Unit-2

Part-A l. What are thc tYPesof fillers? carbonate Calcir"rm Clay '[alc TrihYdrate Aluminium Silica Microspheres Mica 2. What are the functions of fibres? 'r and stiffnessin one Carry load alongthe lengthof the fibre providesstrength direction. ./Canbeorientedtoprovidepropertiesindirectionofprimaryload 3. Define fibre orientation? of the pliesplaysa major sequence in eachlayeras wellas stacking orientation F.ibre and modulusof compositelaminate' role in the strength 4. Dcfine ma{rix? F].lieessentialhhomigenousmatcrialinrvhiclitheflbresorfilamentsofcompostte areernbedded. / Fibresare reinforcedinsidethe matrix' / Act as a load transfermedium' ', Keep fibre in desiredlocationand orientation' 5. What is meant bY resin? weight and no sharp An organicmaterialwith indefiniteand usuallyhigh molecular meltingpoint. 6. What is meant bY lamina? A singleply or layer in a laminatemadeof a seriesof layers'

Part-B process? very briefly hand-lay up I trl,xplain up lar Hand , | .,. t,^, 'flie and is labourintenstve' lav up rnethodrequiredvcry littlc capitalequipment r this methodis very cconomical' For limitedproduction 'l'hc up to30oh volume' productionmethodis suitablefor reinforcement F in the form of woven roving is as lbllows. Reinforcement process F T'heproduction agentto u'ith a release or choppedstrandtnat is placedinsidea mould coated m i n i m i z es t i c k i n g ' '/ e and protectivesurfaceon The rnould is given a gel coat that providesa decoratir the comPonent. 'r with resinin liquid forrnis rnixcdrvith a curins agentand applied A thcrmosetling gets into the gap of the a brush or roller in such a way that thc matrix reinfbrcement. r traterial'Viscosityof the matrix resin and arc widcll' used as t.natrix Polr,csters production rate which is curring timc are irnportantfrom thc point of view of

characteristically lessrviththis rnethod. / Mechanical properlies are sometimes adversely affected by trapped air. Reproducing productproperlies is alsodi{ficult. Advantage of hand lay up of compositestructure 'r Designflexibility 'fooling

cost is low

F Designchanges arc easilyeffected

Disadvantage 'r Only one molded surfbceare obtained '/ F t

l.ow volumeprocess. Longercuretime required. Resins nced to low in viscosity to be workable by hand. This generalll,' comprisestheir mechan ical/thermal properties.

Application '/ wind turbine blades Standard F r / . Boats Archietectural rnouldings. Auto and truck body parls Furniture and accessories

:i'-,:r Alr,,:'r,l $ lri '.r,";l-lr.,t l-n:r-r.,:; L;il rr ::i,r illr; 1r; 1J ;,r 11;,;J lii l-.i l,r I

I h-

:'/'r-)tl 'l I N. I

'0:en'l=erulle |llould Tcrsr Supporting Trnnber. Steel or u$ter sirucrure

Discussthe working principle of injection moulding process?

Iniectionrnouldingrefersto a process that generallyinvolvesfbrcing or injectinga fluid plasticmaterialinto a closedrnold. It is cliflerentiated fiom compression molding in which plasticmaterial in a soft but not fluid condition are formed by transferring them into an openmold which is thenforciblyclosed. 'l'his nrethod is not normallyusedin polymericmatrix compound processes due to fibre damage in the barallcl. Sorreof tlrc reinlbrced thennoplastic composiles rvhichare cornrlonlyinicction molded include nylon.PVC, acetal, polyelhy,lene. polypropylene.

Injectionrnolded thermoset resininclude polycsler. epoxy.phenolic.

