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CHAPTER 1

1.1 INTRODUCTION

Modern composite materials constitute a significant proportion of the engineered


materials market ranging from everyday products to sophisticated applications. While
composites have already proven their worth as weight-saving materials, the current
challenge is to make them cost effective. The efforts to produce economically attractive
composite components have resulted in several innovative manufacturing techniques
currently being used in the composites industry. It is obvious, especially for composites,
that the improvement in manufacturing technology alone is not enough to overcome the
cost hurdle. It is essential that there be an integrated effort in design, material, process,
tooling, quality assurance, manufacturing, and even program management for composites
to become competitive with metals.
For certain applications, the use of composites rather than metals has in fact
resulted in savings of both cost and weight. Some examples are cascades for engines,
curved fairing and fillets, replacements for welded metallic parts, cylinders, tubes, ducts,
blade containment bands etc. Most commonly used matrix materials are polymeric. The
reasons for this are two-fold. In general the mechanical properties of polymers are
inadequate for many structural purposes. In particular their strength and stiffness are low
compared to metals and ceramics. These difficulties are overcome by reinforcing other
materials with polymers. Secondly the processing of polymer matrix composites need not
involve high pressure and does not require high temperature.

1.2 OBJECTIVE

To determine the mechanical behaviour of sisal and bamboo, epoxy reinforced natural
hybrid composite by compression molding.

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CHAPTER 2

LITERATURE REVIEW

2.1 COMPOSITE MATERIALS

A composite material consists of two or more physically and chemically distinct,


suitably arranged or distributed phases, with an interface separating them. It has
characteristics that are not depicted by any of the components in isolation. Most
commonly, composite materials have a bulk phase, which is continuous, called the
matrix, and one dispersed, non-continuous, phase called the reinforcement, which is
usually harder and stronger.
Composites are now extensively being used for rehabilitation/ strengthening
of pre-existing structures that have to be retrofitted to make them seismic resistant, or
to repair damage caused by seismic activity.

Matrix phase

The primary phase, having a continuous character, is called matrix. Matrix is


usually more ductile and less hard phase. It holds the dispersed phase and shares a load
with it.

Dispersed (Reinforcement) phase

The second phase (or phases) is embedded in the matrix in a discontinuous form.
This secondary phase is called dispersed phase. Dispersed phase is usually stronger than
the matrix, therefore it is sometimes called reinforcing phase.

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2.2 TYPES OF COMPOSITES

2.2.1 Metal Matrix Composites (MMC)

Metal matrix composites, as the name implies, have a metal matrix. Examples of
matrices in such composites include aluminum, magnesium and titanium. The typical
fiber includes carbon and silicon carbide. Metals are mainly reinforced to suit the needs
of design

2.2.2 Ceramic Matrix Composites (CMC)

Ceramic matrix composites have ceramic matrix such as alumina, calcium,


alumina silicate reinforced by silicon carbide. The advantages of CMC include high
strength, hardness, high service temperature limits for ceramics, chemical inertness and
low density. Naturally resistant to high temperature, ceramic materials have a tendency to
become brittle and to fracture.

2.2.3 Polymer Matrix Composites (PMC)


Most commonly used matrix materials are polymeric. The reasons for this is two-
fold. In general the mechanical properties of polymers are inadequate for many structural
purposes. In particular their strength and stiffness are low compared to metals and
ceramics. These difficulties are overcome by reinforcing other materials with polymers.
Secondly the processing of polymer matrix composites need not involve high pressure
and does not require high temperature. Polymer composites are used because overall
properties of the composites are superior to those of the individual polymers. They have a
greater elastic modulus than the neat polymer but are not as brittle as ceramics.
Two main kinds of polymers are thermosets and thermoplastics. Thermosets have
qualities such as a well-bonded three-dimensional molecular structure after curing. They
can be retained in a partially cured condition too over prolonged periods of time,
rendering Thermosets very flexible.

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Thermoplastics have one- or two-dimensional molecular structure.

Figure 2.1 Thermoset resin

Figure2.2 Thermoplastics

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2.3 INTRODUCTION TO REINFORCEMENT

Reinforcements for the composites can be fibers, fabrics particles or whiskers.


Fibers are essentially characterized by one very long axis with other two axes either often
circular or near circular. Particles have no preferred orientation and so does their shape.
Whiskers have a preferred shape but are small both in diameter and length as compared
to fibers. Below Figure shows types of reinforcements in composites

Figure 2.3 Types of reinforcement

Reinforcing constituents in composites, as the word indicates, provide the


strength that makes the composite what it is.

2.3.1 Classification of reinforcements



1. Particle-Reinforced (Large-Particle And Dispersion-Strengthened)
2. Fiber-Reinforced (Continuous (Aligned) And Short Fibers (Aligned

Or Random)

3. Structural (Laminates And Sandwich Panels)

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Figure 2.4 Classification of composites


Particulate composites
Particulate Composites consist of a matrix reinforced by a dispersed phase
in form of particles. These are the cheapest and most widely used. They fall in
two categories depending on the size of the particles
1. Composites with random orientation of particles.
2. Composites with preferred orientation of particles.
3. Dispersed phase of these materials consists of two-dimensional flat
platelets (flakes), laid parallel to each other.

