M E C H A N I C A L

Submitted in fulfillment of the partial Requirement for the degree of Bachelor of Engineering (Mechanical Engineering )

PERFORMANCE & QUALITY ASSESSMENT OF TWO RESIN TRANSFER MOULDING (RTM) SYSTEMS (VARTM & HAND LAY UP)
Project Supervisor

E N G I N E E R I N G

Engr. Abdul Ghani Memon

BY

MOHAMMAD BASIT CHANDIO 09ME47

(GROUP LEADER)

FARMAN ALI CHANNA 09ME23

(ASSTT. GROUP LEADER)

P R O J E C T

MAHESH KUMAR MIR BILAWAL MIRJAT 09ME68 MUHAMMAD AMEEN SIYAL 09ME06

09ME19

DEPARTMENT OF MECHANICAL ENGINEERING

QUAID-E-AWAM UNIVERSITY OF ENGINEERING, SCIENCE & TECHNOLOGY, NAWABSHAH.

1

CERTIFICATE

This

to

certify

that

Mr._________________________________________

S/o________________________Roll No.______________ Final Year student of Bachelor of Engineering (Mechanical Engineering) has completed the

compulsory requirement of Project / Thesis during the session, 2012-2013. This thesis titled as PERFORMANCE & QUALITY ASSESSMENT OF TWO RESIN TRANSFER MOULDING (RTM) SYSTEMS (VARTM & HAND LAY UP) is submitted to the Quaid-e-Awam University of Engineering, Science and Technology Nawabshah for the Award of Degree of Bachelor of Engineering (Mechanical Engineering).

Engr. Abdul Ghani Memon Examiner Supervisor

(Department of Mechanical Engineering)

External

QUEST Nawabshah.

Prof. Dr. Altaf Hussain Rajpar Chairman

(Department of Mechanical Engineering)

QUEST Nawabshah

DEDICATION
I am dedicating my whole efforts to my Respected

PARENTS
Whom I am really inspired, their pure love, Devotion, Natural attitude and sincerity is matter of great Pleasure and pride for me Their encouraging and simulating morally, socially and Academically based teachings have always been Proved for me as a

PATH TOWARD SUCCESS

They have give me name, which caused my Identification in Society.

ACKNOWLEDGEMENT

By the Grace of Omnipotent ALLAH Who gave us the strength, courage and determination to complete this thesis, without completing the thesis would never come true. No list of acknowledgement would be completed without authors parents for their sacrifice and encouragements. The author also would like to record his heartiest gratitude to his beloved father and all family members, for their moral support and inspiration throughout the study period. Besides, Interesting to accomplish this thesis is also laborious job could not carried without co-operation of concerned person. In this connection first of all we are grateful to our dignified, whole hearted, polite and friendly attitude of our supervisor Engr. Abdul Ghani Memon (Assistant Professor of Mechanical Engineering Department of QUEST Nawabshah) for his full-fledged support. Special thanks to Engr. Mushtaque Ahmed Lakho who helped us a lot to complete this project. His blessing the dream of

With great respect and thanks, we express our gratitude to our Chairman Prof. Dr. Altaf Hussain Rajpar, for given us the opportunity to work in this field.

GROUP LEADER & MEMBERS

ABSTRACT
4

The composite materials world is continuously enhancing by the introduction of new materials with dependable characteristics required for latest developments in the engineering applications. The latest development in textile composite formation due to their light weight, high heat resistance and least cost of production Air and water medium using systems, sport cars (formula cars), wind energy have need of such type of properties possessing materials. There are further potential applications e.g. defense, land transportation, construction, power generation sectors, rail, automobile machine construct In the present study a textile composite will be developed by using two methodologies prepared for manufacturing composite under consideration is
1. VACUUM

ASSISTED RESIN TRANSFER MOULDING PROCESS

(VARTM)
2. HAND LAYUP MOLDING METHOD

Work will be limited to study 2 & 4layers lamination with different orientations, 0/90, & +45/-45, all other parameters will be kept same.

CONTENTS
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___________________________________________________________________ CHAPTER NO. 01 1.1 1.1.1 1.1.2 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.4.1 1.2.4.2 1.3 1.4 1.4.1 1.4.2 1.5 1.5.1 Introduction Objectives Plan of Work Classification of Engineering Materials Metals Ceramics Composites Plastics Thermoplastic Thermosetting Vinyal Easter Glass Fabric Uses of Glass Fabric Glass-reinforced Plastic Resin Transfer Molding (RTM Process/ Methods of Resin Transfer Molding (RTM) INTRODUCTION 01 01 01 02 02 02 02 03 04 04 05 05 05 06 06 07 07 07 07 08 09 10 11 12 LITERATURE REVIEW 13

1.5.1.1 Vacuum Assisted Resin Injection (VARI) 1.5.1.2 Structural Reaction Injection Moulding 1.5.1.3 Resin Film Infusion (RFI) 1.5.1.3 Hand Layup RTM 1.5.1.4 Vacuum Assisted Resin Transfer Molding (VARTM) 1.5.2 1.5.3 1.5.4 Advantages of the Resin Transfer Molding Process Limitations of the Resin Transfer Molding Process Application of RTM

_____________________________________________________________________ CHAPTER NO. 02 2.1 Literature Review

_____________________________________________________________________ CHAPTER NO. 03 3.1 3.2 3.3 3.4 3.4.1 Introduction History Process of Mould Types of Mould Expendable Mould or One Use Mould
FABRICATION OF MOULD

25 25 25 26 26

3.4.2 3.5 3.5.1 3.5.2

Nonexpendable Mould or Permanent Mould Fabrication of Mould Cutting of Acrylic Sheet for Mould Fabrication of Vises for Holding and Tightening the Transparent Sheets

26 26 26 27

____________________________________________________________________ CHAPTER NO. 04 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Ratio Representation for Sample Development Mould A Mould B Mould C Mould D Mould E Mould F Mould G SAMPLE DEVELOPMENT 32 32 35 35 36 36 37 37 38

_____________________________________________________________________ CHAPTER NO. 05 5.1 5.2 5.2.1 5.2.2 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 5.6 5.6.1 5.6.2 5.7 5.7.1 5.7.2 SSTM-20 KN TESTING MACHINE TEST SPECIMEN OF COMPOSITE MATERIAL A. Test Specimen of Composite Material A1 Test Specimen of Composite Material A2 Test Specimen of Composite Material B Test Specimen of Composite Mateiral B1 Test Specimen of Composite Material B2 Test Specimen of Composite Material C Test Specimen of Composite Material C1 Test Specimen of Composite Material C2 Test Specimen of Composite Material D Test Specimen of Composite Material D1 Test Specimen of Composite Material D2 Test Specimen of Composite Material E Test Specimen of Composite Material E1 Test Specimen of Composite Material E2 Test Specimen of Composite Material F Test Specimen of Composite Material F1 Test Specimen of Composite Material F2 TESTING AND RESULT DISCUSSION 40 41 41 43 45 45 47 49 49 51 53 53 55 57 57 59 61 61 63 7

5.8 5.8.1 5.8.2 5.9 5.10

Test Specimen of Composite Material G Test Specimen of Composite Material G1 Test Specimen of Composite Material G2 test Specimen of Simple Fabric Glass (F.G) Results

65 65 67 69 71 CONCLUSION 72 73 74

_____________________________________________________________________ CHAPTER NO. 06 6.1 6.2 Conclusion Future Work (Suggestions) References

CHAPTER NO. 1 INTRODUCTION

1.1 ENGINEERING MATERIALS Since the earliest days of the evolution of mankind , the main distinguish between human begins and other creatures has been the ability to use and develop materials to satisfy our requirements. Nowadays we use various materials to satisfy our requirements for housing, heating, furniture, clothes, transportation, entertainment, medical care, defense and all the other trappings of a modern, civilized society. 1.1.1 Objectives i. Development of samples by using: ii. iii. 1.1.2 i. Vacuum assisted resin transfer molding Hand layup molding

Testing of developed samples (Tensile behavior) Analyzing of results Plan of work Mould forming

ii. iii. iv.

