THREE BODY ABRASIVE WEAR BEHAVIOR OF GLASS FIBER

REINFORCED EPOXY COMPOSITES WITH ALUMINA-GRAPHITE FILLER

Haseebuddin M.R 1, Puneeth Subramanian 2, Chidambaram G 2, Tridib Das 2

1
Research Scholar/Lecturer, Department of Mechanical Engineering, DSCE, Bangalore.
Email: thereckoner@rediffmail.com
2
UG Scholar, Department of Mechanical Engineering, DSCE, Bangalore – 560078
Email: puneethms@gmail.com, chiduconner@gmail.com, tridibeinstein@gmail.com

ABSTRACT

In this study, effect of alumina-graphite filler blending on Three Body Abrasive wear
Behavior of glass fiber reinforced epoxy composites is evaluated.
Glass fiber epoxy composites without filler and with 2%, 4%, 6% and 8% filler additions
are fabricated by ‘Hand Lay Up’ method. Each composite with filler additions has equal
percentage of alumina and graphite by weight. Specimens from the fabricated plates are
cut and Three Body Abrasive wear are conducted in accordance with ASTM G65. Tests
were conducted for abrading distances of 150 m, 300 m, 450 m and 600 m. Specific wear
rate of different composites is compared for different abrading distances.
Three body abrasive wear tests were conducted and results show increase in specific
wear rate with increase in filler content for different abrading distances. A comparison
between specific wear rates of different filler content is graphically represented.
Also surface morphology is done to study the nature of damage at the surface of the
composites.

Key Words: Alumina-Graphite Blending, Epoxy, Three Body Abrasive Wear, Surface
Morphology.

1. INTRODUCTION

Polymers and their composites have generated wide interest in various engineering
fields. Glass fiber reinforced polymer composites are being increasingly used because of
their low weight, manufacturing flexibility [1], low density, and anti-corrosion properties
in automobile, aeronautical and marine applications. According to some studies polymer
composites reduces component weight up to 50% if aluminum is replaced by polymer
composites. The mechanical properties of polymer composites depend strongly on size,
shape and distribution of filler particles in the polymer matrix and good adhesion at the
interface surface [3].Using particulate fillers into polymers improves various physical
properties of the materials such as mechanical strength, modulus, and heat deflection
temperature [2,8].
Epoxy or polyepoxide is a thermosetting polymer formed from reaction of an
epoxide "resin" with polyamine "hardener". The resin consists of monomers or short
chain polymers with an epoxide group at either end. The hardener consists of polyamine
monomers. When these compounds are mixed together, the amine groups react with the
epoxide groups to form a covalent bond. Each NH group can react with an epoxide
group, so that the resulting polymer is heavily cross linked, and is thus rigid and strong.
Epoxy resins resist moisture and other environmental influences and offer lower
shrinkage and better mechanical properties. The applications for epoxy based materials
are extensive and include coatings, adhesives and composite materials such as those
using carbon fiber and fiberglass reinforcements. In general, epoxies are known for their
excellent adhesion, chemical and heat resistance, good to excellent mechanical properties
and very good electrical insulating properties.
Aluminium oxide is the family of inorganic compounds with the chemical
formula Al2O3. It is an amphoteric oxide and is commonly referred to
as alumina, corundum as well as many other names, reflecting its widespread occurrence
in nature and industry. Its most significant use is in the production of aluminium metal,
although it is also used as an abrasive due to its hardness and as a refractory material due
to its high melting point. It is cost effective and has excellent dielectric properties, good
thermal conductivity[9]. It also resists strong alkali and acid attacks at elevated
temperatures and also available in purity ranges from 94% to 99.5%.
Graphite is an allotrope of the chemical element carbon and is denoted by the
symbol 'C'. It is very soft and has a greasy texture. Although graphite is soft and flexible,
it is not elastic in nature. It is inert to almost all chemicals and hence insoluble in water
and other organic solvents.

