The general objective of this thesis is to develop new panel using hybrid sisal and false banana fiber reinforced by epoxy composite wich has better meterial properties than wood based panel currently used for minibus interior wall panel.
The study is about application of sisal and false banana fiber for automobile body by extraction or buy of sisal and false banana fibers, prepare the fiber, chemical treatment, dry and cut, determine of fiber/matrix contents of the natural fiber composite, selectproper matrix , fabrication of specimens and tests are done according to ASTM test standard.
Depending on tests result and comparison with existing panel material new panel is developed from sisal and false banana fiber reinforced epoxy hybrid composite.
Development of Minibus Interior Wall Panel Using Hybrid Sisal and False Banana Fiber Reinforced Epoxy Composite: FAQ
What is this document about?
This document is a comprehensive preview of a thesis titled "Development of Minibus Interior Wall Panel Using Hybrid Sisal and False Banana Fiber Reinforced Epoxy Composite." It includes the title, table of contents, objectives and key themes, chapter summaries, abstract, acknowledgements, lists of tables and figures, a list of abbreviations and acronyms, and a full reference section. The thesis focuses on developing a new minibus interior wall panel using a hybrid composite of sisal and false banana fibers reinforced with epoxy resin, aiming to improve upon the existing wood-based panels in terms of mechanical properties and water absorption.
What are the main objectives of the study?
The general objective is to develop a new minibus interior wall panel using a hybrid sisal and false banana fiber-reinforced epoxy composite with superior material properties compared to the currently used wood-based panel. Specific objectives include fabricating and characterizing the material properties (flexural strength, fracture toughness, and water absorption), selecting the optimal hybrid composite, comparing the new composite with existing materials, and finally fabricating the new panel.
What materials were used in the study?
The study used sisal fiber, false banana fiber, epoxy resin (GP), hardener (HY-951), NaOH, and water. The sisal and false banana fibers served as reinforcement, while the epoxy resin and hardener formed the matrix. NaOH was used in the fiber preparation process.
What methods were used to fabricate the composite?
The composite was fabricated using a hand lay-up technique. The fibers were prepared through alkali treatment (using NaOH), then mixed with the epoxy resin and hardener. This mixture was then placed in a mold and pressed using a compression molding technique to remove air bubbles and ensure proper curing. The curing process took approximately 24 hours at room temperature.
What tests were conducted on the composite materials?
Three main tests were performed: a flexural test (three-point bending) to determine the flexural strength and modulus of elasticity; a fracture toughness test (compact tension test) to assess the material's resistance to crack propagation; and a water absorption test to evaluate the material's resistance to moisture. These tests were conducted according to ASTM standards.
What were the key findings of the flexural test?
The flexural test revealed that the 50/50 sisal/false banana fiber composite exhibited the highest flexural strength (70 MPa) and flexural modulus (3.9 GPa). The combination of sisal and false banana fibers generally showed better flexural strength than using either fiber alone.
What were the key findings of the fracture toughness test?
The fracture toughness test showed that the 80/20 sisal/false banana fiber composite had the best fracture characteristics, with a stress intensity factor of 2.9 MPa.m1/2 and an energy release rate of 12.5 MPa.m1/2.
What were the key findings of the water absorption test?
The water absorption test indicated that the 100% sisal fiber composite had the lowest water absorption (2.8%) after 24 hours, significantly better than composites with higher proportions of false banana fiber.
What composite material was chosen for the final minibus panel?
Based on the results of all three tests, the 80/20 sisal/false banana fiber composite was selected for the fabrication of the new minibus interior wall panel due to its superior combination of strength, toughness, and water resistance.
What are the advantages of using this new composite panel compared to the existing wood-based panel?
The new composite panel offers increased flexural strength, fracture toughness, and significantly reduced water absorption compared to the wood-based panel currently used in minibus interiors. This translates to improved durability, reduced failure risk under load, and better resistance to damage from moisture.
What are the conclusions and recommendations of the study?
The study concludes that the sisal and false banana fiber reinforced epoxy composite is a viable and superior alternative to the existing wood-based panel for minibus interior wall applications. The researchers recommend its adoption due to its improved mechanical properties and moisture resistance. The study also suggests several avenues for future research, including exploring other natural fiber combinations, developing new molding techniques, and conducting further mechanical and thermal testing.
Where can I find the full thesis?
The provided text is an excerpt, not the full thesis. The full thesis would need to be obtained from Addis Ababa University or through other academic channels.
TABLE OF CONTENTS
ABSTRACT
ACKNOWLEDGEMENT
TABLE OF CONTENTS
LIST OF TABLE
LIST OF FIGURES
NOMENCLATURE
LIST OF ABBREVIATIONS AND ACRONYMS
CHAPTER ONE
1. INTRODUCTION
1.1 Background
1.2 Statement of the problem
1.3 Objectives of the study
1.3.1 The specific objectives
1.4 Research Questions
1.5 Scope of the Study
1.6 Limitation
1.7 Thesis Organization
CHAPTERTWO
2. LITERATURE REVIEW
CHAPTER - THREE
3. MATERIALS AND METHODS
3.1 The raw materials used in this work are
3.1.1 Sisal fiber
3.1.2 False banana fiber
3.1.3 Epoxy resin and hardener
3.1.4 Features of Epoxy
3.1.5 Applications of Epoxy
3.1.6 Hardener (HY-951)
3.1.7 Properties of sisal and false banana fibers
Table 2. Properties of Sisal and False Banana fiber
3.2 Extraction of fiber
3.2.1 False banana fiber extraction
3.2.2 Sisal fiber extraction
3. 3 Preparation of fiber
3.3.1 Weight and volume friction calculation for (70/30) % of epoxy/fiber ratio
3.3.2 Weight Fraction of the Fiber and the Matrix content of the composite
3.3.3 Volume Fraction of the Fiber and the Matrix content of the composite
3.4 Molding
3.4.1 Material needed for molding
3.5 Wet Hand lay-up technique
3.6 Compression and Curing
3.7 Test related to the Panel
3.7.1 Flexural test
3.7.2 Flexural strength (c)
3.7.3 Maximum strain (s)
3.7.4 Flexural Modulus of Elasticity (Ef)
3.7.5 Number of Test Specimens
3.7.3 Summary of Test Method
3.8 Fracture toughness test 13, 18
3.8.1 Calculation of stress intensity factor (KI) and energy release rate (G)
3.8.2 Strain Energy Release Rate
3.8.3 Relation to Fracture Toughness
3.9 Water absorption test[l 1]
CHAPTER FOUR
4. RESULTS & DISCUSSION
4.1 Experimental Results
4.1.1 Flexural test
Figure 19 Three point bending test
4.2 Fracture toughness test
4.2.1 Energy release rate
4.3 Water absorption test
4.4 Discussion
4.4.1 Flexural test results
4.4.2 Observation
4.5 Fracture toughness test result
4.5.1 Observation
4.6 water absorption test result
4.6.1 Observation
4.7 Comparison of new panel with existing panel material
4.8 Fabrication of new panel
4.9 Cost analysis
CHAPTER FIVE
5. CONCLUSION AND FUTURE WORK
5.1. Conclusion
5.2 Recommendation
5.3 Future work
6. References
APPENDIX
ABSTRACT
Development of Minibus Interior Wall Panel Using Hybrid Sisal and False Banana Fiber Reinforced Epoxy Composite
AddisAbaba University, 2018
In automobile sector due to the demanding need of rapid innovation and tough competition, the old products are reengineered by new product with composite materials. Replacement of old product by natural fiber composite is essential mainly due to their availability in large quantities, biodegradability, low cost, low density, recyclability and ease of manufacturing, natural fibers are also have better mechanical properties than tradition material. The minibus interior wall panel is made from wood based fiber board and it is failed during overload the vehicle and absorb water because of these reason it need replacement of this material with another new composite material within better material property. This paper study on application of sisal and false banana fiber for minibus interior wall panel by study flexural strength, fracture toughness and water absorption properties of new developed composite according to test related to the panel. The composite is produced by compression molding technique by using different fiber weight fractions. From test results 50% sisal and 50% false banana fiber composite has better than another species with flexural strength 70Mpa and flexural modulus 3.9 Gpa. 80% sisal and 20% false banana tested specimen have better stress intensity factor 2.9Mpa.m1/2 and energy release rate 12.5Mpa.m1/2and 100% sisal fiber composite have minimum water absorption 2.8% after 24 hours than another species composite. After all tests are done 80% sisal and 20% false banana fiber composite have better material properties than the other species finally new composite panel is fabricated from 80% sisal and 20% false banana fiber composite by compression molding technique.
Key Words: Minibus, hybrid, sisal, false banana, epoxy, interior wall panel, fiber board, flexural,fracture toughness, 'water absorption.