Sample development Testing Result discussion

1.2 CLASSIFICATION OF ENGINEERING MATERIALS Engineering Materials are generally classified into following families 1.2.1 Metals Metals are elements, compounds or alloys that area good conductors of both electricity and heat. Metals also have properties such as luster or shine of their surface (when polished), their malleability (ability to be hammered) andductility (ability to be drawn). 1.2.2 Ceramics Ceramics are compounds between metallic and nonmetallic elements; they are most frequently oxides, nitrides, and carbides. For example, some of the common ceramic materials include aluminum oxide (or alumina, Al2O3), silicon dioxide (or silica, SiO2), silicon carbide (SiC), silicon nitride (Si3N 4), and, in addition, what some refer to as the traditional ceramics those composed of clay minerals (i.e., porcelain), as well as cement, and glass. 1.2.3 Composites As was mentioned that alloys of metals with non-metals could only occur if all the component materials were miscible, that is, soluble in each other in the molten state. Composite materials can be made up from materials that are not soluble in each other. Composite materials are not alloys. In its simplest form a composite material consists of two dissimilar materials in which one material forms a matrix to bond together the other (reinforcement ) material. The matrix and reinforcement are chosen so that their mechanical properties complement each other, whilst their deficiencies are neutralized. For example, in GRP molding, the polyester resin is the matrix that binds together the glass fiber reinforcement.

Material property combinations and ranges have been extended by the development of composite materials. Generally speaking, a composite is considered to be any multiphase material that exhibits a significant proportion of the properties of both constituent phases such that a better combination of properties is realized. According to this principle of combined action, better property combinations are fashioned by the judicious combination of two or more distinct materials. Property trade-offs are also made for many composites. In designing composite materials, scientists and engineers have ingeniously combined various metals, ceramics, and polymers to produce a new generation of extraordinary materials. Most composites have been created to improve combinations of mechanical characteristics such as stiffness, toughness, and ambient and high-temperature strength. In a composite, the reinforcement material, in the form of rods, strands, fibers or particles, is bonded together with the other matrix materials. For example, the fibers may have some of the highest moduli and greatest strengths available in tens ion, but little resistance to bending and compressive forces. On the other hand, the matrix can be chosen to have high resistance to bending and compressive forces. Used together these two different types of material produce a composite with high tensile and compressive strengths and a high resistance to bending. 1.2.4 Plastics Plastics are materials that have some structural rigidity under load, and are used in general-purpose applications. Polyethylene, polypropylene, poly(vinyl chloride), polystyrene, and the fluorocarbons, epoxies, phenolics, polyesters properties. Some plastics are very rigid and brittle. Others are flexible, exhibiting both elastic and plastic deformations when stressed, and sometimes experiencing considerable deformation before fracture. Based on their response to temperature, plastic materials may be classified into two main categories: and vinyleaster

may all be classified as plastics. They have a wide variety of combinations of

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1.2.4.1 Thermoplastic By far the most common in the school workshop. These plastics do not resist heat very well and so can be easily formed into other shapes. On heating this type of plastic does not undergo a chemical change (as is the case with thermosetting plastic) and waste can be re-ground into granules and re-used. A heated sheet of thermoplastic which has been molded into a shape can be reheated and it will go back to its original shape. This returning to shape is referred to as plastic memory. Sometimes, thermoplastics are confused with thermosetting plastics. Although they may sound the same, they actually possess very different properties. While thermoplastics can be melted to a liquid and cooled to a solid, thermosetting plastics chemically deteriorate when subjected to heat. Ironically, however, thermosetting plastics tend to be more durable when allowed to cool than many thermoplastics. Polyethylene, polypropylene and PVC (polyvinyl chloride) are the most common examples of thermoplastic. 1.2.4.2 Thermosetting Thermoset materials are usually liquid or malleable prior to curing and designed to be molded into their final form, or used as adhesives. Others are solids like that of the molding compound used in semiconductors and integrated circuits (IC). Once hardened a thermoset resin cannot be reheated and melted back to a liquid form. A thermosetting polymer is a prepolymer in a soft solid or viscous state that changes irreversibly into an infusible, insoluble polymer network by curing. Curing can be induced by the action of heat or suitable radiation, or both. A cured thermosetting polymer is called a thermoset, these are stronger and harder than thermoplastics. They resist heat and fire and are often used for objects like pan handles and electrical fittings. The most common thermosetting resin used today is polyester resin, followed by vinylester and epoxy. Thermosetting resins are popular because uncured, at room

11

temperature, they are in a liquid state. This allows for convenient impregnation of reinforcing fibers such as fiberglass, carbon fiber, or Kevlar. [6]

1.3 VINYL EASTER Vinyl ester resins are stronger than polyester resins and cheaper than epoxy resins. Vinyl ester resins utilize a polyester resin type of cross-linking molecules in the bonding process. Vinyl ester is a hybrid form of polyester resin which has been toughened with epoxy molecules within the main molecular structure. Vinyl ester resins offer better resistance to moisture absorption than polyester resins but it's downside is in the use of liquid styrene to thin it out (not good to breath that stuff) and its sensitivity to atmospheric moisture and temperature. Sometimes it won't cure if the atmospheric conditions are not right. It also has difficulty in bonding dissimilar and already-cured materials. It is not unusual for repair patches on vinylester resin canoes to delaminate or peel off. As vinylester resin ages, it becomes a different resin (due to its continual curing as it ages) so new vinylester resin sometimes resists bonding to your older canoe, or will bond and then later peel off at a bad time. It is also known that vinylester resins bond very well to fiberglass, but offer a poor bond to kevlar and carbon fibers due to the nature of those two more exotic fibers. Due to the touchy nature of vinylester resin, careful surface preparation is necessary if reasonable adhesion is desired for any repair work. 1.4 GLASS FABRIC Glass fiber is a material consisting of numerous extremely fine fibers of glass. Glass fabric contains large numbers of glass fiber. Glass fiber is commonly used as an insulating material. It is also used as a reinforcing agent for many polymer products; to form a very strong and light fiber-reinforced polymer (FRP) composite material called glass-reinforced plastic (GRP), popularly known as "fiberglass". Glass fiber has roughly comparable properties to other fibers such as polymers and carbon fiber. Although not as strong or as rigid as carbon fiber, it is much cheaper and significantly less brittle. [2] 1.4.1 Uses of Glass Fabric

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Glass fiber is commonly used as an insulating material. It is also used as a reinforcing agent for many polymer products; to form a very strong and light fiber-reinforced polymer (FRP) composite material called glass-reinforced plastic (GRP), popularly known as "fiberglass". Glass fiber has roughly comparable properties to other fibers such as polymers and carbon fiber. Although not as strong or as rigid as carbon fiber, it is much cheaper and significantly less brittle. [3] [4] 1.4.2 Glass-reinforced Plastic Glass-reinforced plastic (GRP) is a composite material or fiber-reinforced plastic made of a plastic reinforced by fine glass fibers. Like graphite-reinforced plastic, the composite material is commonly referred to as fiberglass. The glass can be in the form of a chopped strand mat (CSM) or a woven fabric. [3] [4] As with many other composite materials (such as reinforced concrete), the two materials act together, each overcoming the deficits of the other. Whereas the plastic resins are strong in compressive loading and relatively weak in tensile strength, the glass fibers are very strong in tension but tend not to resist compression. By combining the two materials, GRP becomes a material that resists both compressive and tensile forces well.
[5]

The two materials may be used uniformly or the glass may be specifically placed in those portions of the structure that will experience tensile loads. [3] [4] 1.5 RESIN TRANSFER MOLDING (RTM) The Resin Transfer Molding (RTM) process is a cost-effective fabrication method for the manufacture of polymer composites. In a traditional RTM process, catalyzed thermosetting resin is injected into an enclosed metal mold containing a previously positioned reinforcement preform. The preform is compacted to the specified fiber volume fraction when the matched metal mold is closed. The resin wets out the fiber until the mold is filled, and the part is then cured inside the mold. A schematic diagram of the process is shown in following Figure 1.1. RTM offers several advantages over other composite fabrication methods such as autoclave and compression molding of prepreg tape laminates. First, high fiber volume

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fraction composites can be fabricated with low void contents. Second, parts with highly complex shapes can be molded by incorporating many components into a single preform. This helps to reduce the cost and weight of the structure. Third, hand lay-up of prepreg tape is eliminated. Production rates are increased and operating costs are reduced. Finally, RTM is a closed mold process that reduces the workers exposure to harmful volatiles, i.e., styrene, associated with many of the room temperature processing resins. However, the matched metal tooling used in the RTM procedure is expensive, and the tooling design becomes difficult when fabricating large and complex shaped parts. [7]

Figure 1.1 Resin Transfer molding (RTM) 1.5.1 Processes/Methods of Resin Transfer Molding (RTM) There are so many methods of resin transfer molding, which includes: 1.5.1.1 Vacuum Assisted Resin Injection (VARI) We have moulds that are usually vented. A partial vacuum holds the mould in place and provide the moulding force, the vacuum also aids reduction of voids in laminates of large area. 1.5.1.2 Structural Reaction Injection Moulding In this type of moulding, we have a high pressure rapid dispensing process typically for polythene which has low viscosity. 1.5.1.3 Resin Film Infusion (RFI)

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In this process of moulding, we have a single mould and vacuum bag. The resin introduced as pellets of a film along with the reinforcement. The mould in the vacuum bag is heated under pressure to lower the viscosity of the resin which flows through the thickness as opposed to along the part as with the other methods.

