increase of fibre content.
REGRESSION MODELLING AND ANALYSISThe statistical tool, regression analysis helps
to estimate (predict) the value of one variable from the given value of another.
Regression Models
Regression models involve the following variables:
Unknown parameters, βIndependent variables, XDependent variables, Y
TYPES OF REGRESSIONLinear RegressionNon-linear Regression
Non-Linear Regression AnalysisThe model function is not linear in the parameters the sum of squares must be minimized by an iterative procedure. Most of the researchers use the Nonlinear regression models in various applications.
REGRESSION MODEL RESULTSNonlinear Regression Summary Statistics Dependent Variable WR Source DF Sum of Squares Mean Square Regression 4 .09187 .02297 Residual 5 1.532781E-03 3.065562E-04 Uncorrected Total 9 .09340 (Corrected Total) 8 .07230 R squared = 1 - Residual SS / Corrected SS = 0.97880 Asymptotic 95 % Asymptotic Confidence IntervalParameter Estimate Std. Error Lower UpperK 8.30330E-13 9.41564E-12 -2.33733E-11 2.50340E-11 X -2.046056436 .938599113 -4.458802268 .366689396 Y 7.744994220 2.452698704 1.440131484 14.049856957 Z 1.513272257 866626694 -.714462582 3.741007096
REGRESSION MODEL RESULTS
It is seen that the value of R square is 0.97880, which ensures that the generated non-linear mathematical model for wear resistance is optimal.
CONCLUSIONThe unsaturated composite of e-glass fiber and
epoxy resin is fabricated using the hand lay-up technique.
The weight percentage of different compositions is calculated by volume fraction method.
The wear resisting property is characterized by conducting wear test on Ducom Tribometer.
Applied force, fiber content and velocity are influencing factors. It is observed that the wear resistance increases with increase in fiber content.
Taguchi’s analysis is carried out to find out the most influencing factor and optimization is done by considering the values from signal to noise ratio relationship, analysis of variance.
Regression modelling and analysis is also carried out to validate the wear test results.
By using the non-linear regression analysis method iterations are carried out and the final result ensures the optimization.