ACKNOWLEDGEMENT
First of all, I want to thank The Almighty GOD for giving me the time and chances to finally complete this research. I also want to thank Dr. Daniel T. who have given his best in making me understand how this research has to be done and have guided me throughout the research. I would like to express my sincere gratitude to my supervisor Mr. Araya Abera, for his invaluable guidance, continuous encouragement and constant support in making this research possible. He has always support me in times when I faced difficulties during completing this research and constantly giving the best advice to help me. I am always impressed with his effort in putting up with my attitude and still treated me well as his student after giving him such a difficult time. My sincere thanks go to all staff of the Mechanical Engineering Department, in AAiT especially for all lab technicians, who helped me in many ways whenever I needed. Thanks for always putting up the best effort in helping me to finish this research. The best thanks for all my friends who help me by any means for my research work and for my family I am very thankful to have them as family because they gave me constantly support me morally and financially which are things that I needed the most in order to complete this research. Thanks for always pray for my success and happiness in the past, present and the future. Thanks for all and everything.
LIST OF TABLE
Table 1. Maximum test results for each grade data from Ethiopian Quality and Standard Agency
Table 2. Properties of Sisal and False Banana fiber 18, 19
Table 3. density of the material
Table 4. Weight and Volume friction for each material
Table 5 flexural test result
Table 7. Energy release rate test result
Table 8. water absorption test result
Table 9. Flexural test results.
Table 10. Maximum Load and Stress Intensity factor test result
Table 11. Average value of water absorption (%) in 24 hours
Table 12. comparision of new and existing panel material14,31
Table 13. cost analysis
LIST OF FIGURE
Figure 1 Classifications of fibers
Figure 2. False banana plant
Figure 3. Sisal plant
Figure 4. Addis Ababa city minibus tax interior wall panel
Figure 5. False Banana fibers
Figure 6. Sisal fiber
Figure 7. Preparation of fiber done in AAIT Mechanical Department Laboratory
Figure 8. Mould Pattem
Figure 9. Hand layup technique
Figure 10. Mould curing by press machine in AAIT mechanical department laboratory
Figure 11. Sample composite after mould release
Figure 12. Right Side Minibus Interior Wall Panel
Figure 13. Dimension of flexural Test Specimens
Figure 14. Flexural Test Specimens
Figure 15. Fracture Toughness Specimen Geometry
Figure 16. Fracture Toughness test specimen
Figure 17. Water Absorption Specimens
Figure 18. Specimen for water Absorption Test
Figure 19. Three point bending testwhere P=load, S= 200mm (over all length), L=128mm(length of the span), d=4mm (thichness of the specimen)
Figure 20. UTM of wood technology research center in mechanical testing laboratory
Figure 21. flexural test specimen after test is done
Figure 22. Flexural test result, a) 100S, b) 100B, c) 20S80B, d) 50S50B, e) 80S20B
Figure 23. a, b, c, d e are flexural test result (flexural strength vs strain)
Figure 24. Fracture toughness test done in AAIT mechanical department laboratory
Figure 25. sisal and false banana fiber epoxy composite after fracture toughness compact tension test
Figure 26. a,b,c,d and e Compact Tension test result
Figure 27. Compact Tension Test result for different mass composition, Load Vs Load line displacement
Figure 28. a,b ,c,d,and e Compact Tension test result
Figure 29. Compact Tension Test result for different mass composition, stress intensity factor Vs Load line displacement
Figure 30. Fracture toughness test result (Load vs stress intensity)
Figure 31. Compact Tension Test result for different mass composition, Load Vs stress intensity factor
Figure 32. Water Absorption tests in AAIT mechanical laboratory
Figure 33. water absorption test specimen after soaking 24hours in water
Figure 34. water absorption test result
Figure 35. Maximum flexural strength test result
Figure 36. Maximum of Load and Stress Intensity factor
Figure 37. Comparison water absorption values by chart
Figure 38. Sisal and false banana hybrid reinforced by epoxy resin composite panel for minibus interior wall that fabricated in AAIT mechanical department laboratory
Symbol: Property:
Abbildung in dieser Leseprobe nicht enthalten
LIST OF ABBREVIATIONS AND ACRONYMS
UDF Ultra-low-densityfiiberboard
LDF Low-density fireboard
MDF Medium density fiberboard
HDF High-density fiberboard
ASTM America Society for Testing andMaterial
UTM Universal TestingMachine
100S100% sisal fiber in (70%epoxy and 30% fiber) weight ratio
100B 100% false banana fiber in (70%epoxy and 30% fiber) 'weight ratio
20S80B 20% sisal fiber and 80% false bananafiber in (70%epoxy and 30% fiber) 'weight ratio
50S50B 50% sisal fiber and 50% false bananafiber in (70%epoxy and 30%fiber) 'weight ratio
80S20B 80% sisal fiber and 20% false bananafiber in (70%epoxy and 30% fiber) 'weight ratio
CHAPTER ONE
1. INTRODUCTION
1.1 Background
Natural fiber reinforced composites have a good potential as a substitute for wood-based material in many applications.The development of environment-friendly green materials is because of natural fiber’s are biodegradable and low cost when compared to synthetic fiber. Composites, the wonder material with light-weight, high strength-to-weight ratio and stiffness properties have come a long way in replacing the conventional materials like metals, woods etc. The material scientists all over the world focused theirattention on natural composites reinforced with jute, sisal, banana, coir, pineapple etc. primarily to cut down the cost of rawmaterials 24.Composites are hybrid materials made of a polymer resin reinforced by fibers, combining the high mechanical and physical performance of the fibers and the appearance, bonding and physical properties of polymers. The short and discontinuous fiber composites are responsible for the biggest share of successful applications, whether measured by number of parts or quantity of material used. Applications of continuous fiber reinforced polymers. Instead of mass-manufactured polymer-based products, the domain for continuous fiber reinforced composite parts is in general with advanced capitalintensive materials and products [^.classification of fiber is shown in figure below.
Abbildung in dieser Leseprobe nicht enthalten
Figure 1.1 Classifications of fibers
Many researchers have tested different properties of banana fiber and its composite, but Ethiopian banana which is very similar to false banana stem but different in some cases is not under consideration, since it’s not popular in most countries. False banana plant is a large perennial herb with leaf sheaths that form pseudo stem. Its height can be 10-40 feet (3.0-12.2 meters) surrounding with 8-12 large leaves. This source of fibers provides great strength. Historically, false banana fiber was extraction by hand.This work pertains to utilization of the false banana fiber developed from the stem of false banana tree. After harvesting the ripe false banana fruits, the tree becomes use less and is thrown away False banana fiber is an important agricultural product. The false banana fiber has special importance in the economy of Ethiopia. However, it is facing tough competition from the synthetic fibers. False banana fibers find use in sophisticated fields like decorative and furnishing materials such as lamp shades, wall covers, curtains, upholsteries, etc 3,
Abbildung in dieser Leseprobe nicht enthalten
Figure 2.False banana plant
Sisal is a natural fiber,sisal leaves are found at most of Ethiopia at both high land and lowland area sisal fiber is a yield, stiff fiber traditionally used in making twine and rope. It is a biodegradable and eco-friendly crop. Moreover, sisal is a strong, stable and versatile material and it has been recognized as an important source of fiber for composites. Sisal fiber made from the large spear shaped tropical leaves of the Agave Sisalana plant. Sisal fiber is extracted by a process known as decortications, where leaves are crushed and beaten by a rotating wheel set with blunt knives, so that only fibers remain. Now Sisal has been utilized as an environmentally friendly strengthening agent to replace asbestos and fiberglass in composite materials in various uses the automobile industries 3,
Abbildung in dieser Leseprobe nicht enthalten
Figure 3.Sisal plant
1.2 Statement of the problem
Natural fiber reinforced composites have a good potential as a substitute for wood-based material in many applications like automobile, electronics, structural and etc materials. Wood-based panels are one kind of hydrophilic material, they are easily to absorb or release moisture when ambient temperature and relative humidity fluctuated, consequently mechanical properties were weaken or enhance especially internal bond and modulus of elasticity, does not have good screw holding capacity and not take nails very well 23, The minibus interior wall panel is made from wood based fiber board (MDF)40.It is failedat edge or fully broken during over loaded the vehicle andabsorb moisture. This paper tries to develop new panel have better mechanical properties, fracture toughness and less moisture absorption and also fill the gap which occurs on manufacturing of the panelcan be produced domestically in Ethiopia from sisal and false banana hybrid composite material by simple cold compression molding technique. Failed interior wall panel of Addis Ababa city minibus tax is shown in figure below.
Abbildung in dieser Leseprobe nicht enthalten
Figure 4 Addis Ababa city minibus tax interior wall panel
1.3 Objectives of the study
V The general objective of this thesis is develop new panel using hybrid sisal and false banana fiber reinforced by epoxy composite wich has better meterial properties than wood based panel currently used for minibus interior wall panel.
1.3.1 The specific objectives
- To fabricate and characterize material propery such as flexural strength, fracture toughness and water absorption test for new composite.