1.5.1.3 Hand Layup RTM Hand lay-up is a simple method for composite production. A mold must be used for hand lay-up parts unless the composite is to be joined directly to another structure. The mold can be as simple as a flat sheet or have infinite curves and edges. For some shapes, molds must be joined in sections so they can be taken apart for part removal after curing. Before lay-up, the mold is prepared with a release agent to insure that the part will not adhere to the mold. Reinforcement fibers can be cut and laid in the mold. It is up to the designer to organize the type, amount and direction of the fibers being used. Resin must then be catalyzed and added to the fibers. A brush, roller or squeegee can be used to impregnate the fibers with the resin. The lay-up technician is responsible for controlling the amount of resin and the quality of saturation. Following figure 1.2 shows the basic process of hand lay-up. [8]

Figure 1.2 Hand Lay-up RTM

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1.5.1.4 Vacuum Assisted Resin Transfer Molding (VARTM) Vacuum infusion is a process used for moulding fibre composite mouldings, where uniformly distributed fibres are layered in one of the mould parts, said fibres being rovings, i.e. bundles of fibre bands, bands of rovings or mats, which are either felt mats made of single fibres or woven mats made of fibre rovings. The second mould part, which is often made of a resilient vacuum bag, is subsequently placed on top of the fibre material. By generating a vacuum, typically 80 to 90% of the total vacuum, in the mould cavity between the inner side of the mould part and the vacuum bag, the liquid polymer can be drawn in and fill the mould cavity with the fibre material contained therein. So-called distribution layers and distribution tubes, also called inlet channels, are used between the vacuum bag and the fibre material in order to obtain as sound and efficient a distribution of polymer as possible. In most cases the polymer applied is polyester or epoxy, and the fibre reinforcement is most often based on glass fibres or carbon fibres. During the process of filling the mould, a vacuum is generated by the vacuum channels in the mould cavity, said vacuum in this connection being understood as a negative pressure, whereby liquid polymer is drawn into the mould cavity via the inlet channels in order to fill said mould cavity as shown in following figure 1.3. From the inlet channels the polymer disperses in the mould cavity as flow front moves towards the vacuum channels. Thus it is important to position the inlet channels and the vacuum channels optimally in order to obtain a complete filling of the mould cavity. Ensuring a complete distribution of the polymer in the entire mould cavity is, however, often difficult, and accordingly this often results in so-called dry spots, i.e. areas with fibre material not being sufficiently impregnated with resin. Thus dry spots are areas, where the fibre material has not been impregnated, and where there can be air pockets,

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which are difficult to remove by controlling the vacuum pressure and possibly an overpressure at the inlet side. In connection with vacuum infusion employing a solid mould part and a resilient mould part in the form of a vacuum bag, the dry spots can be repaired after the process of filling the mould by for example perforating the cloth in the respective locations and by sucking out air by means of a syringe needle. Liquid polymer can optionally be injected at the relevant location, which can for example be done by means of a syringe needle as well. This is a time-consuming and tiresome process. In the case of large mouldings, the staff has to stand on the vacuum bag, which is not desirable, especially not when the polymer has not hardened, as it can result in deformations in the inserted fibre material and thus result in local weakening of the structures. [9]

Fig ure 1.3, Vacuum Assisted Resin Transfer Molding (VARTM) 1.5.2 Advantages of the Resin Transfer Molding Process i. Initial investment cost is low because of reduced tooling costs and operating expenses as compared to compression molding and injection molding. For this reason, prototypes are easily made for market evaluation. For example, the dish antenna was first made using an RTM process to validate the design features before capital investment was made for compression molding of SMC parts.
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ii. iii.

Moldings can be manufactured close to dimensional tolerances. RTM processing can make complex parts at intermediate volume rates. This feature allows limited production runs in a cost-effective manner. This lends benefits to the automotive market, in which there is a growing need toward lower production volumes per car model and quicker changes to appeal to more niche markets.

iv.

RTM provides for the manufacture of parts that have a good surface finish on both sides. Sides can have similar or dissimilar surface finishes.

v.

RTM allows for production of structural parts with selective reinforcement and accurate fiber management.

vi. vii.

Higher fiber volume fractions, up to 65%, can be achieved. Inserts can be easily incorporated into moldings and thus allows good joining and assembly features.

viii. ix.

A wide variety of reinforcement materials can be used. RTM offers low volatile emission during processing because of the closed molding process.

x.

RTM offers production of near-net-shape parts, hence low material wastage and reduced machining cost.

xi.

The process can be automated, resulting in higher production rates with less scrap.

1.5.3 Limitations of the Resin Transfer Molding Process Although RTM has many advantages compared to other fabrication processes, it also has the following limitations. i. The manufacture of complex parts requires a good amount of trial and error experimentation or flow simulation modeling to make sure that porosity and dry fiber free parts are manufactured.

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ii.

Tooling and equipment costs for the RTM process are higher than for hand lay-up and spray-up processes.

iii.

The tooling design is complex.

1.5.4 Applications of RTM There are widely so many applications of RTM in the world. Some applications are carried out for manufacturing the following parts: Auto body panels Wind blades Solar collectors (40 ft diameter, 36 parts) Propellers Antenna dishes Swim pool panels Doors Bicycle frames Aircraft parts Truck air deflectors Chemical storage tanks RV components Bathtub/shower units Chairs Helmets Hockey sticks Sports car bodies

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CHAPTER NO. 2 LITERATURE REVIEW

2.1 LITERATURE REVIEW A composite is when two or more different materials are combined together to create a superior and unique material. The first uses of composites date back to the 1500s .C. when early Egyptians and Mesopotamian settlers used a mixture of mud and straw to create strong and durable buildings. Straw continued to provide reinforcement to ancient composite products including pottery and boats. Later, in 1200 AD, the Mongols invented the first composite bow. Using a combination of wood, bone, and animal glue, bows were pressed and wrapped with birch bark. These bows were extremely powerful and extremely accurate. Composite Mongolian bows provided Genghis Khan with military dominance, and because of the composite technology, this weapon was the most powerful weapon on earth until the invention of gunpowder.[10] Birth of the Plastics Era The modern era of composites did not begin until scientists developed plastics. Until then, natural resins derived from plants and animals were the only source of glues and binders. In the early 1900s, plastics such as vinyl, polystyrene, phenolic and polyester were developed. These new synthetic materials outperformed resins that were derived from nature.

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However, plastics alone could not provide enough strength for structural applications. Reinforcement was needed to provide the strength, and rigidity. In 1935, Owens Corning introduced the first glass fiber, fiberglass. Fiberglass, when combined with a plastic polymer creates an incredibly strong structure that is also lightweight. This is the beginning of the Fiber Reinforced Polymers (FRP) industry as we know it today.

Driving Early Composites Innovation Many of the greatest advancements in composites were incubated by war. Just as the Mongols developed the composite bow, World War II brought the FRP industry from the laboratory into actual production. Alternative materials were needed for lightweight applications in military aircraft. Engineers soon realized other benefits of composites beyond being lightweight and strong. It was discovered that fiberglass composites were transparent to radio frequencies, and the material was soon adapted for use in sheltering electronic radar equipment (Radomes). Adapting Composites: Space Age to Everyday By the end of the WWII, a small niche composites industry was in full swing. With lower demand for military products, the few composites innovators were now ambitiously trying to introduce composites into other markets. Boats were an obvious fit for composites, and the first commercial boat hull was introduced in 1946. At this time Brandt Goldsworthy, often referred to as the grandfather of composites, developed new manufacturing processes and products. He is credited with numerous advancements including being the first to fiberglass a surfboard, which revolutionized the sport. Goldsworthy also invented a manufacturing process known as pultrusion. Today, products manufactured from this process include ladder rails, tool handles, pipes, arrow shafts, armor, train floors, medical devices, and more. Continued Advancement in Composites