Long-Fiber Reinforced Composites


1. Long-fiber reinforced composites consist of a matrix reinforced by
a dispersed phase in form of continuous fibers.
2. Unidirectional orientation of fibers.
3. Bidirectional orientation of fibers (woven)

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Laminate composite

When a fiber reinforced composite consists of several layers with different
fiber orientations, it is called multilayer composite.

2.3.2 Natural fibre reinforced composites


Fiber-reinforced polymer composites have played a dominant role for a long time
in a variety of applications for their high specific strength and modulus. The use and
removal of traditional fiber–reinforced plastic, usually made of glass, carbon or aramid
fibers–reinforced thermoplastic and thermoset resins are
considered critically because of environmental problems. By natural fiber composites we
mean a composite material that is reinforced with fibers, particles or platelets from
natural or renewable resources, in contrast to for example carbon or aramid fibers that
have to be synthesized. Natural fibers include those made from plant, animal and mineral
sources. Natural fibers can be classified according to their origin. The main advantage of
natural fibres are bio degradable and low cost.

2.4 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 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.

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2.5 MANUFACTURING OF COMPOSITE MATERIAL
Manufacturing of a composite material is to combine the polymeric resin system
with the fiber reinforcement. Since the orientation of the fibers is critical to the end
properties of the composite, manufacturing process is utmost important to align the fibers
in desired direction.

The composite manufacturing techniques can be classified into two categories:

A. OPEN MOULD PROCESS

a) Hand lay up process

b) Vaccum bag auto clave process

c) Spray up process

d) Filament winding process

B. CLOSED MOULD PROCESS

a) Compression moulding

b) Injection moulding

c) Sheet Moulding Compound (SMC) process

d) Continuous pultrusion process

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2.6 LITERATURE FROM JOURNALS

Srivastava (2015), surveyed that Sisal fibre reinforcement composites have


been prepared by using various fibre weight fractions (15, 20, 25 and 30%). Mechanical
properties, water absorption properties and dynamic mechanical analysis of sisal
composites are investigated. The results show that the addition of sisal fibres in epoxy
matrix up to 30 wt. % increases the mechanical, thermal and water absorption properties.
The values of storage modulus and loss modulus increase with increase in fibre content
up to 25% and then decrease. This composite are found suitable in light weight
automotive parts application.

Sultan et al. (2014), surveyed that Natural plant fibre composites have been
developed for the production of the variety of industrial products, with benefits including
biodegradability and environmental protection sustainability, mechanical properties and
recyclability, and they can be compared with glass fibres. There are three main types of
procedures: mechanical, chemical, and combined mechanical and chemical extraction.
Mechanical extraction methods are more eco-friendly than chemical methods and steam
explosion and chemical methods significantly affect the microstructure of bamboo fibres.

Raghavendra et al. (2010) This author surveyed that the bamboo fibre
reinforced composites prepared by compression molding. These fibres are soaked in 1%
NaOH solution for 30min to remove grassy material and dried under sun for 1 week for
removing amorphous hemi cellulose materials. The author varying the composition by
increasing bamboo fibre content as ( 0%, 10%, 20, 40%,50%) respectively and epoxy is
taken as 60%. The author observed that flexural and compressive properties are found
higher by increasing the bamboo fibre in the composite.

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Prasad et al. (2017), The author studied about the influence of sisal fibre content
on mechanical (i.e. tensile, flexural, impact, hardness and abrasion resistance) and thermal
properties of composites by varying the fibre and epoxy percentage. The composite was
prepared by melt-mixing method, followed by compression molding process. The
percentage of sisal fibre varies from 4% to 10% in steps of 2%. The major mechanical
properties like tensile, hardness, impact, flexural, and moisture absorption are studied.

Yeshika et al. (2015) In this author checked the the workability and strength
properties of sisal fibre reinforced concrete with different mix proportions and different
percentage of fibre addition. The materials were chosen to improve the various strength
properties of the structure to obtain sustainability and better quality structure when the
composition of the sisal fibre is increased gradually in the composite.

Jain, et al. (1992), The tensile, flexural and bamboo fibre reinforced plastic
(BFRP) composite have been evaluated. scanning electron microscopic studies of the
fractured BFRP composites specimens reveal a prefect bonding bamboo fibres and epoxy
further more the high strength, low density, low production cost and ease of
manufacturing make BFRP composite a commercially viable material for structural
applications. The hybrid composite with alkali treated bamboo fibres were found to
posses higher flexural and compressive properties. The elimanition of amorphous weak
hemi cellulose components from the bamboo fibre on alkali treatment may be responsible
for this behaviour.

Ovin et al. (2017) This work is focused on development and evaluation of


physical, mechanical behaviour of epoxy based composite filled with different
percentage of bamboo fibres and coconut powder. Composite panels are made by Hand
lay up process and tested as per ASTM standards. Hardness of the Composite was found
to decrease with the increased in percentage of Bamboo fibre and Coconut powder. water
absorbtion test reveal that, the minimum water absorption was observed for the
composite of 10% bamboo in composition.