- To select hybrid composite that have best material property that used to develop the panel.
- To compare the material property of exicting panel with the new made composite panel.
- To develop new panel using selected fiber and epoxy composite.
1.4 Research Questions
- What are applications of natural fiber composite in Automobile body?
1.5 Scope of the Study
- The study is about application of sisal and false banana fiber for automobile body by extraction or buy of sisal and false banana fibers,prepare the fiber, chemical treatment, dry and cut, determine of fiber/matrix contents of the natural fiber composite, selectproper matrix , fabrication of specimens and tests are done according to ASTM test standard. Depending on tests result and comparison with existing panel material new panel is developed from sisal and false banana fiber reinforced epoxy hybrid composite.
1.6 Limitation
- Study is on natural fiber reinforced with epoxy but not with other matrix and combination only sisal and false banana but not combination of other natural fiber.
- This panel is developed by simple cold comperasion molding technique and it has rectangular and flat shapeand not difficult to fabricate but panel within different shapes done in my future study.
1.7 Thesis Organization
- This report focuses on the fabrication and test related topanel such as flexural, fracture toughness and water absorvation properties test and fabrication of new panel from hybrid sisal and false banana fiber reinforced epoxy composite.The manuscript comprises of five chapters.
- Chapter One: Introduces the background of natural fiber composite materials and this projecf'sobjectives. Problem Statement ,Research question, Scope and limitations
- Chapter Two: Reviewed all relevant research papers regarding natural fiber composite materials, panel material,wood based composite, ranging from polymer types, fiber types, and composite"s chemical, mechanical properties and water absorvation. Recentresearches on sisal and false banana fiber reinforcement on polymers are widely and deeply reviewed.
- Chapter Three:calculation of weight ratio, preparation of fiber, molding techniques, tests related to the panel are discussed.
- Chapter Four:Tests are done such as flexural, fracture toughness and water absorption results are discussed in detail.
- Chapter five: Is the conclusion, recommendation and future work of this thesis report.Conclusions describes application of sisal and false banana fiber composite for minbus interior wall panel that have better in flexural, fracture toughness and water absorption than wood based panel.
CHAPTERTWO
2. LITERATURE REVIEW
Bharath B, et al 2. bio-design and fabrication of bio-composite helmet (sisal, banana, jute and coconut coirvisvesvaraya technological university2015 - 2016. A composite material can be defined as a combination of two or more materials that results in better properties than those of the individual components used alone. In contrast to metallic alloys, each material retains its separate chemical, physical and mechanical properties. The reinforcing phase of the composites provides the strength and stiffness, to make them harder, stronger and stiffer than the matrix. The reinforcement is usually in the form of a fiber or a particulate. The length-to-diameter ratio is known as the aspect ratio, and can vary greatly for fibers because the length of the fiber is much greater than its diameter. Continuous fibers have high aspect ratios, while discontinuous fibers have low aspect ratios, and the orientation of continuous fiber composites normally is perfect, while discontinuous fibers generally have a random orientation. In general, the smaller the diameter of the fiber, the higher its strength, but the cost increases when the diameter becomes smaller. In addition, smaller diameter fibers have greater flexibility, and are more amenable to fabrication processes such as weaving or forming, across the radius. The continuous phase is the matrix, which is a polymer, metal or ceramic.
Abbildung in dieser Leseprobe nicht enthalten
Figure 2.1 Classification of composite materials
Metal Matrix Composites 2
Metal matrix composites have many advantages over monolithic metals, like higher specific modulus, higher specific strength, better properties at elevated temperatures, and low coefficient of thermal expansion. Because of these attributes metal matrix composites are under consideration for a wide range of applications.
Ceramic Matrix Composites 2
One of the main objectives in producing ceramic matrix composites is to increase the fracture toughness. Naturally it is hoped and indeed often found, that there is an improvement in the strength and stiffness of ceramic matrix composites.
Polymer Matrix Composites 2
Polymer matrix composites are recognized to be a more conspicuous class of composites when contrasted with artistic or metal lattice composites once in business requisitions. It includes a matrix from thermoplastic (polystyrene, nylon) or thermosetting (epoxy, unsaturated polyester) or and inserted steel, glass carbon, or Kevlar strands.
Natural fibers 2
Natural fibers are renewable, cheap, completely or partially renewable, biodegradable, and environment friendly materials. This is a new generation of reinforcements and supplements for polymer based materials. Fibers from plants such as cotton, hemp, jute, sisal, pineapple, ramie, bamboo, false banana, etc., as well as wood and seeds of flax are used as the reinforcement in polymer matrix composites. Their availability, low density and price as well as satisfactory mechanical properties, make them attractive alternative reinforcements to glass, carbon and other manmade fibers 9.Preparation of Hybrid Compositethe fabrication of two composite materials is carried out through the hand lay-up technique. Fiber of required dimension is placed on the surface of above prepared mixture. The mixture of resin, accelerator and catalyst are added proportionally by mixing thoroughly and laid upon the mat. Rollers are used to remove entrapped air and uniform distribution of resin on the fiber. The resin is mixed with suitable proportions of accelerator, promoter and catalyst. The resin impregnated fiber is laid on the prepared mold to a desired thickness and pressed with hand roller to eliminate any entrapped air bubbles and extra resin there after dried properly. A study related to the fatigue behavior of natural fiber-reinforced composites was conducted to expand their range of product applications there are only a few studies related to the fatigue of natural fiber composite
Yosuke Ueki et al 9. Study fatigue behavior of natural fiber-reinforced composites.After their experimental test the result is stiffness increasing during fatigue test of natural fiber composite. Composites based on artificial fibers such as carbon fibers and glass fibers are known to show stiffness decreasing due to damage progression while natural fiber composite increase stiffness during fatigue test.But it is remains unclear whether the stiffening effect and the damaging direct relationship not. A previous study indicated that the stiffening effect can be implicated as a result of alignment of the cellulose micro fibrils in the cell wall of natural fibers.
Andersons J.et al 7. Strength distribution of elementary flax fibers r-their study on Flax fibers, along with a number of other natural fibers, are being considered as an environmentally friendlier alternative of synthetic fibers in fiber-reinforced polymer composites. A common feature of natural fibers is a much higher variability of mechanical properties. This necessitates study of the flax fiber strength distribution and efficient experimental methods for its determination. Elementary flax fibers of different gauge lengths are tested by single fiber tension in order to obtain the stress-strain response and strength and failure strain distributions. Results show that the composite elastic modulus and failure stress are linearly related to the maximum stress reached by the matrix in tensile tests. Simple material models are suggested to account for the observed nonlinear viscoelasticity and viscoplasticity.
Layth Mohammed et al 8. study onnatural fiber reinforced polymer composites have beneficial properties such as low density, less expensive, and reduced solidity when compared to synthetic composite products, thus providing advantages for utilization in commercial applications (automotive industry, buildings, and constructions). Using natural fibers as reinforcement for polymeric composites introduces positive effect on the mechanical behavior of polymers. This paper evaluates the characteristics and properties of natural fiber reinforced polymer composites: mechanical, thermal, energy absorption, moisture absorption, biodegradability, flame retardancy, tribology properties. The interfacial properties, internal cracks, internal structure of the fractured surfaces, and the internal surfaces of the drilled holes are examined with the help of scanning electron microscopy.
MesflnKebede et al 6. study on sisal fiber composite material. From their study conclude that a polymer matrix composite contains the sisal fiber was successfully fabricated. Different mechanical properties of sisal fiber reinforced epoxy resin composite were determined from different Sisal to epoxy resin percentage fiber concentrations are less the matrix and fiber interface shows weak boding these affect clearly shown in tensile test. From the Tensile Experimental test results it is found that 35% alkaline treated have better tensile property anyhow from this results we suggest that as the fiber concentrations increases tensile strength also increased. When fiber concentrations are less the matrix and fiber interface shows weak bonding. From the Compression Experimental test results it is found that 25% treated sisal fiber reinforced epoxy resin composite has higher compressive tensile strength as compared to others. From the Bending Experimental test results it is found that 15% untreated sisal fiber has better tensile properties but treated 35% sisal fiber reinforced epoxy resin composite have better flexural modulus. From the compression and tensile test results we suggest since the results is unsatisfactory and difficult to figure out the effect of surface treatment and fiber/matrix in the composite specimen so we suggest further study needed to characterize the bending and compressive properties of sisal fiber reinforced epoxy resin composite. From all the results and comparisons we can conclude that the fabricated sisal fiber reinforced epoxy resins composite have some automotive application which does not need a very high mechanical performance, but need light weight and recyclability such as interior panel.