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In the 1970s the composites industry began to mature. Better plastic resins and improved reinforcing fibers were developed. DuPont developed an aramid fiber known as Kevlar, this fiber has become the standard in armor due to its high tenacity. Carbon fiber was also developed around this time; it has since been replacing metal as the new material of choice. The composites industry is still evolving, with much of the growth is now focused around renewable energy. Wind turbine blades are constantly pushing the limits on size and are requiring advanced materials, designs, and manufacturing. Looking Forward In the future, composites will utilize even better fibers and resins, many of which will incorporate nano-materials. Dedicated university programs and research institutions will continue to develop improved materials and ways to manufacture them into products. Additionally, composites are on the path towards being more environmentally friendly. Resins will incorporate recycled plastics and bio-based polymers. Composites will continue to make the world lighter, stronger, more durable, and a better place to live. [11] Recently research work, new innovations and modified techniques of RTM in textile composite materials and future work suggested by researchers for obtaining best results are described below: In 1999, Jon Dana Skramstad worked on Evaluation Of Hand Lay-Up And Resin Transfer Molding In Composite Wind Turbine Blade Manufacturing and he represented that currently, the majority of the turbine blade industry uses the low budget, hand lay-up manufacturing technique to process composite blades. The benefits of hand lay-up include the ability to fabricate large, complex parts with a quick initial start-up. Yet, the drawbacks of the hand lay-up technique suggest that other methods of composites manufacturing may be more desirable in industrial-scale, wind turbine blade fabrication. Resin transfer molding (RTM) was identified as a processing alternative and shows promise in addressing the shortcomings of hand lay-up in turbine blade manufacturing. The current study compares and evaluates both processes according to fundamental criteria and mechanical performance for a variety of fabric reinforcements, lay-up schedules and turbine blade critical structures. The geometries investigated were flat

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plates, thin flanged T-stiffeners with skin intersections, thick flanged T-stiffeners, I-beam load carriers, and sample root connection joints. The variables that were explored and compared according to process included laminate thickness, fiber volume, cycle time, and porosity. Flat plates were tested under five typical loading conditions: transverse tension, compression, three-point bending, axial tension, and fatigue. The variety of threedimensional substructures was also tested mechanically to determine what effects processing might have on structural performance. In this study it was found that process played an important role in laminate thickness, fiber volume, and weight for the geometries investigated. RTM was found to reduce thicknesses and improve weights for all substructures. In addition, RTM processing resulted in tighter material transition radii and eliminated the need for most secondary bonding operations. These observations were found to significantly reduce weight for complex structures. Hand lay-up was consistently slower in fabrication times when compared to RTM for the manufacturing of the specimens tested in this study. Computed Tomography (CT) technology was introduced as a means to measure porosity for specimens of different processing. However, the current efforts in characterizing porosity via CT suggest further refinement. Analysis of the mechanical testing results for flat plate specimens demonstrated that vacuum-assisted RTM specimens performed notably better than their hand lay-up counterparts for a variety of properties. Yet, thickness played a critical role in comparing the mechanical test results of flat plate specimens. Variations in thickness had the tendency to bias the structural performance results according to process and as a result, fiber volume normalizing techniques were introduced. Specimen normalization was found to reduce the measurable differences between flat plate test results for specimens manufactured by the different processes. It was also noted that in most cases reinforcement played a more instrumental role in mechanical performance than process. Substructure tests demonstrated that differences in processing methods affected specimen mass and moment of inertia. These properties were greater for the hand lay-up specimens and resulted in improvements in ultimate strength and initial damage when compared to RTM substructures. The current root specimen design does not show significant differences according to process and exceeds all static and fatigue requirements. After achieving his results he suggested some future work is given in following steps:

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 Further investigations into alternative warp, unidirectional fabrics may yield a reinforcement that significantly outperforms the current A130 fabric for laminate compressive and bending properties in turbine blade applications. Comparisons in fatigue performance between hand lay-up and RTM flat plates should be expanded with further variations in fiber volume, lay-up, and fabric type. Minimizing the use of gaskets that also serve as spacing materials would be beneficial to future resin transfer moldings. Combination gasket/spacers are poor in dimensional repeatability, can undesirably effect fiber volume, and contribute to complications with maintaining vacuum integrity. [12] In year 1999, Mr. Tom J. Wu* & H. Thomas Hahn, Worked on The Bearing Strength of E-Glass/Vinyl-Ester Composites Fabricated by VARTM and they investigated the bearing properties of mechanically fastened glass-fiber/vinyl-ester composite joints. Two glass composites of deferent fabrics and lay-ups were fabricated by vacuum-assisted resin-transfer molding (VARTM) and tested by using a double-lap joint configuration. The results of this study are presented as experimental characterization and analytical prediction. The major focus of the experimental part of the paper was to characterize the bearing failure behavior of these composites. The erects of geometric parameters were evaluated and correlated with the resulting bearing strength and failure modes by the statistical method of analysis of variance. From the experimental results obtained, it is concluded that the edge-distance ratio (e/d) and thickness of the specimen strongly eject the bearing strength of the composites. On the other hand, the failure mode is determined by the width ratio (w/d). In the analytical part of the study, Chang's strengthprediction model, which is based on a two-dimensional finite-element analysis, was utilized to predict the bearing strength of these composite joints. The predicted values were compared with the experimental data obtained from this study and the results suggest that this model can be used to give accurate pre-dictions of the bearing strength of these composites. After this complete research and study they concluded that double-lap joint bearing tests for E-glass/vinyl-ester epoxy composite (M3 and M4) were per-formed. The following observations were made as a result of the experimental analysis. (a) Ultimate bearing strength increases as thickness and ratio increases.
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(b) At similar/ratio and thickness, M3 specimens with 6.35mm hole have on the average 140MPahigher bearing strength than specimens with 12.7mm hole. (c) When thickness <2.4mm, 50.8mm-wide M3 specimens have higher ultimate bearing strength than 25.4mm-wide specimens. (d) Quasi-isotropic composite (M3) has higher bearing strength than chopped fiber mats composite (M4). (e) Hydrothermally conditioned M3 specimen retains 82% of ultimate bearing strength. (f) Failure mode is a strong function and in addition, Chang's7 model is utilized to predict the failure strength and failure mode of the mechanically fastened joints. In general good accuracy of the method within certain geometric domain is obtained. Thissug-gests that this particular model can be useful in the design of mechanically fastened composite joints. How-ever, modification to include three-dimensional erects might be necessary in order to improve the overall accuracy and robustness of this model.[13] In 2002, Xiaolan Song, Alfred C. Loos, Brian W. Grimsley, Roberto J. Cano and Pascal Hubert worked on Modeling The VARTM Composite Manufacturing Process and they developed a comprehensive simulation model of the VARTM composite manufacturing process. For isothermal resin infiltration, the model incorporates sub models which describe cure of the resin and changes in resin viscosity due to cure, resin flow through the reinforcement preform and distribution medium and compaction of the preform during the infiltration. The accuracy of the model was validated by measuring the flow patterns during resin infiltration of flat preforms. The modeling software was used to evaluate the effects of the distribution medium on resin infiltration of a flat preform. Different distribution medium configurations were examined using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results of the simulations show that the approach used to model the distribution medium can significantly affect the predicted resin infiltration times. Resin infiltration into the preform can be accurately predicted only when the distribution medium is modeled correctly. After this whole study they concluded that they came to a point that developed comprehensive simulation model of the VARTM composite manufacturing process

25

incorporates resin flow through the preform, compaction and relaxation of the preform, and viscosity and cure kinetics of the resin. The computer model can analyze the resin flow details, track the thickness change of the preform, predict the total infiltration time and final fiber volume fraction of the parts, and determine whether the resin could completely infiltrate and uniformly wet out the preform. The modeling software was used to examine how the distribution medium and the position of the resin inlet tube effect the resin infiltration of a flat preform. Three different distribution medium and resin inlet tube configurations were evaluated using the model and the results were compared with data collected during resin infiltration of a carbon fabric preform. The results show how the distribution medium influences the resin infiltration process and that resin infiltration into the preform can be accurately predicted when the distribution medium is modeled correctly. [14] In 2003, C. Ulven, U.K. Vaidyaa and M.V. Hosur researched on Effect of Projectile Shape During Ballistic Perforation of VARTM Carbon/Epoxy Composite Panels and the use of carbon/epoxy composites in aircraft, marine, and automotive structural applications is steadily increasing. Robust composite structures processed using low-cost techniques with the purpose of sustaining high velocity impact loads from various threats are of great interest. An example of a low-cost process is the out-of-autoclave, vacuum assisted resin transfer molding (VARTM) technique. The present study evaluates the perforation and damage evolution created by various projectile geometries in VARTM processed carbon/epoxy laminates. A series of ballistic impact tests have been performed on satin weave carbon/epoxy laminates of 3.2 and 6.5 mm thickness, with projectile geometries representing hemispherical, conical, fragment simulating and flat tip. A gasgun with a sabot stripper mechanism was employed to impact the samples with 50-caliber projectiles of the different shapes. The perforation mechanism, ballistic limit, and damage evolution of each laminate has been studied. The conical shaped projectile resulted in highest ballistic limit, followed by the flat, hemispherical and the fragment simulating. After working on their research they summarized their research as the influence of projectile shape in the studied car-bon/epoxy laminates under high velocity impact resulted in a range of energy absorptions at ballistic limit. Conical projectile high velocity impact resulted in the greatest amount of energy absorbed at ballistic limit followed by flat, hemispherical, and fragment simulating projectile impact. Failure mechanisms of