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Rassiah et al. (2013) This author investigated that bamboo fibre will effectively
remove the impurities and bond between fibre in which the various compositions classified
in different percentage got different results. This paper also reviews the mechanical
properties of bamboo in polymer composites. In this the mechanical properties mainly
provided by the cellulouse content, which is influenced by many factors such as fibre
volume fraction, fibre length, fibre ascept ratio and fibre orientation.

Girisha et al. (2012) In his the effect of moisture absorption on the mechanical
properties of coconut coir and sisal fibre reinforcement hybrid epoxy composite were
investigated and compared with the composite containing the dried fibres. Increasing the
fibre content at drycondition, the tensile and flexural strength increased. At wet condition
the tensile and flexural strength have a high level reduction. Water absorbtion tests were
conducted by immersing specimens in a water bath of 25ºC and 100ºC for different time
durations. The tensile and flexural properties of natural fibre reinforced epoxy composite
specimen were found to decrease with increase in percentage of moisture uptake.

Kumaresan et al (2015) This present work evaluate the effect of fibre


orientation on mechanical properties of sisal fibres reinforced epoxy composites.In this
work Sisal fibre is used as reinforcement which treated with NAOH solution for
enhancing the bonding strength between fiber and resin by removing moisture content. In
this samples are fabricated by compression molding and investigated their mechanical
properties like tensile strength and flexural strength.

Shitole et al. (2011) In this paper, composites were prepared with unidirectional
bamboo fibre reinforced with epoxy resin. Experimental analysis of composite made
from bamboo fibre and epoxy material has carried out to study the tensile strength of the
composite. Tensile test of the composite is carried out on Universal testing machine.

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Aruna et al. (2014) This author investigated the of mechanical behaviour of sisal
fibre reinforced concrete is reported for making a suitable building material in terms of
reinforcement. Fibre reinforced Composite is one such material, which has reformed the
concept of high strength. Sisal fibres are abundantly available in the hot areas. Sisal fibre
has emerged as a reinforcing material for concretes, used in civil structures. Sisal fibre
reinforced cement composite slabs with long sisal fibres were manufactured using a cast
hand lay up technique. Mechanical response was measured under tension. The high energy
absorption capacity of the developed composite system was reflected in high toughness
values under tension respectively.

Chand et al. (1993) Sisal fibres extracted from the leaves of Agava sisalana
plants 3, 5, 7 and 9 years old were tested at different temperatures for tensile strength,
elongation, toughness and modulus. The tensile strength, modulus and toughness values
of sisal fibre decreased with increase in temperature. The effect of plant age on tensile
strength, tensile modulus and toughness of sisal fibre became very much less at 100 as
compared to 30.Fractured fibres were observed by using a scanning electron microscope.

Badshah et al. (2015) The present work deals with the effect of orientation of
tensile, compression and impact properties on sisal fibres orientated composite. Tensile
compression and impact tests are conducted for the composite and the result exhibit an
enhancement in the mechanical properties. The plant has a life span of 7-10 years. On an
average per leaf of a sisal plant contain about 1000 fibres. Sisal fibres are also widely
used around the globe forvarious other commercial purposes.

Zakikhani et al. (2014) Bamboo fibre materials have attracted broad attention
as reinforcement polymer composites due to their environmental sustainability,
mechanical properties, and recyclability, and they can be compared with glass fibres..
Many parameters affect the mechanical properties and composite characteristics of
bamboo fibres and bamboo composites, including fibre extraction methods, fibre length,
fibre size, resin application, temperature, moisture content and composite preparation
techniques.

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Khan et al. (2017) In this work, experimental and numerical study on fracture
behaviour of bamboo fibre reinforced epoxy composites is presented. Optimum NaOH
concentration for treatment of bamboo fibres was determined through single fiber
tensile test and microscopic inspection of fiber surface through SEM (Scanning
Electron Microscopy). The results demonstrated that 6% NaOH treated fibers showed
maximum ultimate tensile strength of 234 MPa. Single fiber fragmentation test results
showed that interfacial adhesion is improved by treating fibers with 6% NaOH.
Bamboo fiber reinforced epoxy composite was fabricated using 6% NaOH treated
bamboo fibers of length 10 mm, 20 mm and 25 mm with random distribution in epoxy
matrix.

Hebel et al. (2014) A straightforward mechanical processing protocol for raw


bamboo, which leads to a fibrous material with physical features that are mainly defined
by the bamboo species, has been developed. This material was used as a natural fiber
source for the production of a high-tensile fiber reinforced composite. The relationship
between tensile strength, pressure, temperature and press/hold time is being analyzed. It
has been observed that the composites reach a maximum tensile strength (180 MPa) at a
certain pressure/ temperature combination and any deviation from this range has a
negative effect on the mechanical.