Fig 1: Crystal lattice of Graphite

Graphite has a sheet like structure where the atoms all lie in a plane and are only
weakly bonded to the graphite sheets above and below. carbon atoms are in flat sheets
and within the sheet, they are arranged in hexagons. Each carbon atom in graphite is
directly linked to only three carbon atoms through covalent bonds. Therefore, of the four
valence electrons in a carbon atom only three are used for bonding and the fourth is
relatively free and can move from one atom to the other. The layers are held by
comparatively weak forces. As a result, the layers are separated by large distances and
can easily slide over the other. The distance between the layers is more than double the
distance between the carbon atoms. This explains the lower density of graphite and also
the slippery nature of graphite.
Abrasive wear is the most important among all the forms of wear because it
contributes to 63% of the total cost of wear. Abrasive wear situations are encountered in
applications such as vanes and gears; pumps handling industrial fluids; bearings in steel
mills subjected to heat; chute liners abraded by coke, coal and mineral ores etc [10].
Abrasive wear is caused due to hard particles that are forced against and move along a
solid surface. The abrasive wear is divided into two groups: two-body and three-body
abrasive wear. In two-body abrasive wear, wear is caused by hard particles on one
surface which can only slide over the other. In three-body abrasion, particles are trapped
between two solid surfaces but are free to roll as well as slide. The rate of material
removal in three-body abrasion is one order of magnitude lower than that for two-body
abrasive wear, because in three-body abrasion the loose particles abrade the solid
surfaces between which they are situated to an extent of only about 10% of the time in
sliding, while they spend about 90% of time in rolling [11].
Three-body abrasion is generally considered more practical, it appears to have
received less attention than a two-body problem. In the last few years, some studies on
polymer composites subjected to abrasive wear are available [4,5,6,7].
Although, A good amount of work has been reported on the three body wear
behavior of polymer matrix composites as in mentioned references above, no literature
could be cited on the abrasive wear aspect of GF/epoxy composites with mixture of
alumina-graphite fillers. Hence an attempt has been made in this work to understand the
role of alumina-graphite filler on three body wear behavior of glass fiber reinforced
epoxy composites.

2. EXPERIMENTAL
2.1 Materials

Composites plates are prepared using glass fibre fabric (200 g/m3) as reinforcement and
epoxy resin is used as matrix material. The hardener used is Araldite HY 951. A mixture
of graphite and alumina in equal percentages is used as filler material.

2.2 Sample Preparation

Fabrication was done by “Hand Lay Up” method and composites are cured at room
temperature. Epoxy resin is well stirred with 10% hardener (Araldite HY 951). Then
glass fabric is placed on the polyester matrix layer. Alternative layers of matrix and glass
fabric are placed and rolled using a roller to remove any tapped air. 13 layers of glass
fibre fabric were used to get the required thickness of 2.5 mm, which was maintained by
using stoppers of 2.5 mm thickness. The procedure was repeated to fabricate 4 more
plates with the addition of mixture of alumina and graphite as filler material in steps of
2%, 4%, 6% and 8% respectively. Specimens were cut in accordance with ASTM G65.
Details of compositions of composites fabricated are given in the table below.

Table 2.1: Details of composition of composites

Samples Matrix Wt. % Reinforcement Wt. % Fillers Wt. %
Alumina Graphite
Epoxy–Glass Fiber 60 40 0 0
Epoxy-Glass Fiber-Filler 60 38 1 1
Epoxy-Glass Fiber-Filler 60 36 2 2
Epoxy-Glass Fiber-Filler 60 34 3 3
Epoxy-Glass Fiber-Filler 60 32 4 4