26

plugging, separation of fibers, or a combination of both were observed in the carbon/epoxy laminates during high velocity impact of different shaped projectiles. Panel thickness has a significant effect on the ballistic limit of panels impacted by different shaped projectiles. Thin carbon/epoxy panels bend easily during a ballistic event which absorbs a majority of the projectiles energy regardless of shape. In thick carbon/epoxy panels, projectile shape induces different failure mechanisms which result in different ballistic limits. The trend of ballistic limits for the carbon/epoxy laminates impacted by the different shaped projectiles was predicted using current analytical equations by Wen. [15] In 2003, Jeffrey A. Acheson, Pavel Simacek and Suresh G. Advani researched on The implications of fiber compaction and saturation on fully coupled VARTM simulation and they stated that Vacuum Assisted Resin Transfer Molding (VARTM) is a process by which resin is drawn through fiber preforms in a one-sided mold using an induced pressure gradient. Although the approach to model flow in VARTM is similar to the Resin Transfer Molding (RTM) process, modeling in VARTM can be significantly more complex if one accounts for fiber compaction and the dual scale nature of the fiber preform which is present in RTM but often neglected. This article investigates the influence of fiber compaction and fiber tow saturation during mold filling in the VARTM process. A non-rigid control volume is used to formulate a set of governing equations to describe the resin flow. Tow impregnation at the micro-scale is coupled with global resin flow at the macro scale by applying conservation of mass principles. Preform compaction is modeled as a non-linear spring bed where compaction pressure is dynamically distributed between the resin and the preform. The variation in preform permeability is modified due to the changes in the fiber volume fraction as a result of changing compaction. A simple one-dimensional mold filling case is solved to investigate the role of compaction and dual scale porous media in VARTM processes. A parametric study allows us to identify situations in which one can neglect compaction and saturation and conditions under which a fully coupled model should be applied for satisfactory results. After their complete research they concluded their whole research as this article investigated the common modeling assumptions that compaction effects and fiber tow saturation has little influence on the VARTM process. A non-rigid control volume was used to formulate a set of governing equations to describe the resin flow. Tow

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impregnation at the micro scale is coupled with global resin flow at the macro scale by applying conservation of mass principles. Preform compaction is modeled as a non-linear spring bed where compacting pressure is dynamically distributed between the resin and the preform. The variation in preform permeability is modified according to the Kozeny Carman equation due to the changes in the fiber volume fraction as a result of changing compaction. The results show that the resin pressure curve can be significantly different with and without compaction. This implies that pressure values derived from uncoupled analytical techniques should expect inaccuracies depending on the varying levels of compaction present in the experiment. The fill times for both the coupled and uncoupled compaction cases can be made to match if an effective permeability is used for the uncoupled case. Note, however, that this effective permeability will be different for the same material being injected under different pressures and may not be accurate in filling complex geometric parts. Because preforms compact non-linearly, most of the change in compaction and hence the change in thickness occurs close to the injection port especially for system where the change in compaction is high. The length of the partially saturated region can be derived analytically. Furthermore, since the shape of the pressure curve varies with time, a single effective permeability will not be able to perfectly fit the curve. However, while the saturation effects on pressure and fill time are small even for the worst cases, the effects on the quality of the final part due to fiber tow saturation can be considerable[16]. They suggested that Future work on this topic should be done on compaction effects in more complex filling geometries and determine whether the use of an effective fiber permeability would still be acceptable in modeling and simulation of the VARTM process similar to the RTM process[17-18-19] In 2004, M. Grujicica, K.M. Chittajallu and Shawn Walsh worked on Non-isothermal preform infiltration during the vacuum-assisted resin transfer molding (VARTM) process and they developed a control-volume finite-element model to analyze the infiltration of a fiber preform with resin under non-isothermal conditions within a highpermeability resin-distribution medium based vacuum-assisted resin transfer molding (VARTM) process. Due to the exposure to high temperatures during preform infiltration, the resin first undergoes thermal-thinning which decreases its viscosity. Subsequently however, the resin begins to gel and its viscosity increases as the degree of

28

polymerization increases. Therefore, the analysis of preform infiltration with the resin entails the simultaneous solution of a continuity equation, an energy conservation equation and an evolution equation for the degree of polymerization. The model is applied to simulate the infiltration of a rectangular carbon fiber based preform with the NBV-800 epoxy resin and to optimize the VARTM process with respect to minimizing the preform infiltration time. The results obtained suggest that by proper selection of the ramp/hold thermal history of the tool plate, one can reduce the preform infiltration time relative to the room-temperature infiltration time. This infiltration time reduction is the result of the thermal-thinning induced decrease in viscosity of the ungelled resin. On the basis of results obtained in their work they drawn following conclusions: 1. By adding to the incompressible-fluid mass conservation equation an energy conservation equation and an equation for the time and temperature evolution of the degree of polymerization of the resin, the control-volume finite-element method originally proposed by Lee and co-workers [2021] has been extended to analyze preform infiltration stage of a high-permeability medium based vacuum-assisted resin transfer molding (VARTM) process. 2. Simulations of the preform infiltration process under non-isothermal conditions showed that, at short infiltration times, the effect of tool-plate heating can be beneficial and can lead to an increase in the rate of infiltration. This effect has been attributed to a thermal-thinning based reduction in the resin viscosity. [22] In 2010, B. J. Jensen, R. J. Cano, S. J. Hales ' , J. A. A lexa2, E. S. Weiser, A. C. Loos and W. S. Johnson researched together on FIBER METAL LAMINATES MADE BY THE VARTM PROCESS and presented that Fiber metal laminates (FMLs) are multicomponent materials utilizing metals, fibers and matrix resins. Tailoring their properties is readily achievable by varying one or more of these components. Established FMLs like GLARE utilize aluminum foils, glass fibers and epoxy matrices and are manufactured using an autoclave. Two new processes for manufacturing FMLs using vacuum assisted resin transfer molding (VARTM) have been developed at the NASA Langley Research Center (LaRC). A description of these processes and the resulting FMLs are presented. After completing their research they concluded that two types of fiber metal laminates were prepared by vacuum assisted resin transfer molding. Both methods provide for
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through the thickness infusion by either the insertion of resin flow pathways or by utilizing a metal deposited layer with porosity. The VARTMFMLs provide good mechanical properties that can be optimized by proper selection of metal foil, fiber, resin and size and distribution of the pathways. The VARTMPCLs allow the incorporation of a plasma deposited metal layer that can improve functional properties like electrical and thermal conductivity.[23] In 2011, J.M. Balvers, H.E.N. Bersee, A. Beukers working on SETTLING OF GLASS WOVEN FABRIC IN STEEL RTM MOULD: IMPACT ON RESIDUAL STRESSES they stated that With embedded fibre Bragg grating sensors it is proven that thermal loading of steel RTM mould containing glass woven fabrics leads to different behavior when fabric still has to settle. Heating and cooling along the same trajectory do not imply a reversible process with respect to expansion/contraction of the preform. After completing their research they concluded whether thermal loading has an influence on residual strain can now be answered when looking at following Table 2.1 and Figure 2.1. Table 2.1: Slope of 'Locus of zero stress'-line (10-6K-1)

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(a)

(b)

Figure 2.1 Residual strain in woven glass fabric (a) Without thermal loading (090403), (b) With thermal loading (090401) Although on average the residual strain curves for each panel coincided, less spread in experimental data was observed for the panel that had undergone thermal loading. Since none of the other process parameters or inputs were intentionally altered, it may be concluded that thermal loading did not change the residual strain curve significantly, but resulted in less spread in experimental data between the specimens mutually. This could also have influences on the scatter in mechanical properties. However, after analyzing the specimens that were annealed, it turned out that some of the optical fibres were not perfectly aligned with the fibres of the reinforcement. A maximum angle of 2 was measured for one of the specimens. This small misalignment can also be the cause of the spread in experimental data. If the spread was due to the misalignment, one can conclude that the observation of settling and the approach of thermal loading did not influence the residual strain. [24]

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CHAPTER NO. 3 FABRICATION OF MOULD

3.1 INTRODUCTION It is a shaped cavity used to give a definite form to fluid or plastic material or Mould is a frame on which something may be constructed. It may be a hollow container used to give shape to molten or hot liquid material when it cools and harden known as mould. 3.2 HISTORY The art of mould making has been around for centuries and since the demand for mould making has increased over that time so has the demand for Mould Maker. Mould makers is a career in which the person creates tools, moulds and parts for products and machinery that we use in our everyday lives. Mould makers use many different types of tools to aid them such as lathes, grinders, and mills. A lathe is a machine tool for shaping metal or wood, the lathe works by turning about a horizontal axis against a fixed tool. The lathe was first invented by John Wilkinson in 1775. The lathe that Wilkinson created was a tool that cut holes in metal that was then used in steam engines. Eli Whitney in 1818 invented the first mill. A mill is a device that is designed to break a solid material into smaller pieces. There are many different types of grinding mills and many types of materials processed in them. The mill created by Whitney allowed more mould makers and machinists to produce parts and tools much faster and with less skill. 3.3 PROCESS OF MOULD Moulding is the process of manufacturing by shaping pliable raw material as fluid, glass, ceramic material etc using a rigid frame or model called a pattern to form any desired shape of object.