Gowda et al. (2017) In the present study an attempt is made to determine the
mechanical properties of sisal fiber reinforced polyester composites. The fibers obtained
are dried and brushed to remove the dirt left over to get the sisal fibers. In the present
study, randomly oriented sisal fiber reinforced polyester matrix composite specimens of
thicknesses 2 mm, 3 mm, 4 mm, 5 mm and 6 mm were fabricated by using hot
compression moulding technique. 5% NaOH treated sisal fibers of length 10 mm is used
as reinforcement for casting the composite specimens. Composite panels of fiber volume
fraction 10%, 15%, 20%, 25% and 30% were casted and the test specimens were cut
from the panels and tested for its tensile strength and flexural strength as per ASTM D-
3039 and ASTM D-7264 respectively.

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Mallikarjun et al. (2017) This author investigate the mechanical properties such
as tensile strength and compressive strength of the sisal fiber reinforced polymer
composites. The strength analysis of the sisal fiber reinforced polymer composites has been
made with volume fraction and different combinations such as unidirectional and
orientations. The specimens were prepared by hand layup technique and are as per the
ASTM standards. The experimental results showed that the tensile strength of the sisal fiber
reinforced polymer composites with unidirectional gives better results as compare to
orientation composites, but the compression strength is better for orientation composites.

Ram et al. (2017) In the present work, the finite element analysis (FEA) of
glass/epoxy composite based industrial safety helmet has been performed using solid-
works simulation software. The modeling results show that glass fiber reinforced epoxy
composite can be used as a material for fabrication of industrial safety helmet which has
good mechanical properties than the existing helmet material. The fiber based polymer
composites are more popular because these have high strength, light inweight, low cost
and easily available.

2.7 MATERIAL USED


This chapter describes the details of processing of the composites and the
experimental procedures followed for their mechanical characterization. The raw
materials used in this work are
Matrix Material
Epoxy resin
Reinforcement
1. Sisal fibre
2. Bamboo fibre

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2.7.1 Epoxy

Epoxy resins are low molecular weight pre-polymers or higher molecular weight
polymers which normally contain at least two epoxide groups. The epoxide group is also
sometimes referred to as a glycidyl or oxirane group.

Figure 2.5 epoxy resin

Epoxy resins are polymeric or semi-polymeric materials, and as such rarely exist
as pure substances, since variable chain length results from the polymerisation reaction
used to produce them. High purity grades can be produced for certain applications, e.g.
using a distillation purification process. One downside of high purity liquid grades is
their tendency to form crystalline solids due to their highly regular structure, which
require melting to enable processing.

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Properties of Epoxy

1. The property of high adhesive strength to almost all the materials

2. Low possibility for shrinkage during curing time

3. Higher dimensional stability

4. Naturally gained gap filling properties

5. Thermosetting Property- Won’t melt

6. Higher resistance to chemicals and variety of environment condition

7. Can cure even in wet conditions. For example Underwater construction

8. Greater ease of application

Applications of Epoxy

1. Structural applications

2. Industrial tooling and composites

3. Electrical system and electronics

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2.7.2 Sisal fibre
Sisal Fiber is one of the most widely used natural fibre and is very easily
cultivated. It is obtain from sisal plant. The plant, known formally as Agave sisalana.
These plants produce rosettes of sword-shaped leaves which start out toothed, and
gradually lose their teeth with maturity. Each leaf contains a number of long, straight
fibers which can be removed in a process known as decortication. During decortication,
the leaves are beaten to remove the pulp and plant material, leaving the tough fibers
behind. The fibers can be spun into thread for twine and textile production, or pulped to
make paper products.

Figure 2.6 Sisal fiber

Sisal fibre is fully biodegradable, green composites were fabricated with soy
protein resin modified with gelatin. Sisal fiber, modified soy protein resins, and
composites were characterized for their mechanical and thermal properties. It is highly
renewable resource of energy. Sisal fibre is exceptionally durable and a low maintenance
with minimal wear and tear. Its fibre is too tough for textiles and fabrics. It is not suitable
for a smooth wall finish and also not recommended for wet areas.
The fine texture of Sisal takes dyes easily and offers the largest range of dyed
colours of all natural fibres. Zero pesticides or chemical fertilisers used in sisal
agriculture. It is a stiff fiber traditionally used in making twine, rope and also dartboards
Sisal fiber is manufactured from the vascular tissue from the sisal plant (Agavesisalana).
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It is used in automotive friction parts (brakes, clutches), where it imparts green strength
to performs, and for enhancing texture.
Chemical compositions of sisal fibre

Cellulose 65%
Hemicelluloses 12%
Lignin 9.9%
Waxes 2%
Total 100%

Properties of sisal fibre


1. Sisal Fiber is exceptionally durable with a low maintenance with minimal wear and
tear.
2. It is Recyclable.
3. Sisal fibers are obtained from the outer leaf skin, removing the inner pulp.
4. It is available as plaid, herringbone and twill.
5. Sisal fibers are Anti static, does not attract or trap dust particles and does not
absorb moisture or water easily.
6. The fine texture takes dyes easily and offers the largest range of dyed colours of all
natural fibers.
7. It exhibits good sound and impact absorbing properties.
8. Its leaves can be treated with natural borax for fire resistance properties.