Hemant Patel et al 9. Mechanical behaviors of sisal and banana hybrid composites reinforced using of various parameter the result of their study is mechanical properties change with change in composition of fibers. On combination of sisal and banana where banana is in excess amount than sisal tensile strength value is high but bending values are low. Sisal fiber individually had the highest tensile strength but low bending and impact strength so it should be mix with banana fiber to obtain the desired strength and mechanical properties. Increase in hardener ratio with epoxy resin mechanical properties will change and excessive hardener will lead towards brittleness of composite material. Composite made from 50%sisal and 50% banana had less strength from composite having 80% sisal and 20% banana fiber ratios.In this experiment the length of fibers are kept constant, if length variation takes place, properties also changes. On application side, banana fiber is some extent used in automotive applications. As banana fiber is known for its remarkable smoothness its mixture with sisal fiber will lead towards better surface finish of the product with desired strength.
Kumaresan. M et al 15. Study on Effect of Fiber Orientation on Mechanical Properties of Sisal Fiber Reinforced Epoxy Composite.Fhexx work is evaluated the effect of fiber orientation on mechanical properties of sisal fiber reinforced epoxy composites. In this work sisal fiber is used as reinforcement which treated with NaOH solution for enhancing the bonding strength between fiber and resin by removing moisture contents. Samples of different orientations of sisal fiber reinforced composites were fabricated by compression molding and investigated their mechanical properties like tensile strength and flexural strength. The work of this experimental study has been carried out to determine the mechanical properties due to the effect of sisal fiber orientations such as 0/90°, 90° and 45° orientation. The results of this study indicate the orientation 90 o shows the better mechanical properties compare than 0°/90° and 45°.
Mohamed. AbdRahman et al 16.study on Flexural Strength of Banana Fibre Reinforced Epoxy Composites Produced through Vacuum Infusion and Hand Lay-Up Techniques - A Comparative Study.Txom their study natural fibers from such as kenaf, sisal, pineapple leaf and banana are becoming popular nowadays due to their many advantages over traditional glass fibers in reinforcing polymer composites. These fibers are renewable, abundantly available, economical, lightweight and environmental friendly. This work compared the flexural property of banana fiber- reinforced epoxy composites produced via vacuum infusion and hand layup processes. Banana fibers were treated with sodium hydroxide (NaOH) solution for 1 hour before been dried in the oven for 24 hours at 100°C. An aluminum vacuum infusion mold was manufactured per the standard flexural test specimen of 127mm x 12.7mm x 3.2mm. Composite specimens were produced while varying fiber volume fraction of 20% and 40% as well as fiber length of 63 mm and 127mm. The highest flexural strength of 136.27 MPa was achieved by specimens made by vacuum infusion process with 40% volume fraction and 63mm fiber length while for hand layup process, the highest flexural strength was only 80.71 MPa with equal fiber content and fiber length. At both fiber lengths, using vacuum infusion resulted in the increase in flexural strength in the range of 31.4 to 107.9% over hand layup. Using vacuum infusion has resulted in banana fiber-reinforced epoxy composites with better flexural properties compared to those produced using hand layup process which allow excellent reinforcing characteristic of banana fibers to be realized.
R. PrasannaVenkatesh et al 17. study on Tensile, Flexural, Impact and Water Absorption Properties of Natural Fiber Reinforced Polyester Hybrid Composite. In their investigation, the effect of the hybridization of sisal fiber with bamboo best fiber on the mechanical and water absorption properties was studied. The following conclusions are derived from this study. When increasing the fiber length and fiber content in sisal/unsaturated polyester natural fiber composites, mechanical properties were increased with the fiber content and optimum results of mechanical properties such as tensile strength, flexural strength and impact strength were noticed like 19.62 MPa, 54.12 MPa and 14.82 kJ/m2, respectively, at a fiber length of 15 cm and fiber content of 20%. The addition of bamboo fiber in the composite increased the mechanical properties, as opposed to sisal/unsaturated polyester alone. When sisal/bamboo fiber weight percentage was varied from 100/0 to 0/100, 75% bamboo addition leads to increased mechanical properties, whereas low water absorption behavior is noticed at a 50% bamboo addition. Considering mechanical properties and water absorption behavior as equally important parameters for the composites, the condition which enables maximum mechanical properties and minimum water uptake is concluded as 50/50 sisal/bamboo hybridization, and the results at this condition were 23.42 MPa for the tensile strength, 56.71 MPa for the flexural strength, 19.12 kJ/m2 for the impact strength and 19.62 % for the moisture uptake. The addition of 50% bamboo fbre in the composite results in a 19% increase in tensile strength, 5% increase in flexural strength and 29% increase in impact strength. The hybrid polyester composites prepared with treated bamboo and sisal fibers showed a significant increase in all mechanical strength properties, with positive effects being achieved in the tensile, flexural and impact strength. Marginal increases in mechanical properties are due to poor interfacial bonding between the matrix and fiber, which is evident from SEM analysis. Interfacial bonding between the fiber and matrix will be improved by chemical treatment with a coupling agent. The treated composite bonds a little better than the untreated hybrid composite.
Araya AberaBetelie et al 19.study on Facture Toughness Investigation of Chopped Sisal Fiber Reinforced Epoxy Resin Composite. Considering the increasing attention given to Natural fiber reinforced polymer matrix composites based on the possessed high strength to weight ratio, environmental friendliness and more, this study has been launched, ratio of 15/85%,25/75%, 30/70%, 35/65%, and 40/60% was determined using experiment and the selected best mass composition, 30/70% was validated using FEM by the help of ABAQUS software.Chopped sisal fiber as reinforcement was successfully fabricated and from the fracture toughness test results it is found that 30/70 wt% have a better fracture property among the other fiber-matrix compositions. Furthermore, both results justify that the 30/70 composition of chopped sisal fiber and epoxy resin matrix have robust fracture characteristics with KIC of 5.48 MPa.m1/2 and critical strain energy release rate (GIC) OF 13.72 MPa.m1/2. From all the results and comparisons we can conclude that the fabricated chopped fiber reinforced epoxy composite have a good fracture toughness property and it is recommended to use it for light weight applications including production of internal door panel and Automobile dash board.
MayurThombre et al 21. Study of mechanical properties of hybrid natural fiber composite. IOSR Journal of Mechanical and Civil Engineering hybrid composite.Hybrid composites are more advanced composites as compared to conventional FRP composites. Hybrids can have more than one reinforcing phase and a single matrix phase or single reinforcing phase with multiple matrix phases or multiple reinforcing and multiple matrix phases. They have better flexibility as compared to other fiber reinforced composites. Normally it contains a high modulus fiber with low modulus fiber. The high modulus fiber provides the stiffness and load bearing qualities, whereas the low- modulus fiber makes the composite more damage tolerant and keeps the material cost low. The mechanical properties of a hybrid composite can be varied by changing volume ratio and stacking sequence of different plies.
Application of Natural Fiber composites 21
The natural fiber composites can be very cost effective material for following applications: Building and construction industry: panels for partition and false ceiling, partition boards, wall, floor, window and door frames, roof tiles, mobile or pre-fabricated buildings which can be used in times of natural calamities such as floods, cyclones, earthquakes, etc.
Stephen K. Kimutai et al 22.axe study on Comparative Study of Composite Made from Ensete Banana Fibers and Polyethylene with Block Board and the conclude that Plastic waste andEnsete banana fibers can be used to produce composites for the construction industry. Ensete banana fiber content influences water absorption, compression strength, bending strength and impact strength of the composites. Higher fiber content resulted in high water absorption by the composite but it is significantly higher for the block board in the market. Machining operations such as grinding, milling, drilling and cutting can be performed on the composite without any difficult. Use of Ensetebanana ReinforcedPolyethylene as an alternative to block board production from wood not only saves forest but also a very effective way of recycling waste plastics.
Poo Chow, Charlie T et al 33. study on Fasteners resistance of non-woven and melt-blended composite panels made from cornstalk fibers and recycled plastics.The average values of the fastener resistance properties (except the edge screw holding power) obtained from the pressurerefined cornstalk -fiber/polypropylene composite panels do meet the minimum requirement. Naturalfiber composite panels did affect both staple and nail holding power capacity. It appears that the recycled plastic composite panels made from the cornstalk performed as well as the kenaf stalk. Low average screw holding power values were obtained, especially the edge screw holding from all cornstalk- plastics composite panels. In summary, the test results show that some of the steam-pressure refined cornstalk fibers-polypropylene fibers composite panels.
Manufacturing process of wood based fiber board panels 14.
A. Dry process fiberboard:- wood fiberboard with a forming line moisture content, as a mass fraction, ofless than or equal to 20 % and whose primary bonding results from applied adhesives or resins
B. wet process fiberboard:- wood fiberboard with a forming line moisture content, as a mass fraction, of greater than 20 % and whose primary bonding results from felting of wood fibers and their inherent adhesive properties
Classification of wood based boards 14
Abbildung in dieser Leseprobe nicht enthalten
Table 1. Maximum test results for each grade data from Ethiopian Quality and Standard Agency
Noah Matsumoto and John A. Nairn 31 are study on fracture toughness of wood and wood composites. During crack propagation critical stress intensity factors, KIc forMDF is 0.309 MPa Vm - 0.409 MPa \m magnitude of the increase in toughness with crack propagation is much lower indicating less effective fiber bridging. Wood fibers in MDF tend to lie in the plane of the panel and are therefore have less effective at bridging out-of-plane cracks than in-plane cracks.