3.4 TYPES OF MOULD

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There are main two types of molds given below 3.4.1 Expendable Mould or One Use Mould This type of mold includes sand, plastic, shell, and investment (lost-wax technique) mouldings. All of these involve the use of temporary and no reusable moulds, and need gravity to help force molten fluid into casting cavities. In this process the mould is used only once. 3.4.2 Nonexpendable Mould or Permanent Mould This mold differs from expendable mould in that the mould need not be reformed after each production cycle. This technique includes at least four different methods: permanent, die, centrifugal, and continuous casting. 3.5 FABRICATION OF MOULD The mould which we need for our research is a Nonexpendable mould or permanent mould and can be fabricated by using acrylic sheet (transparent hard sheet) and M.S (mild steel) and Procedure for fabrication of our required mold is defined below: 3.5.1 Cutting of Acrylic Sheet for Mould We took and done all the following steps and processes for the fabrication of transparent sheets shown in figure 3.1 for moulds: First of all we cut acrylic sheet of the square measurement of 381mm381mm by machine saw. Than we made square root of measurement of 8mm width8mm depth by leaving the distance of 38.1mm from all four edges with the help of milling machine. After that process we made three holes by drilling process of the measurement of 9mm one on the centre of whole transparent sheet and other two holes on the opposite edges of transparent sheet by leaving space of 38.1mm and taking the centre of that corner side.

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Finally after drilling process we made threads with the help of tap of 10mm in the holes drilled near to two opposite edges and 20mm for central hole and fixed small copper pipes into holes

Figure 3.1 Bottom Sheet and Top Sheet 3.5.2 Fabrication of Vises for Holding and Tightening the Transparent Sheets For making of vise, first of all we will took 5mm thick M.S (mild steel) sheet than we cut it of the measurement 114.3mm width 381 lengths on shearing machine as shown in figure 3.2.

Figure 3.2 Shearing Machine

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After this we bent it by both edges on hydraulic brake press bending machine shown in figure 3.3of the 25.4 measurement.

Figure 3.3 Ilam Din Hydraulic brake press bending machine After this with same process we cut M.S (mild steel) bar on shearing machine of 12.7mm width 381mm length then we temporary welded the M.S (mild steel) sheet and bar on either edge of sheet as shown in figure 3.4.

Figure 3.4 Temporary welded bar with M.S Sheet

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After this process with the help of drilling machine shown in figure 3.5, we made three holes one on the centre, means we drilled by leaving the distance of 190.5mm from either edges of the measurement of 6.35mm tip and other two on both edges leaving the distance of 50.8mm with the same measurement of 6.35 drill, We make threads with the help of tap 9.525mm into the drilled holes by holding the mold in bench vise as shown in figure 3.6.

Figure 3.5 AMK-13E radial drilling & boring machine

Figure 3.6 Holes drilled into vise

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We made two holes of the measurement of 9.525mm leaving the distance of 120.65mm from both corner sides of sheet for making pin joints for sliding of inner M.S bar as shown in figure 3.7.

Figure 3.7 Vise making pin joint with M.S bar Finally we hold the vise on shaper machine shown in figure 3.8 for making the fleet on both edges with the help of try square putting it at 450, after that for removing chips, smoothness and removing extra material from vise by grinder machine also by filing process.

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Figure 3.8 SHAPING MACHINE After fabrication of top sheet and bottom sheet and holding vises, we tightened the both sheets in vises, we obtained the mould shown in figure 3.9.

Figure 3.9 Fabricated Mould

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CHAPTER NO: 04 SAMPLE DEVELOPMENT

4.1 RATIO: The ratios of the items by which samples are developed are following: Vinyl Ester: This is a resin (matrix) material. Cobalt: This is a catalyst material and it was used to increase the rate of reaction. MEKP: This is a hardener material and was used in reaction with resin Fabric (glass fabric 200mg): The standard dimension for the glass fabrics sheet is 304.48mm/304.48mm. 4.2 PREPARATION FOR SAMPLE DEVELOPMENT Following methods were used for development of samples: 1. Bottom Sheet Applying vex on whole sheet Placing sealing sheet strips on all four sides of sheet for stopping air interruption. Placing fabrics of 304.48mm/304.48mm on sheet

Figure 4.1 Bottom Sheet with Vex applied and Placed Sealing Sheet 2. TOP Sheet
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Proceeding same process, we apply vex on whole sheet also on roots of sheet.

3. Placement of Top Sheet upon Bottom Sheet After vex on top sheet we place top sheet upon the bottom sheet clearly because the placement of vises will be with good manner. 4. All Sides of Sheets have been tightened by Vices Each vice is placed in sides of sheet and bolts of vice are tightened by key clearly because of no air crossing occurs.

Figure 4.2 Sheets tightened by Vices

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5. Connect the mould to vacuum The function of vacuum is to remove the air so when air is removed we use chuck plass on vacuum pipe.

Figure 4.3 Mould connected to vacuum pump 6. Resin preparation We mixed up the resin, cobalt and MEKP hardener with proper ratio in a beaker and then we continuously mixed it as it must not become solid. 7. All prepare resin is vacuumed in mould At first vacuum the whole mould with the help of vacuum pump from working space than allow the resin to mould cavity. 8. De mould After 24-hours we demoulded the sample.

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In this our research, we developed following seven composite samples for testing tensile behavior and we will conduct tensile test of simple glass fabric. 4.3 MOULD A Two layers (+45,-45) of fabric glass were used to develop the sample shown in figure 4.4.

Figure 4.4 Mould A 4.4 MOULD B Two layers (0/90and + 45) of fabric glass were used to develop the sample shown in figure 4.5.

Figure 4.5 Mould B

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4.5 MOULD C Alternate four layers of (0/90 and + 45) of fabric glass were used to develop the sample shown in figure 4.6.

Figure 4.6 Mould C 4.6 MOULD D Four layers of ( +45 ) shown in figure 4.7. of fabric glass were used alternatively to develop the sample

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Figure 4.7 Mould D 4.7 MOULD E Four layers of (0/90) of fabric glass were used to develop the sample shown in figure 4.8.

Figure 4.8 Mould E 4.8 MOULD F Two layers of (0/90) of fabric glass were used to develop the sample shown in figure 4.9.

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Figure 4.9 Mould F 4.9 MOULD G Two layers of (0/ 90) of fabric glass were used and resin was transferred by hand layup RTM to develop the sample as shown in figure 4.10.

Figure 4.10 Hand layup Mould

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CHAPTER NO. 05 TESTING AND RESULT DISCUSSION

Development of composite material is crucial issue due to their mechanical properties and application. Efforts are being made to locally develop a composite material in the laboratory of Mechanical Engineering Department by using vacuum assisted resin transfer mold. Fabric glass was selected in composite material. Secondly resin which is a matrix material is also selected from market. In this experimental study we have tested fabric glass with multi oriented arrangements and laminates with vinyl ester resin. In this chapter we conducted tensile testing of developed samples on UTS machine (detailed given in section 6.1) and those samples are detailed in previous chapter. Tensile testing on UTS machine was used to carry out various tests. Following tests were conducted UTS machine in laboratory for this developed composite material. A) Tensile stress B) Youngs modulus of elasticity C) Breaking elongation % D) Percentage elongation We cut two strips of 1 width of each from each developed samples to achieve good and correct results. In this chapter we present a complete discussion in order to clarify the obtained results.

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5.1 SSTM-20KN TESTING MACHINE The united SSTM-20KN testing machine is a mechanical type, Universal Testing Machine shown in following figure. It is a computer inclusive, electromechanical, test system designed to accommodate a variety of testing instruments and accessories to conduct various tests such as Impact test, Hardness test, simple tensile test, shear stress test, uniaxial test etc of various types of material including ceramics, plastics, polymers, metals and composites.