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Applications of sisal fibres
From ancient times sisal has been the leading material for agricultural twine
because of its strength, durability, ability to stretch, affinity for certain dyestuffs, and
resistance to deterioration in saltwater.
1. Sisal is used commonly in the shipping industry for mooring small craft, lashing,
and handling cargo.
2. It is also surprisingly used as the fibre core of the steel wire cables of elevators,
being used for lubrication and flexibility purposes. Traditionally sisal was the
leading material for agricultural twine or baler twine. Although this has now been
overtaken by polypropylene.
3. It is used in automobile industry with fiberglass in composite materials.
4. Other products developed from sisal fiber include spa products, cat scratching
posts, lumbar support belts, rugs, slippers, cloths and disc buffers.

2.7.3 Bamboo fibre


In consequence of the consumers choosing industrialized products, among other
effects, activities are suppressed in rural areas or even in small towns, and renewable
materials are wasted and causing permanent pollution.

Figure 2.7 Bamboo fibre

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In this sense, it becomes obvious that ecological materials satisfy such fundamental
requirements, making use of agricultural by-products such as rice husk, coconut fibers, sisal
and bamboo and therefore minimizing energy consumption, conserving non-renewable
natural resources, reducing pollution and maintaining a healthy environment. Bamboo is
one material, which will have a tremendous economical advantage, as it reaches its full
growth in just a few months and reaches its maximum mechanical resistance in just few
years. Moreover, it exists in abundance in tropical and subtropical regions of the globe.
Bamboos are giant grasses and not trees as commonly believed. They belong to
the family of the Bambu soideae. The bamboo column, in general, is a cylindrical shell,
which is divided by transversal diaphragms at the nodes. Bamboo shells are orthotropic
materials with high strength in the direction parallel to the fibers and low strength
perpendicular to the fibers respectively. Bamboo is a composite material, consisting of
long and parallel cellulose fibers embedded in a ligneous matrix. The density of the fibers
in the cross-section of a bamboo shell varies along its thickness. This presents a
functionally gradient material, evolved according to the state of stress distribution in its
natural environment.

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Advantages of Bamboo fibre:
1. Softer than cotton, with a texture similar to a blend of cashmere and silk.
2. Because the cross-section of the fibre is filled with various micro-gaps and
micro-holes, it has much better moisture absorption and ventilation.
3. Natural antibacterial elements (bio-agent bamboo kun) in bamboo fibre keep
bacteria away from bamboo fabrics.
4. 100% bamboo yarns show a great elasticity i.e. nearly 20%. Even in 100%
bamboo woven fabrics a remarkable elasticity can be obtained wherein the use
of elastomeric fibres like elastanes may be eliminated.
5. Bamboo fabrics need less dyestuff than cotton, modal or viscose. It seems that
the absorption of dyestuffs is remarkably better.
6. Anti-ultraviolet nature of bamboo fibre has made it suitable for summer
clothing, especially for the protection of pregnant ladies and children from the
effect of ultraviolet radiation.
7. Product of bamboo fibre is eco-friendly and bio-degradable

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Applications Of Bamboo Fibre
1. Bamboo Clothing: The inherent anti fungal and antibacterial properties of
bamboo fabrics make it suitable for such clothing as underwears, t-shirt and socks.
2. Home Furnishings Fabrics: Bamboo fabric has also come to occupy important
place in manufacturing of home furnishings due its many qualities including,
softness, strength, & durability among others.
3. Bathroom Textiles: Bamboo fabric is increasingly being used in making
bathroom furnishings bad odor.
4. Non woven fabrics: Bamboo pulp is also used for making non woven fabrics that
are then used in making hygiene products such as sanitary napkin, masks, mattress,
absorbent pads, food-packing bags. Again, they are preferred for such products due
to anti-bacteria and absorbtion properties
5. Medical and Hygienic Clothing & Products: Apart from non wovens, bamboo
fabric itself is also used in the production of such items as textiles for surgical
practices including masks, bandage, gowns etc. apart from linens, towels and
drapes in hospitals.

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CHAPTER 3
DESIGN AND FABRICATION
3.1 COMPOSITION
The composition of the composite has been taken from the literature papers. For
this composition samples were fabricated by compression moulding and tested as per
ASTM standards.
Table 3.1 compositions

SAMPLES MATRIX REINFORCEMENT REINFORCEMENT


MATERIALS (SISAL FIBRE) (BAMBOO FIBRE)
(EPOXY)

1 60 40 0

2 60 30 10

3 60 20 20

4 60 10 30

5 60 0 40

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3.2 CALCULATIONS
Density
The theoretical density of composite materials in terms of weight fraction can easily
be obtained as for the following equations given by Agarwal and Broutman
1
ρc = 1 2 3
( ρ + ρ+ ρ )

Volume of composite:
Vc = length x breadth x thickness
= 300 x 300 x 3.2
Vc = 288 cm3
Density of Epoxy = 1.2g/cm3
Density of Sisal = 1.43g/cm3
Density of Bamboo = 1.36g/cm3

