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208
International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai
Epoxy
(wt. %)
40
38
36
34
209
International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai
Theoretical
density
(g/cm3)
1.64
Measured
density
(g/cm3)
1.636
Void
fraction
(%)
2.4
2CSP-C-E
1.53
1.518
7.8
4CSP-C-E
1.55
1.532
12.9
6CSP-C-E
1.58
1.556
22.1
Sample
C-E
Mechanical properties
The mechanical properties of carbon fabric reinforced
epoxy (C-E) filled with different content of cenospheres
(CSP) are shown in Figures 1 and 2 From these figures, it can
be seen that the loading of CSP greatly decreased the tensile
strength, flexural strength, and significantly increased the
tensile modulus and flexural modulus of C-E composite,
which can be attributed to the high modulus and hardness of
the carbon fibers. In the experimental range, the best
mechanical properties were obtained with the C-E composite
with 4 wt.% CSP.
Tensile strength (MPa)
S
= 10 log 1 y 2
n
N
(1)
769.69
780
760
740
720
700
680
660
640
620
600
708.915
675
664
C-E
C-E +
2%Ceno
C-E +
4%Ceno
C-E +
6%Ceno
Composites
(a)
Tensile modulus (GPa)
120
100
80
72.84
72.98
C-E
C-E +
2%Ceno
97.8
95.9
C-E +
4%Ceno
C-E +
6%Ceno
60
40
20
0
Composites
(b)
1200
1000
996.205
968.735
800
800
865.245
600
400
200
0
C-E
C-E +
2%Ceno
C-E +
4%Ceno
C-E +
6%Ceno
Composites
(a)
Flexural nodulus (GPa)
Density
The theoretical and measured densities of all composite
samples along with the corresponding volume fraction of
voids are presented in Table 3. It may be noted that the
composite density values calculated theoretically from weight
fractions using rule of mixtures and are not in agreement with
the experimentally determined values. The difference is a
measure of voids and pores present in the composites. It is
clear from Table 3 that the percentage of voids in an unfilled
C-E is negligibly small i.e. 0.20% and this may be due to the
absence of any filler. With the addition of light weight fly ash
cenosphere, the volume fraction of voids is found to be at
about 1%.
76
74
72
70
68
66
64
62
66.4
C-E
74
73.5
C-E +
4%Ceno
C-E +
6%Ceno
67.4
C-E +
2%Ceno
Composites
(b)
Fig. 2 Mechanical properties of CSP-filled C-E. (a) Flexural strength,
(b) Flexural modulus.
International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai
Erosion rate
Main effects plots for S/N ratios and their interactions of
samples are shown in Figures 5 and 6 respectively. It can be
seen that the erosion rate was a maximum at 300 impingement
angle for both composites at the different impact velocities
studied. It is known that impingement angle is one of the most
important parameters for the erosion behaviour of materials.
In the erosion literature, materials are broadly classified as
ductile or brittle, based on the dependence of their erosion rate
on impingement angle. The behaviour of ductile materials is
characterized by maximum erosion rate at low impingement
angles (1530). Brittle materials, on the other hand, show
maximum erosion under normal impingement angle (90).
Reinforced composites have been shown, however, to exhibit
a semi-ductile behaviour with maximum erosion occurring in
the angular range 450600 [3]. However, in the literature
mixed trends have been reported even for nominally brittle or
ductile materials. According to Hutchings [20], materials can
show either ductile or brittle behaviour. If the erosion
conditions are changed, such as impingement angle, impact
velocity, particle flux, erodent properties such as shape,
hardness or size, etc. Tilly and Sage [25] investigated the
influence of velocity, impingement angle, particle size and
weight of impacted abrasive for nylon, carbon fiber reinforced
nylon, epoxy, polypropylene and glass fiber reinforced plastic.