SSTM-20KN Testing Machine

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5.2 TEST SPECIMEN OF COMPOSITE MATERIAL A. Sample was developed by vacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Two layers ( is divided into two parts equal length and equal width. 5.2.1 Test Specimen of Composite Material A1 Specimen A1 is the strip cut from the composite material sample A1 and is shown in figure 5.1(a) before test and in figure 5.1(b) after test. ) of fabric glass were used as a

fabric material and vinyl ester resin as matrix material was used, this composite specimen

. Figure 5.1(a) Composite material test specimen A1(before test).

Figure 5.1(b) Composite material test specimen A1(after test). The specifications of specimen A1 shown in figure 5.1(a) of developed composite material sample A are shown in table 5.1. Table: 5.1 Specifications of Composite material specimen A1. Name of specimen Length width Point A A1 254 25.4 1.20 thickness Point B 1.15 Point C 1.10

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All the specifications are in mm. Specimen A1 of Composite material sample A were tested in tensile testing machine, fig: 5.1(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen A1.

Figure 5.1(C) Observation graph and results for composite material specimen A1.

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5.2.2 Test Specimen of Composite Material A2 Specimen A2 is the strip cut from the composite material sample A and is shown in figure 5.2(a) before test and in figure 5.2(b) after test.

Figure 5.2(a) Composite material test specimen A2 (before test).

Figure 5.2(b) Composite material test specimen A2 (after test).

The specifications of specimen A2 shown in figure 5.2(a) of developed composite material sample A are shown in table 5.2. Table: 5.2 Specifications of Composite material specimen A2. Name of specimen Length width Point A A2 254 25.4 1.25 Thickness Point B 1.00 Point C 0.9

All the specifications are in mm.

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Specimen A2 of Composite material sample A were tested in tensile testing machine, fig: 5.2(c) shows the graph in Stress v/s Extension of tensile test conducted in the laboratory for test specimen A2.

Figure 5.2(C) Observation graph and results for composite material specimen A2.

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5.3 TEST SPECIMEN OF COMPOSITE MATERIAL B Sample was developed by vacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Two layers ( 45, 0/ 90) of fabric glass were used as a fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width. 5.3.1Test Specimen of Composite Material B1 Specimen B1 is the strip cut from the composite material sample B and is shown in figure 5.3 (a) before test and in figure 5.3(b) after test.

Figure 5.3(a) Composite material test specimen B1 (before test).

Figure 5.3(b) Composite material test specimen B1(after test). The specifications of specimen B1 shown in figure 5.3 (a) of developed composite material sample B are shown in table 5.3. Table: 5.3 Specifications of Composite material specimen B1 Name of specimen Length width Thickness Point A B1 254 25.4 1.30 Point B 1.05 Point C 1.15

All the specifications are in mm

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Specimen B1 of Composite material sample B were tested in tensile testing machine, fig: 6.3(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen B1.

Figure 6.3 (C) Observation graph and results for composite material specimen B1

5.3.2 Test Specimen of Composite Material B2

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Specimen B2 is the strip cut from the composite material sample B2 and is shown in figure 5.4 (a) before test and in figure 5.4(b) after test.

Figure 5.4 (a) Composite material test specimen B2 (before test).

Figure 5.4(b) Composite material test specimen B2 (after test).

The specifications of specimen B2 shown in figure 5.4(a) of developed composite material sample B are shown in table 5.4. Table: 5.4 Specifications of Composite material specimen B2 Name of specimen Length width Point A B2 254 25.4 1.10 thickness Point B 1.00 Point C 1.15

All the specifications are in mm. Specimen B2 of Composite material sample B was tested in tensile testing machine, fig:5.4(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen B2.
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Figure 5.4 (C) Observation graph and results for composite material specimen B2

5.4 TEST SPECIMEN OF COMPOSITE MATERIAL C Sample was developed by vacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three

55

points for taking uniform thickness. Alternate four layers of ( 45, 0/90) of fabric glass were used as a fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width. 5.4.1Test specimen of composite material C1 Specimen C1 is the strip cut from the composite material sample C and is shown in figure 5.5(a) before test and in figure 5.5(b) after test.

Figure 5.5 (a) Composite material test specimen C1(before test).

Figure 5.5 (b) Composite material test specimen C1 (after test). The specifications of specimen C1 shown in figure 5.5(a) of developed composite material sample C are shown in table 5.5. Table: 5.5 Specifications of Composite material specimen C1 Name of specimen Length width Point A C1 254 25.4 1.20 thickness Point B 1.30 Point C 1.05

All the specifications are in mm. Specimen C1 of Composite material sample C was tested in tensile testing machine, fig: 5.5(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen C1.

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Figure 5.5 (C) Observation graph and results for composite material specimen C1

5.4.2 Test Specimen of Composite Material C2 Specimen C2 is the strip cut from the composite material sample C and is shown in figure 5.6 (a) before test and in figure 5.6(b) after test.

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Figure 5.6 (a) Composite material test specimen C2 (before test).

Figure 5.6 (b) Composite material test specimen C2 (after test).

The specifications of specimen C2 shown in figure5.6(a) of developed composite material sample C are shown in table 5.6. Table: 5.6 Specifications of Composite material specimen C2 Name of specimen Length width Point A C2 254 25.4 1.00 thickness Point B 0.9 Point C 0.95

All the specifications are in mm.

Specimen C2 of Composite material sample C was tested in tensile testing machine, fig: 5.6(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen C2.

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Figure 5.6 (C) Observation graph and results for composite material specimen C2

5.5 TEST SPECIMEN OF COMPOSITE MATERIAL D Sample was developed byvacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Four layers of ( 45) of fabric glass were used
59

alternatively as a fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width. 5.5.1Test Specimen of Composite Material D1 Specimen D1 is the strip cut from the composite material sample Dand is shown in figure 5.7(a) before test and in figure 5.7(b) after test.

Figure 5.7 (a) Composite material test specimen D1 (before test).

Figure 5.7 (b) Composite material test specimen D1 (after test). The specifications of specimen D1 shown in figure 5.7(a) of developed composite material sample D are shown in table5.7. Table: 5.7 Specifications of Composite material specimen D1 Name of specimen Length width Point A D1 254 25.4 1.05 thickness Point B 0.9 Point C 1.00

All the specifications are in mm. Specimen D1 of Composite material sample D was tested in tensile testing machine, fig: 5.7(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen D1.

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Figure 5.7 (C) Observation graph and results for composite material specimen D1

5.5.2 Test Specimen of Composite Material D2 Specimen D2 is the strip cut from the composite material sample D and is shown in figure 5.8(a) before test and in figure 5.8(b) after test.

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Figure 5.8 (a) Composite material test specimen D2 (before test).

Figure 5.8 (b) Composite material test specimen D1 (after test).

The specifications of specimen D2 shown in figure 5.8(a) of developed composite material sample D are shown in table 5.8. Table: 5.8 Specifications of Composite material specimen D2 Name of specimen Length width Point A D2 254 25.4 1.5 thickness Point B 1.6 Point C 1.2

All the specifications are in mm.

Specimen D2 of Composite material sample D was tested in tensile testing machine, fig: 5.8(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen D2.

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Figure 5.8 (C) Observation graph and results for composite material specimen D2

5.6 TEST SPECIMEN OF COMPOSITE MATERIAL E Sample was developed by vacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Four layers of (0/90) of fabric glass were used as a

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fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width. 5.6.1Test Specimen of Composite Material E1 Specimen E1 is the strip cut from the composite material sample Eand is shown in figure 5.9 (a) before test and in figure 5.9(b) after test.

Figure 5.9 (a) Composite material test specimen E1 (before test).

Figure 5.9 (b) Composite material test specimen E1 (after test). The specifications of specimen E1 shown in figure 5.9(a) of developed composite material sample E are shown in table 5.9. Table: 5.9 Specifications of Composite material specimen E1 Name of specimen Length width Point A E1 254 25.4 2.1 thickness Point B 1 Point C 1.5

All the specifications are in mm. Specimen E1 of Composite material sample E was tested in tensile testing machine, fig: 5.9(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen E1.

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Figure 5.9 (C) Observation graph and results for composite material specimen E1

5.6.2 Test Specimen of Composite Material E2 Specimen E2 is the strip cut from the composite material sample E and is shown in figure 5.10 (a) before test and in figure 5.10(b) after test.

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Figure 5.10 (a) Composite material test specimen E2(before test).

Figure 5.10 (b) Composite material test specimen E2(after test).

The specifications of specimen E2 shown in figure 5.10(a) of developed composite material sample E are shown in table 5.10. Table: 5.10 Specifications of Composite material specimen E2 Name of specimen E2 254 25.4 Length width Point A 2.1 thickness Point B 1 Point C 1.5

All the specifications are in mm.