S From all retirature review I conculed that many scholars are study on property characterization of composite material but not on application and properties chraterization depend on application for this resoan this paper is done on properties chariterization of natural fiber composite and also their application. Study on application of composite material is very essential to expand their application.
CHAPTER - THREE
3. MATERIALSAND METHODS
This chapter describes the details of processing of fabrication of sample composites and the experimental procedures followed for their mechanical properties characterization and water absorption test.
3.1 The raw materials used in this work are
A. Natural Fibers (Sisal, False Banana)
B. Epoxy resin (GP)
C. Hardener(HY-951)
D. NaoH (PALLETS 93% CH880)
E. Water (H2O)
3.1.1 Sisal fiber is a natural fiber of a type of leaf fiber is extracted from sisal plant leaves, sisal leaves are found at most of Ethiopia at both high land and lowland area. Sisal fiber extracted by using processes called decortications with blunt knives traditionally used for making twine and rope.
3.1.2 False banana fiber comes from family name (Musaceac) family a type of best fiber, extracted from the stem of false banana tree by hand; False Banana plant is mostly found southwestern part of our Ethiopia. False banana also kwon as ensete is used for nutrition and also use in sophisticated fields like decorative and furnishing materials such as lamp shades, wall covers, curtains etc.
3.1.3 Epoxy resin and hardener is used as a reinforcement material. Epoxy resin GP was used as a matrix, which is purchased from the local sources in Addis Ababa, Ethiopia, and epoxy resin is cured by adding hardener HY-951, which causes a chemical reaction without changing its own composition as well as property. Density and dynamic viscosity of epoxy resin are 1.2 g/cm3 and 11.789 Pa- s.
3.1.4 Features of Epoxy 2
- Light weight
- Resists most alkalis and acids
- Resists stress cracking
- Retains stiffness and flexibility
- Low moisture absorption
- Non-staining easily fabricate.
3.1.5 Applications of Epoxy 2
- Structural applications,
- Industrial tooling and composites,
- Electrical system and electronics.
3.1.6 Hardener (HY-951) 2
Hardener is a curing agent for epoxy or fiberglass. Hardener is buying from local market from Addis Ababa city. Epoxy resin requires a hardener to initiate curing; it is also called as catalyst, the substance that hardens the adhesive when mixed with resin. It is the specific selection and combination of the epoxy and hardener components that determines the final characteristics and suitability of the epoxy coating for given environment.
3.1.7 Properties of sisal and false banana fibers
Abbildung in dieser Leseprobe nicht enthalten
Table 2. Properties of Sisal and False Banana fiber 18, 19
3.2 Extraction of fiber
3.2.1 False banana fiber extraction
Mature false banana pseudo-stem was obtained from farm and was cut into length of 500 mm The stems from false banana plants were selected from an 11-month-old plantation. The plantation is located 1,050 meters above sea level and the stem of false banana is cut and extracted by hand by using wood lumber and another sharp wood after extracted the fiber dry in the sun 22, In southwestern of Ethiopia false banana fiber is extracted by women and false banana used for this work is extracted from wolkite.
Abbildung in dieser Leseprobe nicht enthalten
Figure 5 False Banana fibers
3.2.2 Sisal fiber extraction
Ethiopian sisal leave is 500mm long and it is vary in its length depend on is age and is location Sisal leaves were extracted by blunt knives, after the fiber is extracted it is dry in the sun. Extracted sisal fiber from Ethiopia around Adama town is shown in figure blow 5,
Abbildung in dieser Leseprobe nicht enthalten
Figure 6. Sisal fiber
3.3 Preparation of fiber
- Alkali treatment is the simplest method of chemical treatment of fibers; it leads to the increase in the amount of amorphous cellulose at the expense of crystalline cellulose. The important modification occurring here is the removal of hydrogen bonding in the network structure.
- Put into some container preparing for Alkali treatment.
- Mixing with 90% of H2O and 10% of sodium hydroxide (NAOH) and soaked in this solution for 24hours.
- After this wash by tap water until neutral PH is attained
- Then dry and cut the fiber by cutting length of fiber ~ 6-9 mm
Abbildung in dieser Leseprobe nicht enthalten
Figure 7. Preparation of fiber done in AAIT Mechanical Department Laboratory
1. Mixing fiber with water and sodium hydroxide in container
2. Kept mixed solution for 24Hours
3. Wash the fiber until neutral Ph is attained
4. Dried and cut fiber
3.3.1 Weight and volume friction calculation for (70/30) % of epoxy/fiber ratio
3.3.2 Weight Fraction of the Fiber and the Matrix content of the composite
Abbildung in dieser Leseprobe nicht enthalten
Table 3. density of the material
Abbildung in dieser Leseprobe nicht enthalten
3.3.3 Volume Fraction of the Fiber and the Matrix content of the composite
Abbildung in dieser Leseprobe nicht enthalten
3.3.4 Mass fraction 30% sisal with 70%Epoxy resin
Abbildung in dieser Leseprobe nicht enthalten
Table 4. Weight and Volume friction for each material
3.4 Molding
All material for molding ready first then mould release wax was varnished overall of mould surface after that weighted chopped sisal, false banana, epoxy and hardener according to each specific fiber/matrix ratio and mass and volume friction table 3.2then we pour mixture of fiber epoxy and hardener mixture into Contenairs and mixing by shaking for few minutes after this we add chopped fiber into mould hand lay out techniques. Then we press the mold on press machine until epoxy is flow on edge of mould and left for 24 hours. The composite gets dried up in 24 hours in which the sisal and false banana fiber and the epoxy adheres itself tightly in the presence of hardener. After a day we put out the mould from the press machine .Then the mold steel lower base is slowly and gently hammered on the boundary of its attachment when the lid and the composite separate out. Then carefully plastics are removed from the steel mold.
3.4.1 Material needed for molding
- Prepared fiber, epoxy Resin, hardener and wax
- Containers and mixing materials
- Safety gloves, shoes and clothes
- Press machine
- Balance with capable reading 0.1g
- The pattern with size (229mm x229mm) and the pattern is made up of mild steel.
Abbildung in dieser Leseprobe nicht enthalten
3.5 Wet Hand lay-up technique
Hand lay-up technique is the simplest method of composite processing. The infrastructural requirement for this method is also minimal. The processing steps are quite simple. First of all, we balance the fiber, epoxy and hardener used for that composite, mix hardener with epoxy and smear with wax on the mold surface to avoid the sticking of polymer to the surface.Hand-lay-up method was adopted to fill up the prepared mould with an appropriate amount of epoxy resin mixture and layers of random sisal and false banana fibers, such that starting and ending with layers of resin. The quantity of accelerator and catalyst added to resin at room temperature for curing was 1% by volume of resin each. Fiber deformation and movement should be minimized to yield good quality, random fiber composites. Therefore, at the time of curing a compression pressure of 5 MPa was applied on the mould and the air gaps formed between the fibers during the processing were gently squeezed out by hydraulic press to force the air present in between the fibers and resin, and kept several hours to get the perfect samples the processed wet composite were then pressed hard and the excess resin is removed and dried. Fiber configuration and volume fraction are two of the most important factors that affect the properties of the composite. In this work, configuration is limited to random, equal to the thickness of specimen 7, 5 Mpa of pressure was maintained and it requires 24 hours for curing at room temperature. When we press the mold we must be take care for thickness of the expected sample composite it may be not uniform or not equal with calculated thickness of composite. Press until epoxy is seen on tip of edge of the mould is enough to get expected thickness and we must be sure at all comer uniform fit and engagement is needed then we left for 24hours for curing. After curing period the sisal and false banana fiber hybrid composite were removed from the moulds.
Abbildung in dieser Leseprobe nicht enthalten
Figure 9. Hand layup technique7,
3.6 Compression and Curing
Abbildung in dieser Leseprobe nicht enthalten
Figure 11 Sample composite after mould release
3.7 Test related to the Panel 14
Tests shall be applied to the various fiberboard grades are listed below and all propertyrequirements shall be met at dispatch from the factory. The tests are done according to each grade is depend on the application of the panel.
- Bending strength
- Modulus of elasticity Internal bonding
- Thickness swelling
- Surface soundness
- Moisture resistance
- Wet bending strength
Tests related to this panel are bending test, internal bonding test and water absorption test of the composite. Thickness swelling, surface soundness, wet bending are not significant test for this kind of panel. Flexural test, fracture toughness and water absorption testby using tests calculation equations from (3.1-3.11) and must be done for such like panel according to test mandatory for this panel 14, MDF panel is cut from fiber board 245x122cm2 with thickness used for panel is (3-10) mm. minibus interior wall panel is by local name called “Tappissery” after cut within its standard dimension cover by synthetic leather and installation is done. Panel at right side and geometry is as follows this panel is subjected flexural load due to overload vehicle than other interior panel.