3.2.1 Density of composite


SAMPLE 1 1
ρc = 1 2 3
( ρ + ρ+ ρ )

=
1
0.6 0.4 0
( 1.2 +1.43 +1.36 )

1
=
0.779

Density of composite = 1.28 g/cm3


Weight of composite:
Wc = ρc x Vc
= 1.28 x 288
Wc = 368.64g
Weight of epoxy = 368.64 x 0.6= 221.18g
Weight of sisal fibre = 368.64 x 0.4 =147.53g

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SAMPLE 2
Epoxy = 60% Sisal = 30% Bamboo = 10%
1 1

ρc = =
0.6 0.3 0.1

( + 1.43 + ) 0.783

1.2 1.36

Density of composite = 1.27 g/cm3


Wc = ρc x Vc
=1.27 288
=365 g
Weight of epoxy = 0.6 x 365
= 219 g
Weight of sisal = 0.3 x 365 =109.5 g
Weight of bamboo = 0.1 x 365 =36.5 g

SAMPLE 3
Epoxy = 60% Sisal = 20% Bamboo = 20%
1 1

ρc = (
0.6
+
0.2
+
0.2
) = 0.787

1.2 1.43 1.36

Density of composite = 1.27 g/cm3


Wc = ρc x Vc
=1.27 x 288
=365 g
Weight of epoxy = 0.6 x 365
= 219 g
Weight of sisal = 0.2 x 365 =73 g
Weight of bamboo = 0.2 x 365 =73 g

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SAMPLE 4
Epoxy = 60% Sisal = 10% Bamboo = 30%
1 1

ρc = (
0.6
+
0.1
+
0.3
) = 0.790

1.2 1.43 1.36

Density of composite = 1.265 g/cm3


Wc = ρc x Vc
=1.265 x 288
=365 g
Weight of epoxy = 0.6 x 364
= 218.4 g
Weight of sisal = 0.1 x 364 =36.4 g
Weight of bamboo = 0.3 x 364 =109.2g

SAMPLE 5
Epoxy = 60% , sisal = 0 , Bamboo = 40%
1 1

ρc = (
0.6
+
0
+
0.4
) = 0.794

1.2 1.43 1.36

Density of composite = 1.26g/cm3


Wc = ρc x Vc
=1.26 x 288
=362.8 g
Weight of epoxy = 0.6 x 362.8
= 218g
Weight of bamboo = 0.4 x 362.8 =145.12 g

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3.3 FABRICATION METHOD
3.3.1 Surface treatment of fibers
Freshly drawn fibers generally include lots of impurities that can adversely affect
the fiber matrix bonding. Consequently the composite material made from such fibers
may not possess satisfactory mechanical properties. Therefore it is desirable to eliminate
the impurity content of the fibers and perhaps enhance the surface topography of the
fibers to obtain a stronger fiber -matrix bonding.

Figure 3.1 NaOH Solution Figure 3.2 Fibres in NaOH solution

The fibers were left to treat with 5% NaOH for 3-4 hrs. Later they were drawn
and dried under sunlight for 1-2 hours.

3.3.2 Compression molding


Compression molding has been chosen for fabrication of this composite for
achieving more mechanical and physical properties than compared to injection moulding
and hand lay up technique.
This mold is closed with a top force or plug member, pressure is applied to
force the material into contact with all mold areas while heat and pressure are maintained
until the molding materials has cured.This process employs thermosetting resins in a
partially cured stage either in form of granules or preforms.In comparison with injection
molding process, better physical and mechanical properties can be obtained in
compression molding.

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Compression molding is a well known technique to develop variety of
composite products. It is a closed molding process with high pressure application. In this
method, two matched metal molds are used to fabricate composite product. In compression
molder, base plate is stationary while upper plate is movable. Reinforcement and matrix are
placed in the metallic mold and the whole assembly is kept in between the compression
molder. Heat and pressure is applied as per the requirement of composite for a definite
period o.f time. The material placed in between the molding plates flows due to application
of pressure and heat and acquires the shape of the mold cavity with high dimensional
depends upon mold design. Curing of the composite may carried out either at room
temperature or at some elevated temperature.

Figure 3.3 Compression molding


After curing, mold is opened an composite product is removed for further
processing. In principle, a compression molding machine is a kind of press which is
oriented vertically with two molding halves (top and bottom halves).Generally, hydraulic
mechanism is used for pressure application in compression molding. The controlling
parameters in compression molding method to develop superior and desired properties of
the composite are shown in figure 2. All the three dimensions of the model (pressure,
temperature and time of application) are critical and have to be optimize deffectively to
28
achieve tailored composite product as every dimension of the model is equally important
to other one. If applied pressure is not sufficient, it will lead to poor interfacial adhesion
of fiber and matrix. If pressure is too high, it may cause fiber breakage, expulsion of
enough resin from the composite system. If temperature is too high, properties of fibers
and matrix may get changed. If temperature is low than desired, fibers may not get
properly wetted due to high viscosity of polymers especially for thermoplastics.