5 Reinfbrcement are typicallvglassfibre in the rangeof 0.l25-0.5in length.Fibreloading

var-rtiorn 5% to 10o/oby weight. The molding compoundis feed into injectionchamberthroughthe feed hoppcr.The rnolding colrpoundis heated in the injection charnbcr uhere it changes to liquid forni

7 11 is lbrcedinto the infectionmold by the plunger. 8

'l'hc inicction rrtolding proce ss gencralll' has the lirllonins adrantase over the

cornprcssio rr m olding More readilr automated process /

Permitsfiner part detail. 'l-he parl and the mold can olten bc designed in a rnanncr so that no subsequent

trinrrning or machinitrg operations arc required. Howeverall plasticmaterialcannotbe i n-jected molded succcssfu I l1'.

t 0 Thereare two basiccategories of plasticinjectionmolding

', Thermoplastic

il

In the fbrmer a thennoplasticmaterialis melted and forced through an orifice into the -fhe mold. which is kept relativell,cool. materialsolidifiesin the mold from which it canthenbe rcmoved

t2 In thermoset,injectionmolding the solidificationoccursat high temperature. Therefore

a rcactionmaterial is forced into a generallywarm nrold in which the material fLrrther polymerizes into solid par1"

l 3 This method is nonnally usedfor high volume and low cost componentmanufacturing.
The disadvantage of the method is that it is limited to materialswith very shoft fibre length.Also since tlrerc is large amount of flow during the process, materialnonuniforrnities do cxist.

In,icction lltolding

ru

l5 Explain spray up processvery briefly? Spray up method '/ Sprayrnethodlacilitates a highcrratcof production. '. Howcverwitlr tlris'Tethod. continuous fibre cannotbe used. / Chopped f-ibre.resin and catalyst (accelerates the curing) are fed into a gun which spraysthe mixtureon to the mould which is coatedwith a release asenr lor nonstickirrg and a gel fbr a decorative and protectivesurfacc.

obtainsmoclth surfbcc llnish. r lrillcrssuchas calciumcarbonate and alurninium trihydrate can be incorporated in the spravup resirr to irnprove cerlainpropefties. reduce cost. F General purpose polyester resin are the normal resun used in sprav up application. lsophthalic polycster and vinvlester arealso used. F '/ Sprav up parts are typically curcd at room temperature however mild external heat is sometimes appliedto accelerate the rateof cure. Typicallv spray up reinlbrcement are glassfibre choppedinto lengthsof t/z inch and I I 12 incl't.Extra reinforcernent in the fonn of mats. woven rovins. fabric tapeor other can be placedb,vhand as rcquired. 'r Additionalresincan be appliedusingthe sprayup gun resin.Inaddition. similar to hand lay up. VariouscoreInaterial can bc embedded in the Iaminate including honevcomb. PVC or polyurethane foam, plywood. balsa.corrugated sheet.

Advantage F F / / . Effectiveprocess to producew,idcvariety of compositepans. IJses low costtoolingand sirnple rranufbcturing method. Well suitedto produce cornplex shapes Virluallv no restriction on thc sizco1-the parlsthat can be manufactured. l.ends itselltnore readilvto mcchanization of process than hand lay up. This help to oll'setlaboratorlinlensive naturc of opcn rrolcll-abrication. Limitation r F '/ r Onc appcarance surfbce Laborper unit produced is relatively high in comparison to otherprocess" Good operator skill is required. Emission of volatilechcrnicals fiorn resiusvstent.

Application l . B o o th r - r l l s 2" Aulo and truck par1s. pools 3. srvimming 4. tanks 5. corrosion resistan etq u i p m e n t . 6. furniturc and accessories 7. eleclrical equiprnent housing 8. enclosures 9. duct and air handling equipment.
. : j

l6 Discussvery briefly compressionmoulding process? Compression moulding is one of the oldest manufbcturing lechniquein the composite 'l-he industry'. rccent development of high strength,fast cure, sheetmoulding compounds and advancemcnts in presstechrrology is rnakingthe compression rnoldingprocess very popularfbr rnass production parls.Fully fbrmedparlsare moldedin matched of compositc metalcompression mols that give the final partshape. r 'l'he principaladvantage ol-comprcssion molding is its ability to producepartsof

colnplcxgeometry in shoftperiodoltirne. I'.xarnplc: Non-unilbnnthickness. ribs. bosses" f'lanses. holesand shoulders can be incorporated duringthe compression rnoldingprocess. F 'l'hus it allows the possibilityof eliminatinga number of secondary finishing

opcration suclras drilling.forrningand rvelding. / 'l'his process presses utilizeslargetonnage where in the parl is cure between two