Abbildung in dieser Leseprobe nicht enthalten
Figure 12 Right Side Minibus Interior Wall Panel
3.7.1 Flexural test 12
- ASTM-D7264:- Standard Test Method for Flexural Properties of Polymer Matrix Composite Materials
- The flexural test specimens are prepared as per the ASTM D7264 standards. The 3-point flexural test is the most common flexural test and used in this experiment for checking the bending strength of the composite samples. The five test specimens of each made up of sisal/false banana fiber reinforced epoxy composites are prepared and tested by applying three point flexural loading with the help of UTM.
- The testing process involves placing the test specimen in the UTM and applying force to it until its fractures and breaks.
- The result of flexural strength of each specimen is observed and the results are compared.
Abbildung in dieser Leseprobe nicht enthalten
3.7.2 Flexural strength (c)is Beam simply supported at two points and loaded at the midpoint, the maximum stress at the outer surface occurs at mid-span. The stress may be calculated for any point on the load-deflection curve by the following equation.
Abbildung in dieser Leseprobe nicht enthalten
3.7.3 Maximum strain (e)at the outer surface also occurs at mid-span, and it may be calculated as follows:
Abbildung in dieser Leseprobe nicht enthalten
Where:
Abbildung in dieser Leseprobe nicht enthalten
3.7.4 Flexural Modulus of Elasticity (El)- the flexural chord modulus of elasticity is the ratio of stress range and corresponding strain range. For calculation of flexural chord modulus, if the data is not available at the exact strain range end points (as often occurs with digital data), we can use the closest available data point.
Abbildung in dieser Leseprobe nicht enthalten
3.7.5 Number of Test Specimens
Test at least five specimens per test condition unless valid results can be gained through the use of fewer specimens, such as in the case of a designed experiment for statistically significant data.
Abbildung in dieser Leseprobe nicht enthalten
Figure 13 Dimension of flexural Test Specimens
Abbildung in dieser Leseprobe nicht enthalten
Figure 14 Flexural Test Specimens
3.7.3 Summary of Test Method 12
a) A bar of rectangular cross section, supported as a beam, is deflected at a constant rate as follows:
b) Three point bending —The bar rests on two supports and is loaded by means of a loading nose midway between the supports
c) Force applied to the specimen and resulting specimen deflection at the center of span are measured and recorded until the failure occurs on either one of the outer surfaces, or the deformation reaches some pre-determined value.
3.8 Fracture toughness test 13, 18.
- ASTM-D5045 Fracture Toughness TestingPlane strain Fracture Toughness and Strain Energy Release Rate of Plastic Materials
- These test methods based on American Society of Testing Materials (ASTM) D 5045. Involve loading a notched specimen that has beenpre cracked, in either tension (compact tension) or three-point bending.
- The use of composite materials for panel depends on the values of the various applicable mechanical properties. One of these properties is fracture toughness, or the ability of a material to resist fast fracture by unstable crack propagation caused by notch, hole and screw holding at tip of the panel
Abbildung in dieser Leseprobe nicht enthalten
The ratio of crack length to width (a / W) is to be maintained between 0.45 and 0.55.
Abbildung in dieser Leseprobe nicht enthalten
Figure 15 Fracture Toughness Specimen Geometry
Abbildung in dieser Leseprobe nicht enthalten
Figure 16 Fracture Toughness test specimen
3.8.1 Calculation of stress intensity factor (KI) and energy release rate (G)
In this test method stress intensity factor KI is calculated from the following expression:
Abbildung in dieser Leseprobe nicht enthalten
3.8.2 Strain Energy Release Rate 18
The strain energy release rate (or simply energy release rate) is the energy dissipated during fracture per unit of newly created fracture surface area. This quantity is central to fracture mechanics because the energy that must be supplied to a crack tip for it to grow must be balanced by the amount of energy dissipated due to the formation of new surfaces and other dissipative processes such as plasticity. For the purposes of calculation, the energy release rate is defined as:-
Abbildung in dieser Leseprobe nicht enthalten
3.8.3 Relation to Fracture Toughness
Abbildung in dieser Leseprobe nicht enthalten
3.9 Water absorption test[ll]
Z ASTM D570-98:-Standard test method for water absorption of plastics was used water absorption characteristics of sisal/ false banana hybrid fiber reinforced Epoxy resin composite. Samples are removed at regular intervals and weighted immediately after wiping away water from the surface, and a precise 4-digit balance was used to find out the content of water absorbed. The following equationis used to determine the water absorption.
Abbildung in dieser Leseprobe nicht enthalten
Figure 17 Water Absorption Specimens
Abbildung in dieser Leseprobe nicht enthalten
Figure 18 Specimen for water Absorption Test
CHAPTER FOUR
4. RESULTS & DISCUSSION
4.1 Experimental Results
4.1.1 Flexural test
The flexural test measures the force required to bend a beam under three point loading situations. The data is often used to select elements for parts that will support loads without inflection. Flexural modulus is used as an indication of a material’s stiffness when inflection. Three point bend test was carried out in an UTM machine in accordance with ASTM standard to measure the flexural strength of the composites. For flexural test there were five specimens in each groups of sisal/false banana ratio (100S, 100B, 80S20B, 50S50B, and 20S80B). The load was applied in the middle span of the specimen at a speed of 0.5mm/min. The span length was 128mm. UTM Testing Systems are highly integrated testing packages that can be configured to meet different testing needs. UTM Testing machine is having capacity of 10KN and rate is varying starting from 0.5mm/min. this machine is universal testing machine with three point bending test vice. All dimensions of specimen and vice arrangement are according to ASTM standard. The machine reading is manual from load, deflection reading device and controlled by human.
Abbildung in dieser Leseprobe nicht enthalten
Figure 19 Three point bending testwhere P=load, S= 200mm (over all length), L=128mm(length of the span), d=4mm (thichness of the specimen)
Abbildung in dieser Leseprobe nicht enthalten
Figure 20 UTM of wood technology research center in mechanical testing laboratory
Abbildung in dieser Leseprobe nicht enthalten
Figure 21 flexural test specimen after test is done
Abbildung in dieser Leseprobe nicht enthalten
Table 5 flexural test result
Abbildung in dieser Leseprobe nicht enthalten
4.2 Fracture toughness test
Compact tension test apply to material contain cracks or stress concentrate, such as properties of fiber and brittle inclusions of matrix material. When crack like defects are present either as surface cracks or internal ones, failure may begin at much lower applied stresses. Fracture toughness is related to the amount of energy required to create fracture surfaces. The compact tension test for first mode fracture toughness (Ki) is done by UTM machine in AAIT mechanical department laboratory within speed of cross head 0.5mm/min and capacity of 10KN.
Abbildung in dieser Leseprobe nicht enthalten
Figure 24 Fracture toughness test done in AAIT mechanical department laboratory
Abbildung in dieser Leseprobe nicht enthalten
Figure 25 sisal and false banana fiber epoxy composite after fracture toughness compact tension test.
Abbildung in dieser Leseprobe nicht enthalten
Figure 29 Compact Tension Test result for different mass composition, stress intensity factor Vs Load line displacement
Abbildung in dieser Leseprobe nicht enthalten
Figure 30 Fracture toughness test result (Load vs stress intensity)
Abbildung in dieser Leseprobe nicht enthalten
Figure 31 Compact Tension Test result for different mass composition, Load Vs stress intensity factor
4.2.1 Energy release rate
Maximum Energy release rate (G) for test specimen is calculated and put in table below.
Abbildung in dieser Leseprobe nicht enthalten
4.3 Water absorption test
Moisture in take was determined by measuring the weight periodically by soaking the specimen in water for 24 hours. The specimens were obtained by cutting according ASTM D570-98. The specimens for compression test were cut into 76.2 mm length and 25.4 mm widthWater absorption behavior of the composite is a concern in composites panel applications 11,
- Balance analytical capability of reading 0.0001g
- Temperature uniform at 23+l°C and 73.4+1.8°F
- Two hours repeatedly immersion from Ohour to 24hours
- Three specimen for each sisal/false banana fiber matrix.
- Average result of water absorption of each specimen in repeatedly measuring by 2hours interval in 24hours and put in the Table 7.
Abbildung in dieser Leseprobe nicht enthalten
Figure 32 Water Absorption tests in AAIT mechanical laboratory
Abbildung in dieser Leseprobe nicht enthalten
Figure 33 water absorption test specimen after soaking 24hours in water
Abbildung in dieser Leseprobe nicht enthalten
Table 7. water absorption test result
Abbildung in dieser Leseprobe nicht enthalten
Figure 34 water absorption test result
4.4 Discussion
4.4.1 Flexural test results
The maximum results are calculated from average of each specimen and flexural modulus also calculated after sketching stress strain graph at which stress strain is proportional the generalized calculated results are put in the table below.