3. THREE BODY ABRASIVE WEAR TEST

Abrasive Wear Studies

The tribological behavior of Glass fiber reinforced Epoxy composites with and without
filler were studied using a Dry Sand Abrasive Tester as per ASTM G65. Specimens of
size 75mm x 25mm were weighed (Initial Weight) and were held against the rotating
wheel of diameter 200 mm.
The abrasive particles of AFS 60 grade silica sand were angular in shape with sharp
edges the abrasive was fed at the contacting face between the rotating rubber wheel and
the test sample. The tests were conducted at a rotational speed of 200 rpm. The rate of
feeding the abrasive 250 ±5 g/min. The sample was cleaned (dry) and its initial weight
determined in a high precision digital balance (0.1 mg accuracy) before it was mounted in
the sample holder. The abrasives were introduced between the test specimen and rotating
abrasive wheel composed of cholorobutyl rubber tyre (hardness; Durometer-A 58-62),
the test specimen was pressed against the rotating wheel at a specified force by means of
lever arm while a controlled flow of abrasive abrades the test surface. The rotation of the
abrasive wheel was such that its contacting face moves in the direction of sand flow, the
pivot axis of the lever arm lies within a plane, which is diameter along which the load is
applied. At the end of a set test duration, the specimen was removed, thoroughly cleaned
and again weighed (final weight). The difference in weight before and after abrasion was
determined. At least three tests were performed and the average values so obtained were
used in this study, the experiments were carried out at 23 N loads at a constant sliding
velocity of 2.15 m/s. Furthermore, the abrading distances were varied in steps of 150m
form 150-600m. For the second (i.e., longer duration test; involving say 300m distance)
the abrasion test were carried out on the same wear track where first (i.e., 150 m) shorter
runs were involved. The wear was measured by the loss in weight, which is then
converted into wear volume using the measured density data. After the wear test, the
sample was again cleaned. The specific wear rate (Ks) was calculated from the equation
 Ks = V/LD m3/Nm ………………... equ 3.1
Where
V is the volume loss in m3,
L is the load in Newton and
D is the sliding distance in meters.

4. RESULT AND DISCUSSION

Fig 4.1: Wear Volume v/s Abrading Distances

 Fig 4.2: Specific Wear Rate v/s Abrading Distances

It is observed from figure 4.1, blending of alumina-graphite fillers with glass fiber
reinforced epoxy composites has led to increase in wear volume when compared to
composites with out fillers. Glass fiber woven mat reinforced epoxy composites without
filler has lesser wear volume compared with composites with fillers. Wear volume
increases with increase in filler content at 150 m abrading distance. Also wear volume
was evaluated at 300m, 450 m, and 600 m abrading distances and it is found to be
increasing with increase in abrading distances. From the wear volume the Specific wear
rate (Ks) was calculated and it tends to increase with increase in filler content as shown in
figure 4.2.

Surface Morphology

Fig 4.3: 0 % filler content Fig 4.4: 2 % filler content

 Fig 4.5: 4% filler content Fig 4.6: 6% filler content

Glass fiber reinforced epoxy composites without and with different filler content
subjected to different abrading distances at load of 23 N are displayed in figure 4.3 to fig
4.6 using Vision Measuring Machine. Figure 4.3 shows worn surfaces of composites
without filler at constant load of 23 N at abrasive distances of 150 m. The worn surfaces
of composites with 2%, 4% and 6% fillers are shown in figures 4.4 - 4.6 respectively. It
can be seen from figures that formation of tracks by plowing. Surface exhibits scratches
owing to ploughing. Photomicrographs of composites with higher filler content at
abrading distance of 150 m show higher surface damage and the tracks are found to be
more. Matrix wear and distortion is found to be more compared to composites without
filler.

6. CONCLUSIONS

The following are the salient observations made from the above investigation.

Differing trend in abrasive wear volume were seen with increase in filler content
in glass fabric reinforced epoxy resin composites.

The abrasive wear volume strongly depends on the applied load and abrading
distance for all composites.

With addition of weight percentage of alumina-graphite filler were observed to be
not beneficial to abrasive wear performance. There is increase in tracks by
plowing at higher abrading distances.
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