'['he matchedstccl dies under pressurc arrd higlr tcrnperature. moving platen is

heatedeither by steanror electricityto prornotetherrnalcuring. Curing of the parl is aflectedby the folloiving lactors | . Size of platendetenn inesthe lcnglh and width of the parl can be cured" 2. 'l'otal tonnage of the press determinesthe pressureto be exerted on the

projcctedsurfaceareao1-the part. After placing the laminateto be curedcalledthe chargein the core of the mold. the cavity is then closedat a rate of usually4-12 mm/sec.In most cases the mold is heatedto 150'C which causes the chargeviscosityto be reduced.With increasing mold pressurc as the mold is closed,the cliargeflow towardsthe cavity extremities lorcing airoutolthe cavity. 'l'he rnolding pressure basedon projcctedpart arearangesfrom 0.7 to 9 MPa. IJigh

rnoldingpressure causesink marksrvhile lower pressure causes scummingof the rnoldand porosity. 'fhe curing time is usually between25 scc to 3 rninutesdepending on several

factors including resin initiator inhibitor reactivity, part thickness, component complexity and mold temperature. 'l'he cxerlionof high pressure climates thc problemof development of voids.The

primary advantage of the compression rnolding is its ability of producinglarge numberof parlswith little dimensional variations. if any from partto part.A wide varietr of shapes sizeand complexity can bc produced by comprcssion moulding. An irlportantfactorto be considered befbredecidingto use compression rnolding is thc high tooling cosl and thc nccd lbr largehcatcdpresses.'l'hus this methodis not practical fbr low volurneproduction. Cure time is verv critical. lf the resin cure exothermis not properll,controlled crackinsand blistering or warpingmay occur. [)uring Inolding a complex heat transl'erand a viscous florv phenornenon take placein the cavity.

Upi!'r

rmkl

'.r I

?
{llrlrtq

l'.r I

ww u:;)
nx
,7 Llu,cr.rpr.l El.._Jl

t"

ilurr

n*ld rnll

,,i-l

Lr-Tr-{l t .'VH,l ---LfI'

{ri-{h-.,;l

F i

ti-ilitions and t 7 What is the composition of glassfibrcs? Mcntion theadvantag"r.

application of glassfibres. Composition of glassfibre Glassfibres are classifiedinto E-glass S-glass D-glass Z-glass C-glass Composition of B-glass

sior-54.4%
Al2O3-14.4o B:Os-8o% MgO-4.5% CaO-l7.5o/o NalO-0.3% KjO-}.2o FerOr-0.40% IleC)-O.3olo Composition of S-glass si0r-65% AIIO,*25oh M g O -l 0 % Compositionof D-glass

sior-74% Mg O-0 .2 %
CaO-0.2% lic);-o.lon NalO-1.2% KrO-I.3% B:Or-23ozi, Compositionof Z-glass

si o r-6 0 % T i O:-5 %
NarO-20% LrO:-15oh Compositionof C-glass

si o r-6 5 %
Al:Or-.1.5%

CaO-4.5o/o MgO-3% Naro-8.5% B:Or-5%o Application of glassfibre 'fhc arc application of glassf-rbrcs pritducts l. Military'and aerospacc replacement. 2" Asbestos 3. optical deviccs 4. Radomes rotor blades 5. Helicopter 6. Ballistic. 7. Ciircuitry panels of composile 8. Production 9. Surl'boards and othersimilardevices. Advantage of glassfibre , [,ow cost / High tcrrsile strength F High chemical resistance propertics. insulation t7 [:]xcellent Disadvantageof glassfibre r Low tensilc modulus / | I i g hs p c c i l i c gravitl /. High hardncss

l8

re the thermoset and therm I ney are rorn polymenzatron

resins? j-Tfe-)' aakfiTlon are formed . by polymerization condensation osettrng

her arc Tinear pollneis. sol eiworkol cross r c r t a r e c o m o o s c d ' o l 'c h a i n d i m i : n s i o n an linkedrnolecule linked rnolecule moleculcs rtr'leculcs

i i
I

:
4 5
- , 6

l mouTdeilon bEi-morildb-dlnTo i fnt aennot tf'n* an 6e eaSrTv

i intoan-y shape remoulded anyhewshape

t
i I
|

r---

again btreCttcled 1-Ihw - , ^ ] _ . , c-nnotbe reclrcle{f llTle)'can for l'her cannot bereclalmecF Th.cr can bc rcclairned
value Thev are ToTt.-w-eakand brittle -Ileis Tfci-aic hard ttrons a brittle-