Abbildung in dieser Leseprobe nicht enthalten
Table 8. Flexural test results
Figure 35. Maximum flexural strength test result
4.4.2 Observation
- Sisal/ false banana ratio is affect the flexural strength of the sisal and false banana fiber reinforced epoxycomposite.False banana fiber is individual better in flexural strength and sisal fiber epoxy composite has less flexural strength from the all fiber/matrix ratio.
- Combination of 50% sisal and 50% false banana fiber reinforced epoxy composite has greater flexural strength and flexural modulus. From testing result 50S50B tested specimen has better flexural strength than another with flexural strength 70Mpa and flexural modulus 3941Mpa.
- On combination of sisal and false banana where false banana is in excess amount than sisal have high bending strength values.
- in this experiment the length of fibers are kept constant, if length variation takes place, properties also changes.
- Flexural test result with better flexural strength value is have better flexural modulas.
- As false banana fiber is known for its remarkable smoothness its mixture with sisal fiber will lead towards better surface finish of the product with desired strength.
- Combination of sisal and false banana fiber composite has better flexural strength than individual sisal and false banana composite.
4.5 Fracture toughness test result
As clearly observed from the experimental analysis, 80S20B of sisal and false banana hybrid fiber epoxy composite material has the best fracture characteristics as its stress intensity factor implies. The summarized critical intensity factors for different mass compositions of fiber matrix orientation is tabulated and compared using a chart as follows.
Abbildung in dieser Leseprobe nicht enthalten
Table 9. Maximum Load and Stress Intensity factor test result
Abbildung in dieser Leseprobe nicht enthalten
Figure 36. Maximum of Load and Stress Intensity factor
4.5.1 Observation
- A polymer matrix composite containing the chopped sisal and false banana fiber as reinforcement was successfully fabricated and from the fracture toughness test results it is found that 80S20B wt% have a better fracture property among the other fiber-matrix compositions 80S20B tested specimen has better stress intensity factor 2.9Mpa.m1/2 and energy release rate 12.5Mpa.m .
- Combination of sisal and false banana fiber reinforced epoxy composite has better stress intensity factor than individual sisal and false banana fiber reinforced epoxy composite.
- The stress required to start the crack propagation is maximum stress and stress intensity factor is maximum at the point where stress is maximum.
- As the number of discontinuity increases the stress intensity factor decreases up to one discontinuity and then increases. As fiber volume percentage goes on increasing the fracture toughness increases.
4.6 water absorption test result
Average value water absorption in 24 hours of each specimen is calculatedAfter immersion for 24 h. Sisal and false fiber composites are subjected to water immersion tests in order to study the effects of water absorption on the mechanical properties. Water absorption tests were conducted by immersing the composite specimens in distilled water in beaker at room, temperature for different time durations. After immersion for 24 h, the specimens were taken out from the water and all surface water was removed with a clean dry cloth or tissue paper. The specimens were weighed regularly at 0, 2, 4, 6, 8, 10, 12 and 24 hrs exposures. The moisture absorption was calculated by the weight difference. The percentage weight gain of the samples was measured at different time intervals.
Abbildung in dieser Leseprobe nicht enthalten
Table 11. Average value of water absorption (%) in 24 hours
Abbildung in dieser Leseprobe nicht enthalten
Figure 37.Comparison water absorption values by chart
4.6.1 Observation
- Sisal fiber reinforced epoxy composite has less water absorption property than other species and matrix have more sisal fiber also better in water absorption properties.
- False banana fiber reinforced epoxy composite is more water intake than another species.
- Combination of sisal and false banana fiber composite is less water absorption property than false banana fiber reinforced epoxy composite.
- The percentage of moisture uptake increased as the increasing order of the filler loading due to the high cellulose content.
4.7 Comparision of new panel with existing panel material
Abbildung in dieser Leseprobe nicht enthalten
4.8 Fabrication of new panel
From all test result 80S20B have good test result from all test result we will be use this fiber/fiber matrix by using predefined 30/70 fiber/matrix weight ratio therefore new panel is made up of this combine sisal and false banana fiber composite Epoxy 1358.4g, False Banana fiber 119g, Sisal fiber 475.41g and Hardener 13.58g is needed to fabricate the panel from total mass of panel around 1,966g all are from calculation of weight friction and volume of panel is (120x43x0.3) cm3. Fabrication of the panel was carried out by adopting the following hand lay process procedure initially coated wax on plate surface and add a layer of epoxy - GP and hardener HY-951 mixture which will act as an adhesive for a bottom layer of chopped fiber and over the fibers once again a layer of epoxy is applied. Now these fibers are compressed with help of another plate by using manual press machine to ensure the proper bonding between reinforcement and fibers then allowed for settling time of about 24 hours for curing the new composite was released and cut as geometry of panel shown in figure below.
4.9 Cost analysis
Abbildung in dieser Leseprobe nicht enthalten
Table 12 cost analysis
- Reference from local market 1kg fiber=20Birr, IL epoxy=130Birr, IL of hardener =130Birr and 500g of NaoH=250Birr paint or color 0.05L= 25Birr and total cost for panel is (200- 300)Birr
- Weight of MDF panel 0.8 x 120 x 43 x(0.3-8)= 3302g =(1.2-3kg) MDF board 122-245cm2 is 250-380 Birr and Synthetic leather (l-1.4)m is (250-500)Birr
Abbildung in dieser Leseprobe nicht enthalten
Figure 38. Sisal and false banana hybrid reinforced by epoxy resin composite panel for minibus interior wall that fabricated in AAIT mechanical department laboratory
CHAPTER FIVE
5. CONCLUSION AND FUTURE WORK
5.1. Conclusion
Apanelwich made up of polymer matrix composite containing chopped sisal and false banana fiberwas successfully fabricated this is include such activites fabrication of hybrid composite and experimental test of flexural strength, fracture toughness and water absorption for this composite, the results are discussed and compared with existing panel material. Moreover such tests constitute fundamental confirmation of the reliability of hybrid sisal and false banana compisite and its usage in minibus interior wall panel. Few points can be concluded as follows:
- The panel is successfully fabricated from sisal and false banana fiberreinforced epoxy composite by using simple cold compression molding technique.
- Using Newcomposite panel is increaseflexural strength by 42.8%, fracture toughness by 86% and water absorption properties by 80%when I compare with wood based panel.
- From all results and by comparisons with existing panel material I can conclude that the fabricated chopped sisal and false banana fiber reinforced epoxy composite is better to use for minibus interior wall panel than wood based panel.
5.2 Recommendation
- I recommendedthat instead of usingwood based panelfor minibus interior wall panel using sisal and false banana fiber reinforced epoxy compositeis better which has good mechanical and moisture absorption properties than wood based panel.
5.3 Future work
There are many studies for future work related to natural fiber composite material and their related field of application, design and development of composite material. Sisal and false banana hybrid reinforced epoxycomposite material also need another research to use in automobile body application more than panel or interior parts. The followings are the future studies related to this paper.
- Develop different parts of Automobile from sisal and false Banana fiber reinforced epoxy composite like car door, roof and dash board.
- Design and manufacturing of fiber cutting and extraction machine.
- Study on natural fiber composite other than sisal and false banana fiber.
- Develop molding techniques and mould pattern.
- Design and manufacturing of press machine.
- Characterization of mechanical properties like Fatigue test, shear test, Impact test and thermal test of the composite.
- SEM and Finite Element Analysis can be carried out.
6. References
1) K. van Rijswijk, M.Sc. W.D. Brouwer, M.Sc. and Prof. A. BeukersApplication of Natural Fibre CompositesStructures and Materials Laboratory Faculty of Aerospace Engineering Delft University of Technology 20 December 2001
2) Bharath B, Chethan Kumar G, Shivanna G , Syed SajjadHussainbio-design and fabrication of bio-composite helmet (sisal, banana, jute and coconut coir)”visvesvaraya technological university2015 -2016
3) M.M. Kabir, H. Wang, K.T. Lau, F. Cardona, Chemical treatments on plant-based natural fiber reinforced polymer composites: An overview, Composites: Part B; 2012; 43: 2883 2892.
4) Panthapulakkal S, Sian M., Injection-molded short hemp fiber/glass fiber reinforced polypropylene hybrid composites mechanical, water absorption and thermal properties, Applied Polymer Science; 2007; 103:2432 2441.
5) Sathasivam K, Haris M.R.H.M., Noorsal K., The Preparation and Characterization of Esterified False false banana Trunk Fibers/Poly(vinyl alcohol) Blend Film, Polymer-Plastics Technology andEngineering; 2010; 49(13): 1378-1384.
6) Biswal M., Mohanty S., Nayak S.K., Effect of Mercerized False false banana Fiber on the Mechanical and Morphological Characteristics of Organically Modified Fiber Reinforced Polypropylene Nanocomposites, Polymer-Plastics Technology and Engineering; 2011; 50(14):1458-1469. DOI: 10.1080/03602559.2011.593079.