Application:
1. Method is equally applicable for both thermosetting and thermoplastic polymer
based Composites.
2. A very wide application spectrum ranging from kitchen goods to automobiles, toys,
electrical items and aeroplane parts.
3. Typical products include automobile panels, roof, life gates, battery trays, fenders,
hoods, bumpers, spoilers, air deflectors furniture kitchen bowls and trays, dinnerware,
buttons, large containers, recreational vehicle body panels, medical equipments
Advantages of the Compression Molding Process
1. Production rate is high as the mold cycle time is in few minutes.
2. Good surface finish with different texture and styling can be achieved.
3. High part uniformity is achieved with compression molding process.
4. Good flexibility in part design is possible.
5. Extra features like inserts, bosses and attachment can be molded in during the
processing.
6. Raw material wastage is minimum.
7. Maintenance cost is low.
8. Residual stresses are absent or negligible in the molded component.
9. Twisting and shrinkage in product is reduced therefore dimensional accuracy is
good

29
Disadvantages of compression molding process
1. Due to expensive machinery and parts, the initial capital investment associated with
compression molding is high.
2. The process is suitable for high production volume. It is not economical for making
a small number of parts or for prototyping applications.
3. It is a labour intensive process.

Application:
1. Method is equally applicable for both thermosetting and thermoplastic polymer
based Composites.
2. A very wide application spectrum ranging from kitchen goods to automobiles, toys,
electrical items and aeroplane parts.
3. Typical products include automobile panels, roof, life gates, battery trays, fenders,
hoods, bumpers, spoilers, air deflectors furniture kitchen bowls and trays, dinnerware,
buttons, large containers, recreational vehicle body panels, medical equipments
(ultrasound equipments).

30
3.4 FABRICATED SAMPLES
Sample 1

Figure 3.4 Sample 1


Sample 1: It contains epoxy 60%, sisal 40% and 0%bamboo

Sample 2

Figure 3.5 Sample 2


It contains 60% epoxy, Sisal 30% and Bamboo 10%
31
Sample 3

Figure 3.6 Sample 3


It contains 60% epoxy, 20 % sisal and 20% bamboo

Sample 4

Figure 3.7 Sample 4


It contains 60% epoxy, 10% sisal and 30% bamboo

32
Sample 5

Figure 3.8 Sample 5


It has 60% epoxy, 40% bamboo and 0% sisal.

33
CHAPTER 4
TESTING AND RESULTS
Specimen preparation as per ASTM standards
The samples are cut to the following dimensions as per ASTM standards
for testing.

Mechanical Testing of Composite Laminates

Mechanical properties such as Ultimate tensile strength (UTS), Young’s modulus,


Flexural strength (FS), Flexural modulus, Inter laminar shear strength (ILSS) of carbon
and glass fiber reinforced vinyl ester composites are computed from the test conducted
using universal testing machine (UTM) in accordance to ASTM standards for
specimen preparation. The 10 ton capacity UTM machine is supplied by Kalpak
instruments and controls, Pune, India. UTM Specification. The observed following test
results are
• Tensile test
• Flexural test
• Impact test
• Water absorption test

Table : 4.1 ASTM standards


Sl. No ASTM Code Mechanical Test Sample Dimensions (mm)

1 ASTM-D3039 Tensile 250 × 25 × 3.2

2 ASTM-D790 Flexural 127 ×12.7× 3.2

3 ASTM-D256 Impact 63.5 ×12.7× 3.2

4 ASTM-D590 Water absorption 20 ×20 × 3.2

34
4.1 TENSILE TEST
1. The tensile is one of the important test performed on the material, it is simple,
relatively inexpert tensile specimen is a standardized sample of cross section.
2. ASTM D3039 is a helpful guide when testing polymer matrix composite
materials reinforced by high-modulus fibers.
3. ASTM D3039 determines the tensile properties of the composite for research
and development, quality assurance, and structural analysis and design.

Table: 4.2 Specifications Of Universal Testing Machine


Parameter Specifications

Capacity 10 tones

Load frame Mild steel C channel with double ball screw


mechanism pre-loaded ball screw with zero
backlash covered with bellow
Mounting Free standing

Load range 1 kg-1000 kg using 1 ton load cell


1 kg-10000 kg using 10 ton load cell

Mechanical properties such as Ultimate tensile strength (UTS), Young’s


modulus, Flexural strength (FS), Flexural modulus, Inter laminar shear
strength (ILSS) of carbon and glass fiber reinforced vinyl ester composites
are computed from the test conducted using universal testing machine
(UTM) ) in accordance to ASTM standards for specimen preparation. The 10
ton capacity UTM machine is supplied by Kalpak instruments and controls

35
30
Tensile strength N/mm² 27.851 27.213

25
23.25 22.622

19.679
20

15

10

0
sample 1 sample 2 sample 3 sample 4 sample 5

Samples

Figure 4.1 Tensile strength


Table: 4.3 Tensile strength

Sample CS Pea % Bre UTS


no Area k elongati ak (N/mm
(mm² load on load )
) (N) (N)
1. 75.0 1743.36 1.76 10.6 3611.6
00 5 0 63 12

2. 75.0 2088.9 3.53 2088.9 4193.80


00 90 0 90 8

3. 75.0 1696.3 1.76 1577.3 3992.


