DESIGN AND FABRICATION OF SANDWICH

COMPOSITE PANELS

A PROJECT REPORT

Submitted by

M.AJITHKUMAR (720315114006)

J.ARUNKUMAR (720315114015)

C.FRANCISKENNATHAMRETH (720315114034)

S.NANDHA KUMAR (720315114075)

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

AKSHAYA COLLEGE OF ENGINEERING AND TECHNOLOGY

KINATHUKADAVU, COIMBATORE-642 109

ANNA UNIVERSITY:: CHENNAI-600 025

APRIL 2018
 ANNA UNIVERSITY: CHENNAI-600 025

BONAFIDE CERTIFICATE

Certified that this project report on “DESIGN AND FABRICATION OF

SANDWICH COMPOSITE PANELS” is the bonafide work of

M.AJITHKUMAR (720315114006)

J.ARUNKUMAR (720315114015)

C.FRANCISKENNATHAMRETH (720315114034)

S.NANDHA KUMAR (720315114075)

Who carried out the project work under my supervision

SIGNATURE SIGNATURE
Mr.M.SELVARAJU,M.E.,(Ph.D)., Mr.A.KANAGARAJ,M.E.,
HEAD OF THE DEPARTMENT SUPERVISOR
Associate Professor Assistant Professor
Dept of Mechanical Engineering, Dept of Mechanical Engineering,
Akshaya College of Engineering and Akshaya College of Engineering and
Technology, Technology,
Kinathukadavu, Kinathukadavu,
Coimbatore – 642 109. Coimbatore – 642 109.

Submitted for the university Viva-voce held on_______________________

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

The success of a work depends on the terms and its cooperation. We take
this opportunity to express our gratitude and sincere thanks to everyone who
helped us in our project. First and foremost, we would like to thank our
management for the excellent infrastructure, facilities and the support provided for
the successful implementation of the project work.

We are indebted to the Director, Dr.K.THANUSHKODI,M.Sc.,Ph.D., for

his continuous motivation, inspiring words and guidance throughout this project.

We express our sincere thanks to the Joint Director,

Dr.N.SUGUNA,M.E.,Ph.D., for her valuable guidance and support.

We express our heartfelt thanks and deep sense of gratitude to the principal
Dr.J.JAYA,M.Tech.,Ph.D., for the continuous encouragement, guidance and
support.

Our special thanks to Prof.M.SELVARAJU,M.E.,(Ph.D)., Associate

Professor and Head Of the Department of Mechanical Engineering for his valuable
guidance, continuous support and suggestions to improve the quality of the project
work.

We express our sincere thanks to our guide Mr.A.KANAGARAJ,M.E.,

Assistant Professor, Department of Mechanical Engineering, for his valuable
guidance, insightful comments and continuous support to carry out the project
work.

Our sincere thanks to our faculty members, family members and friends
for their support and motivation to carry out the project successfully.
 TABLE OF CONTENTS
CHAPTER PAGE
TITLE
NO. NO.
ABSTRACT I
LIST OF SYMBOLS AND
Ii
ABBREVIATIONS
LIST OF TABLES Iii

LIST OF FIGURES Iv

1. INTRODUCTION 1

1.1 OVERVIEW 1 1

1.2 COMPOSITE MATERIALS 2

2. LITERATURE REVIEW 7

3. OBJECTIVE 12

4. METHODOLOGY 13

4.1 PROCESS LAYOUT 13

4.2 MATERIALS 14

4.3 DESIGN AND CALCILATIONS 18

4.4 PREPARATION 29

4.5 COMPARISION OF RESULTS 30

5. BLOCK DIAGRAM 31

5.1 MAIN PARTS 31

6. BILL OF MATERIALS 32

7. TESTING PROCEDURES 33

7.1 BEND TEST 34

8. ADVANTAGES AND DISADVANTAGES 36

 8.1 ADVANTAGES 36

8.2 DISADVANTAGES 36

9. APPLICATIONS 37

10. COST ESTIMSTION 38

11. CONCLUSION 39

REFERENCES

PHOTOGRAPHY
 ABSTRACT

The main aim of this project is to develop sandwich composite panels.

Aluminum AL 6061 sheet is taken as base material and bottle caps are used as

core. The structure is formed by bonding of Epoxy resin between the base, face

and core. The formed panels exhibit high strength, low mass density and less

weight compare to wood. Due to its superior performance, the composite panels

are mainly used in doors, frames; auto materials are widely used in the automobile

industry, especially for vehicle body applications. Aluminum Composite with

plastic honeycomb sandwich structures is therefore of great significance. In this

project Sandwich Composite with Aluminum with Bottle cap specimen is

subjected to bend test and it exhibits high bending strength.

i
 LIST OF ABBREVIATIONS

MMC Metal matrix composites

Al Aluminum
PVC Polyvinylchloride

UTM Universal Testing Machine

SI Silicate
AR Acryl ate

ii
 LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

4.1 Polar Moment of Inertia 22

4.2 Bending Moment 23

4.3 Comparisons 30

6.1 Bill of Materials 32

10.1 Cost Estimation 38

iii
 LIST OF FIGURES

FIGURE NO. DESCRIPTION PAGE NO.

1.1 Basic Construction of Composites 2

1.2 Particle Reinforced Composites 3

1.3 Fibre Reinforced Composites 3

1.4 Laminar Composite Panels 4

1.5 Sandwich Composite Panels 5

1.6 Formation of Sandwich Panels 6

5.1 Block Diagram of Sandwich Composite 31

Panels

7.1 Bend Test 34

7.2 Sandwich Composite Bend Test in UTM 35

7.3 Specimen After Bend Test 35

iv