7) Mesfinkebede,Yonas, and Araya AberaFabrication and Mechanical Property Characterization of Sisal fiber Reinforced Epoxy Resin Composite Material for Automotive body Application in2015
8) Venkateshwaran N, Elayaperumal A, Sathiya GK, Prediction of tensile properties of hybrid-natural fiber composites. Composites: Part B;2012;43(2):793-796
9) K.N. Indore, JyotishkumarParameswaranpillai, and Sabu Thomas, (2013) Mechanical properties & Failure topography of false banana fiber, Hindawi Publishing Corporation, ISRN Polymer science.
10) Hemant Patel , Prof. AshishParkhe , Dr P.KShrama mechanical behaviors of sisal and banana hybrid composites reinforced using of various parameter 2016
11) ASTM D570-98 (Reapproved 2005), Standard test method for water absorption of plastics.
12) ASTM D7264M - 07 Standard Test Method for Flexural Properties of Polymer Matrix Composite Materials.
13) Ravi Tumkur Suryawanshi, Gopalan Venkatachalam, and Suthenthira Veerappa Vimalanand Determination of Stress Intensity Factor of Banana Fibre Reinforced Hybrid Polymer Matrix Composite Using Finite Element Method Received 08 January 2016; accepted after revision 16 March 2016.
14) International standard isol6895 first edition 2016-02-01wood-based panels — dry-process fiberboard
15) Kumaresan. M, Sathish. S and Karthi. Are N Study on Effect of Fiber Orientation on Mechanical Properties of Sisal Fiber Reinforced Epoxy Composite.Joumal of Applied Science and Engineering, Vol. 18, No. 3, pp. 289294 (2015).
16) Mohamed AbdRahman, Abdul Aziz Jasani and MohdAzizuddinlbrahim are study on Flexural Strength of Banana Fibre Reinforced Epoxy Composites Produced through Vacuum Infusion and Hand Lay-Up Techniques - A Comparative Study.Intemational Journal of Engineering Materials and Manufacture (2017) 2(2) 31-36.
17) R. PrasannaVenkatesh, K. Ramanathan, and V. Srinivasa Raman are study on Tensile, Flexural, Impact and Water Absorption Properties of Natural Fiber Reinforced Polyester Hybrid Composite.DOI: 10.5604/12303666.1196617.
18) Araya AberaBetelie, YonasTsegayeMegera, Daniel TelahunRedda and Antony Sinclair are study on Facture Toughness Investigation of Chopped Sisal Fiber Reinforced Epoxy Resin Composite.AIMS Materials Science, 5(1): 93-104. DOI: 10.3934/matersci.2018.1.93 Received: 20 July 2017, Accepted: 08 January 2018, and Published: 30 January 2018
19) R. Prasanna Venkateshl, K. Ramanathan2, V. Srinivasa Raman3Tensile, Flexual, Impact and Water Absorption Properties of Natural Fibre Reinforced Polyester Hybrid CompositesDOI: 10.5604/12303666.1196617
20) N. Venkateshwaranand A. ElayaPerumal Mechanical and Water Absorption Properties of Woven Jute/Banana Hybrid Composites Engineering Design Division, Department of Mechanical Engineering, Anna University, Chennai, India (Received October 7, 2011; Revised February 13, 2012; Accepted February 25, 2012)
21) MayurThombre, AnimeshAgarwal, Chandrajeet, Sandeep Nair Study of mechanical properties of hybrid natural fiber composite. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 01-05.
22) Stephen K. Kimutai, Zachary O. Siagi, Joan J. Kiptarus, and Anthony D. KibetComparative Study of Composite Made from Ensete False Banana Fibres and Polyethylene with Block Board Journal of Energy Technologies and Policy ISSN 2224-3232 (Paper) ISSN 22250573 (Online) Vol.4, No.12, 2014.
23) Poo Chow, Charlie T. Bowers and John A. Youngquist, Jim H. Muehl, Andrezej M. KrzysikFasteners resistance of non-woven and melt-blended composite panels made from cornstalk fibers and recycled plastics published on International Wood and Natural Fiber Composites Symposium April 10-11, 2002 in Kassel/Germany.
24) DebiprasadGon, Kousik Das, Palash Paul, SubhankarMaity Jute Composites as Wood Substitute International Journal of Textile Science 2012, 1(6): 84-93 DOI: 10.5923/j.textile.20120106.05
25) G. Ananthakrishna: „Current theoretical approaches to collective behavior of dislocations"; Physics Reports 440 (2007) 113-259, Elsevier Ltd., 2007
26) M.M.S. Dwaikat, C. Spitas, V. Spitas: „Predicting nonlinear stress-strain curves of unidirectional fibrous composites in consideration of stick-slip," Composites: Part B 44 (501-507); Elsevier Ltd., 2012.
27) Adjemian, F., and Evesque, P.: “Experimental study of stick-slip behavior”. International Journal forNumerical and Analytical Methods in Geomechanics, Vol. 28. pp 501-530, 2004.
28) M.K Gupta,R.kSrivastavatensile and flexural property of sisal fiber reinforced epoxy compositeAcomparison between unidirectional and mat form of fibers international comference on advances inManufacturing Material 2014 pp:2431-2438
29) Girisha.C, Sanjeevamurthy, GuntiRangaSrinivasSisal/Coconut Coir Natural Fibers Epoxy Composites: Water Absorption and Mechanical Properties International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 3, September 2012ppl67- 170.
30) Dr. K R Dinesh, Jagadish S P , Dr. A Thimmanagouda, Dr. Neeta Hatapaki4, Characterization andlnvestigation of Tensile and Compression Test on Sisal Fibre Reinforcement Epoxy Composite MaterialsUsed as Orthopaedic Implant International Journal of Application or Innovation in Engineering &Management Volume 2, Issue 12, December 2013
31) Noah Matsumoto: - fracture toughness of wood and wood composites during crack propagationprofessor and Richardson ChairWood Science & EngineeringOregon State UniversityCorvallis, OR, USA in 2011.
32) W. Wang, M. Sain, P.A. Cooper Study of moisture absorption in natural fiber plastic composites.Received 20 July 2005; accepted 20 July 2005 Available online 26 September 2005.
33) A. hambali, s. M. Sapuan, N. ismail, y. NukmanMaterial selection of polymeric composite automotive bumper beam usinganalytical hierarchy processCentral South University Press and Springer-Verlag Berlin Heidelberg 2010
34) K. P. Ashik, Ramesh S. Sharma A Review on Mechanical Properties of Natural Fiber Reinforced HybridPolymer CompositesJoumal ofMinerals and Materials Characterization and Engineering, 2015, 3, 420-426.
35) VysyarajuNeelima, J.BalaBhaskaraRao, and K.Viswatej, M.TechDesign and Analysis of Bumper Beam with Composite Materialsjune 2016.
36) Adjemian, F., and Evesque, P.: “Experimental study of stick-slip behavior”.Intemational Journal for Numerical and Analytical Methods in Geomechanics, Vol. 28.pp 501-530, 2004.
37) M.K Gupta,R.kSrivastavatensile and flexural property of sisal fiber reinforced epoxy compositeAcomparison between unidirectional and mat form of fibers international comference on advances inManufacturing Material 2014 pp:2431-2438
38) Girisha.C, Sanjeevamurthy, GuntiRangaSrinivasSisal/Coconut Coir Natural Fibers - Epoxy Composites: Water Absorption and Mechanical Properties International Journal of Engineering and Innovative Technology (IJEIT) Volume 2, Issue 3, September 2012
39) Dr. K R Dinesh, Jagadish S P , Dr. A Thimmanagouda, Dr. Neeta Hatapaki4, Characterization andlnvestigation of Tensile and Compression Test on Sisal Fibre Reinforcement Epoxy Composite MaterialsUsed as Orthopaedic Implant International Journal of Application or Innovation in Engineering &Management Volume 2, Issue 12, December 2013.
40) Observation of car maintenance Garage of Addis Ababa city Nifas Silk Laftosubcity city around Saris.
APPENDIX
A.1 Basic Required Test for Wood Based Board Panel
Abbildung in dieser Leseprobe nicht enthalten
Table A1. Maximum Tests results of Ultra-density fiberboard (UDF)
Abbildung in dieser Leseprobe nicht enthalten
Table A3. Maximum Test result of Medium density fiber board (MDF)
Abbildung in dieser Leseprobe nicht enthalten
Table A4. Maximum test result of high density fiber board (HDF)
(Source Al, A2, A3 and A4 from Ethiopia Quality and Standard Agency)
[...]
- Quote paper
- Lemi Demissie (Author), 2018, Development of Minibus Interior Wall Panel Using Hybrid Sisal and False Banana Fiber Reinforced Epoxy Composite, Munich, GRIN Verlag, https://www.grin.com/document/1334593