Specimen E2 of Composite material sample E was tested in tensile testing machine, fig:5.10(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen E2.

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Figure 5.10 (C) Observation graph and results for composite material specimen E2

5.7 TEST SPECIMEN OF COMPOSITE MATERIAL F Sample was developed by vacuum assisted resin transfer mold (VARTM). During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Two layers of (0/ 90) of fabric glass were used as a fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width.

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5.7.1Test Specimen of Composite Material F1 Specimen F1 is the strip cut from the composite material sample Fand is shown in figure 5.11 (a) before test and in figure 5.11(b) after test.

Figure 5.11 (a) Composite material test specimen F1(before test).

Figure 5.11 (b) Composite material test specimen F1(after test). The specifications of specimen F1 shown in figure 5.11(a) of developed composite material sample F are shown in table 5.11. Table: 5.11 Specifications of Composite material specimen F1 Name of specimen Length width Point A F1 254 25.4 1.6 thickness Point B 1.4 Point C 1.2

All the specifications are in mm. Specimen F1 of Composite material sample F was tested in tensile testing machine, fig: 5.11(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen F1.

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Figure 6.11 (C) Observation graph and results for composite material specimen F1

5.7.2 Test Specimen of Composite Material F2 Specimen F2 is the strip cut from the composite material sample F and is shown in figure 5.12 (a) before test and in figure 5.12(b) after test.

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Figure 5.12 (a) Composite material test specimen F2(before test).

Figure 5.12 (b) Composite material test specimen F2(after test).

The specifications of specimen F2 shown in figure 5.12(a) of developed composite material sample F are shown in table 5.12. Table: 5.12 Specifications of Composite material specimen F2 Name of specimen Length width Point A F2 254 25.4 1.5 thickness Point B 1.5 Point C 1.4

All the specifications are in mm.

Specimen F2 of Composite material sample F was tested in tensile testing machine, fig: 5.12(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen F2.

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Figure 5.12 (C) Observation graph and results for composite material specimen F2

5.8 TEST SPECIMEN OF COMPOSITE MATERIAL G Sample was developed by hand layup RTM. During experimentation it was difficult to maintain the thickness of specimen so we took three points for taking uniform thickness. Two layers of (0/ 90) of fabric glass were used as a fabric material and vinyl ester resin as matrix material was used, this composite specimen is divided into two parts equal length and equal width.
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5.8.1Test Specimen of Composite Material G1 Specimen G1 is the strip cut from the composite material sample G and is shown in figure 5.13(a) before test and in figure 5.13(b) after test.

Figure 5.13 (a) Composite material test specimen G1(before test).

Figure 5.13 (b) Composite material test specimen G1(after test). The specifications of specimen G1 shown in figure 5.13 (a) of developed composite material sample G are shown in table 5.13. Table: 5.13 Specifications of Composite material specimen G1 Name of specimen Length width Point A G1 254 25.4 2.0 thickness Point B 1.5 Point C 1.5

All the specifications are in mm. Specimen G1 of Composite material sample F was tested in tensile testing machine, fig:5.13(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen G1.

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Figure5.13 (C) Observation graph and results for composite material specimen G1

5.8.2 Test Specimen of Composite Material G2 Specimen G2 is the strip cut from the composite material sample G and is shown in figure 5.14 (a) before test and in figure 5.14(b) after test.

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Figure 5.14 (a) Composite material test specimen G2 (before test).

Figure 5.14 (b) Composite material test specimen G2 (after test). The specifications of specimen G1 shown in figure 5.14 (a) of developed composite material sample G are shown in table 5.14. Table: 5.14 Specifications of Composite material specimen G2 Name of specimen Length width Point A G2 254 25.4 1.7 thickness Point B 1.00 Point C 1.2

All the specifications are in mm.

Specimen G2 of Composite material sample F was tested in tensile testing machine, fig: 5.14(c) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen G2.

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Figure 5.14 (C) Observation graph and results for composite material specimen G2

5.9 TEST SPECIMEN OF SIMPLE FABRIC GLASS (F.G) Simple fabric glass was taken as a specimen for conducting tensile test. For this purpose we take the one (0, 90) layer of fabric glass. For a specimen, we cut it in the width of 25.4mm and length of 245mm as shown in figure 5.15(a).
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Figure 5.15 (a) Composite material test specimen F.G (before test).

The specifications of specimen F.G shown in figure 5.15 (a) of developed composite material sample F.G are shown in table 5.15. Table: 5.15 Specifications of Composite material specimen F.G Name of specimen Length width Point A Fabric Glass 254 25.4 0.7 thickness Point B 0.7 Point C 0.7

All the specifications are in mm.

Specimen F.G of simple fabric glass was tested in tensile testing machine, fig: 5.15(b) shows the graph in Stress v/s Extension and results of tensile test conducted in the laboratory for test specimen F.G.

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Figure 5.15 (b) Observation graph and results for simple fabric glass specimen F.G

5.10 RESULTS We developed various samples by the different laminating and orienting arrangements having the different properties as shown in following table 5.16. Table 5.16, Mechanical properties of our developed samples Name of Specimen Yield (N) Yield Str. Tensile (N) Tensile Str. MOE Break Elong Yield Elong
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(MPa) A1 A2 B1 B2 C1 C2 D1 D2 E1 E2 F1 F2 G1 G2 F.G 476.16 1053.51 0.00 0.00 1377.15 0.00 773.78 1149.20 0.00 0.00 0.00 0.00 0.00 0.00 69.25 1617.38 3919.32 0.00 0.00 4138.08 0.00 3358.42 2805.65 0.00 0.00 0.00 0.00 0.00 0.00 247.33 799.73 1053.51 2118.01 1785.47 1377.15 1565.48 779.54 1181.73 1543.21 1370.51 5493.7 5550.2 1781.1 1588.9 113.43

(MPa) 2716.46 3919.32 7879.49 6947.49 4138.08 6794.63 3383.43 8885.09 6028.16 2676.78 15328 14453.6 6626.11 6206.77 405.10 71289 94030 144131 143180 58949 116813 50973 43533 83062 47836 241901 214819 124032 124032 4593

(%) 4.05 16.08 5.49 4.94 28.90 5.91 41.27 33.94 7.57 4.5 6.88 7.39 5.26 4.78 38.28

(%) 2.29 7.02 0.00 0.00 6.10 0.00 34.52 31.22 0.00 0.00 0.00 0.00 0.00 0.00 8.22

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CHAPTER NO: 06 CONCLUSION

6.1 CONCLUSION
In this research work, we developed a comprehensive Vacuum Assisted Resin Transfer Molding (VARTM) process system for development of composite materials. we developed the samples of composite materials by using glass fabric as a reinforcing material and vinyl ester as a matrix material. During the experimentation we tried our level best to achieve the good samples of composite but reaction rate of vinyl ester, MEKP and cobalt and was too high so their mixture became solid rapidly and cannot be transferred easily into the mold by the vacuum pump because our vacuum pump used for VARTM was not working properly and we could not able to purchase new one because of high cost, so we used the pump manufactured locally at mechanical department workshop by the students of previous batches. Mold locally fabricated by us was not sealed in a good manner, so air interrupted and affected the samples. During testing, specimen were slipping from the jaws of UTS machine and somehow we could not achieve the best results. Our locally developed material is best innovative try in the world of engineering materials and it will also fulfill the needs and spaces in the need for lighter and strengthen material, specially where high strength is required and elongation is minored. .

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6.2 FUTURE WORK (Suggestions): We have developed proper moulds for completing VARTM system and now it is ready to use for development of composite material by using different reinforcement material and various matrix material. Different layers/ types of fabric can be developed and tested. Different matrix materials are available in the market for further usage, various destructive and non-destructive tests can be carried out for development of composite materials. For stopping the air interruption, appropriate sealing sheet and vex should be used on moulds. In the mould, flow of the matrix material cannot maintained by using the weak vacuum pump, so appropriate and good vacuum pump should be used. Some how we developed samples by using compressor for vacuuming purpose but it is essential to arrange a proper vacuum pump for best results. Ratio of vinyl ester, MEKP and cobalt becomes solid rapidly after 7 minutes of there reaction, so it is suggested that vacuuming process should be maintained during that time as best results can be achieved. During conducting the mechanical test on UTS machine, material sips out from the holding clips of the UTS, so clips for holding the material in UTS should be manufactured for achieving best results. During testing, specimen were slipping from the jaws of UTS machine and somehow we could not achieve the best results. For this we suggest to develop some extra clips frame to hold a specimen and than that frame will have been tighten to UTS machine jaws.

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