Their results showed that, for the particular materials and
conditions of their test, composite materials generally behaved
in an ideally brittle fashion (i.e. maximum erosion rate
occurred at normal impact). Miyazaki and Takeda [26],
Miyazaki and Hamao [30], reported that the peak erosion rate
for neat nylon, ABS and epoxy matrix occurs at around 300
impingement angle. However, in the case of carbon or glass
fiber reinforced nylon, ABS, and epoxy composites the peak
of the erosion rate shifts to a larger value of impingement
angle (60). However, in the present study, peak erosion rate
were observed at 300 for both composites. A possible reason
for the erosion behaviour found in the present study is that
high modulus carbon fiber was used as reinforcement for the
epoxy matrix are typical semi-ductile materials, so that
erosion is mainly caused by such damage mechanisms as
micro-cracking due to the impact of solid particles. The
TABLE 5
ANALYSIS OF VARIANCE FOR SN RATIOS
TABLE 4
SIGNAL TO NOISE RATIO (S/N) TABLE FOR EROSION RATE
Velocity
(A)
-58.06
-58.59
-63.18
5.12
2
Level
1
2
3
Delta
Rank
Filler
(B)
-66.76
-60.80
-52.26
14.50
1
Erosion
time (D)
-59.44
-60.20
-60.18
0.76
5
Angle (C)
-61.19
-57.78
-60.84
3.41
3
Erodent
size (E)
-59.23
-60.70
-59.89
1.48
4
Source
DF
Seq SS
Adj SS
Adj MS
Vel
142.66
142.662
71.331
3.91
Filler
955.91
955.911
477.956
26.17
0.000
0.042
Angle
63.26
63.265
31.632
1.73
0.208
Erosion
time
3.43
3.430
1.715
0.09
0.911
Erodent
size
9.83
9.833
4.916
0.27
0.767
Residual
Error
16
292.20
292.196
18.262
Total
26
1467.3
Main Effects Plot for SN ratios
Data Means
VELOCITY
-52
FILLER
ANGLE
-56
Mean of SN ratios
-60
-64
-68
30
40
50
ERO TIME
-52
30
60
90
ERO SIZE
-56
-60
-64
-68
2
212
425
600
International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai
V. REFERENCES
[1]
[2]
[3]
[4]
Interaction Plot for SN ratios
Data Means
[5]
VELOCITY
30
40
50
-50
[6]
Mean
-55
[7]
-60
[8]
-65
[9]
-70
0
2
FILLER
[10]
[11]
[12]
IV. CONCLUSIONS
Based on the research presented in this paper the following
conclusions are drawn:
1. Inclusion of cenospheres filler in the C-E composite
decreases the tensile strength as well as the density.
However, CSP filler loading into C-E greatly
increased the tensile modulus and flexural modulus.
2. The addition of cenospheres filler in carbon fabric
reinforcement epoxy composites have shown marked
improvement in erosion wear behaviour.
3. Erosion characteristics of the composites have
successfully analyzed using Taguchi experimental
design. Taguchi method provides a simple,
systematic and efficient methodology for the
optimization of the control factors.
4. Factors like filler content, impact velocity,
impingement angle, erodent time and erodent size are
found to be the significant control factors affecting
the erosion rate. The erosion time is identified as the
least significant parameter as far as the wear of such
composites is concerned.
5. From the Taguchi experimental design, Filler content
is identified as the most significant factor influencing
the erosion wear of cenosphere filled carbon fabric
reinforced
epoxy composite. Further, this
investigation reveals that maximum erosion takes
place at the impingement angle of 30.
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
[21]
[22]
[23]
212
International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai
[24] Tilly G. P., Sage W.: The interaction of particle and material
behavior in erosion process. Wear, 16, 447 465 (1970).
[25] Zahavi J., Schmitt G. F.: Solid particle erosion of reinforced
composite materials. Wear, 71, 179190 (1981).
[26] Miyazaki N., Takeda T.: Solid particle erosion of fiber reinforced
plastics. Journal of Composite Materials, 27, 2131 (1993).
[27] Bitter J. G. A.: A study of erosion phenomena part I. Wear, 13, 5
21 (1963).
[28] Bitter J. G. A.: A study of erosion phenomena part II. Wear, 13,
169190 (1963).
[29] Roy M, Vishwanathan B, Sundararajan G. The solid particle
erosion of polymer matrix composites. Wear;171:14961.(1994)
[30] Miyazaki N, Hamao T. Effect of interfacial strength on erosion
behaviour of FRPs. Journal of Composite Materials;30:35 50.
(1996)
[31] Mody, P.B., Chou, T.W. and Friedrich, K.. Effect of Testing
Conditions and Microstructure on the Sliding Wear of Graphite
Fiber/PEEK Matrix Composites, J. Mat. Sci., 23(12): 4329-4330.
(1988)
[32] ASTM D 2583-07, Standard test method for indentation hardness
of rigid plastics by means of a Barcol impressor. ASTM
International. Revision as of 2007-03-01.
[33] R.V. Kurahatti, A.O. Surendranathan, S. Srivastava, N. Singh,
A.V. Ramesh Kumar and B. Suresha. Role of zirconia filler on
friction and dry sliding wear behaviour of bismaleimide
nanocomposites. Mater Design;32:2644-2649. (2011).
[34] S.M. Kulkarni, Kishore. Influence of matrix modification on the
solid particle erosion of glass/epoxy composites. Polym Polym
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