00 84 0 70 560

4. 75.0 1475.5 2.35 1466.5 3879.29


00 61 0 85 0

5. 75 204 2.35 839. 179


0
.0 0.90 36 667 3.25
00 2 0
4.2 FLEXURAL TEST

Figure 4.2 Flexural test

ASTM D 790 is the Standard Test Method for Flexural Properties of Polymer
Composite. The samples are cut to the dimensions as per ASTM standards for flexural
testing. The test specimen geometry as specified in the above standard for balance
symmetric carbon and glass fiber composites (0/90) are width 12.7 mm, length 127
mm, thickness 6 mm.
35
32.859 33.262
30.997 31.638

30
27.455

25
Flexural Stength Mpa

20

15

10

0
sample 1 sample 2 sample 3 sample 4 sample 5
Samples

Figure 4.3 Flexural test graph

37
Sample no CS Peak Break Flextural Flextur
Area load load strength al
(mm²) (N) (N) (Mpa) modulu
s (Gpa)
1. 39.000 38.77 0.0 30.997 3611.6
0 7 00 12

2. 39.000 40.68 0.0 32.859 4193.8


0 2 00 08

3. 39.000 41.18 0.0 33.262 3992.5


0 2 00 60

4. 39.000 39.17 0.0 31.638 3879.2


0 1 00 90

5. 39.000 33.99 0.0 27.455 1793.2


0 2 00 50

Table : 4.4 Flexural strength

38
4.3 IMPACT TEST

➢ Impact test determines the amount of energy absorbed by a material


during fracture. The absorbed energy is a measure of a given materials
notch toughness and acts as a tool to study temperature dependent ductile-
brittle transmission.
➢ The specimen is prepared as per ASTM D256 standard size.
63.5

12.7mm

3m
Figure 4.4 Impact test

0.4

0.35
0.35

0.3 0.3 0.3


0.3
Impact test J Value

0.25
0.25

0.2

0.15

0.1

0.05

0
sample 1 sample 2 sample 3 sample 4 sample 5
Samples

Figure 4.5 Impact test graph


39
S.NO Izod impact value
in J

1. 0.30

2. 0.25

3. 0.30

4. 0.35

5. 0.30

Table: 4.5 Impact test

4.4 WATER ABSORPTION TEST

1. One of the most important properties of a good quality composite is low


permeability, especially one resistance to freezing.
2. The test procedure involves drying a specimen to a constant weight, weighing it.
3. Then immersing it in water for specified amount of time and weighing it again.
4. The increase in weight as a percentage of the original weight is expressed as its
absorption
5. The average sample of the test samples shall not be greater than 5%

40
SI.NO Water Absorption %

1 1.035

2 3.172

3 5.242

4 5.454

5 4.979

Table: 4.6 Water absorption test

Series 1
6
5.454
5.242
4.979
5
Water Absorbtion %

3.172
3

1.035
1

0
sample 1 sample 2 sample 3 sample 4 sample 5
Samples

Figure 4.6 water absorption test

41
4.5 ADVANTAGES
1. The main advantages of polymer matrix composite are:
2. Low specific weight, resulting in a higher specific strength and stiffness
than glass fiber.
3. Low density: which may lead to a weight reduction of 10 to 30%.
4. Producible with low investment at low cost, which makes the material
an interesting product for low wage countries.
5. Reduced wear of tooling, healthier working condition, and no skin
irritation.
6. High Damping and no corrosion
7. High strength to density ratio and high modulus to density ratio
8. Design flexibility can be made per requirement.
9. Occupational health benefits compared to glass fibers during production.

4.6 APPLICATIONS

Polymer composites can be used in many different forms ranging from structural
composites in the construction industry to the high technology composites of the
aerospace and space satellite industries
The following are some of them
1. 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.
2. Storage devices: post-boxes, grain storage silos, bio-gas containers, etc.
3. Furniture: chair, table, shower, bath units, etc.
4. Electric devices: electrical appliances, pipes, etc.
5. Everyday applications: lampshades, suitcases, helmets, etc.
6. Transportation: automobile and railway coach interior, boat, etc.

42
CHAPTER 5
CONCLUSION
These natural fibers have been successfully reinforced with the epoxy
resin by compression molding. The aim of this work is to find the tensile,
flexural, water absorption and impact strength of natural fiber reinforced
composites with varying compositions. The fibers like bamboo fibers and sisal
fibers were successfully used to fabricate hybrid-composites with varying the
fiber percentage and also find that density of the composite decreases with
decreasing the percentage of sisal fibre in the composites. The composite
sample 2 shows the maximum value of mechanical properties like tensile and
flexural as compared to other samples. Water absorption properties is increased
with increase in percentage of bamboo fibre. These hybrid composite can be
used in Aerospace and automobile applications. So, it is clearly indicates that
reinforcement of natural fibers have good and comparable mechanical
properties as conventional composite materials.

43
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