57

CHAPTER 4
MATERIALS AND EXPERIMENTAL METHODS

4.1

INTRODUCTION
The properties of natural fibers reinforced composites depend on a

number of parameters such as fiber content, fiber length, fiber-matrix

adhesion, stress transfer at the interface and orientation. Figure 4.1 gives the
complete details of the investigation carried out on banana fiber and
banana/kenaf hybrid fiber reinforced polyester hybrid composites. The
experimental plan involves studying two types of fiber reinforced composites,
namely banana and kenaf fiber. Two forms of fibers, randomly oriented and
woven hybrid composite are taken for the investigation. Two types of
conditions such as alkali treatment of fibers and sodium lauryl sulphate, are
used in this study.
4.2

MATERIALS
For experimental study, the kenaf and banana fibers are separated

and extracted from the stem of kenaf plant and stem of the banana plants as
mentioned in Chapter 3. Then they were prepared in woven fabric form
(Figure 4.2). The mechanical properties of the kenaf and banana fiber are
listed in Table 4.1.

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Figure 4.1 Flow chart of present investigation

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Figure 4.2 Different weave pattern of hybrid fabrics

Table 4.1 Mechanical properties of banana and kenaf fiber
Strength
(MPa)

% of
elongation

Youngs modulus
(Gpa)

Kenaf

890 - 960

5-9

53

Banana

470 - 550

4-6

12

Fiber

4.3

UNSATURATED POLYESTER

4.3.1

Properties of the Matrix

The thermoset resins are usually liquids or low melting point solids

in their initial form. By its three dimensional cross linked structure, they have
high thermal stability, chemical resistance, good dimensional stability and
also high creep properties. The most common thermosetting resins used for
composite manufacturing are unsaturated polyesters, epoxies, vinyl esters and
phenolics. Unsaturated polyester is economical as is used due to its excellent
process ability and good cross linking tendency as well as mechanical

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properties when cured (Regnier and Mortaigne 1995, Mortaigne et al 1999)
and due to these reasons, unsaturated polyester has been chosen. The typical
properties of the unsaturated polyester are listed in Table 4.2.
Table 4.2 Typical properties of unsaturated polyester resin matrix

4.4

Appearance
Specific Gravity at 25 C
Viscosity

Yellow viscous liquid

1.1

(a) FC-4 (Seconds) at 30 C

110

(b) Brookfield (CPS) at 25 C RVT model

480

Volatile content (%) at 150 C

42.5

Acid value (Mg.KOH/G)

6.97

PREPARATION OF COMPOSITES PLATES

The kenaf and banana woven fabrics were placed in a mold

measuring 300 mm 300 mm 4 mm. The accelerator was mixed with resin
and the air bubbles were removed by degassing. Catalyst was added and
poured into the mold. The mold was closed and, a dead weight of 45 kg was
placed above. The composites was allowed cure for 24 hrs. Followed by
initial curing, the samples were post cured in an oven at 50 C for an hour.
Composites with fiber content of 40 wt % and 50 wt % were fabricated.
4.5

MECHANICAL TESTING
Mechanical properties of fabric reinforced composite depend on the

nature of the polymer matrix and the weave pattern of the reinforcing fabric,
the nature of the fibermatrix interfaces and of the interphase region. One of
the most important and widely measured properties of composite materials
used in structural applications is tensile strength i.e., the ability of a material

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to resist breaking under tensile load. The tensile strength of the composites
was measured with a computerized Schimadzu universal testing machine in
accordance with the ASTM D638 procedure at a cross head speed of
5mm/min.
The flexural tests were performed on Instron 3382 universal testing
machine, using the three-point bending fixture according to ASTM D790 with
the cross head speed of 5mm/min. Flexure testing is often done on relatively
flexible materials such as polymers, wood and composites. The three-point
flexure test is the most common for polymers. Specimen deflection is usually
measured by the cross head position. Test results include flexural strength and
flexural modulus. In a three-point test, the area of uniform stress is quite small
and concentrated under the center loading point.
The impact strength of the samples was measured using an Izod
impact test machine as per ISO 180 standards. All the impact test samples
were notched. The test specimen was supported as a vertical cantilever beam
and broken by a single swing of a pendulum. At the point of impact, the
striker has a known amount of kinetic energy. The impact energy is calculated
based on the height to which the striker would have risen, if no test specimen
was in place, and this compared to the height to which the striker actually
rises. Tough materials absorb a lot of energy, whilst brittle materials tend to
absorb very little energy prior to fracture. ISO and ASTM standards express
impact strengths in different units. ISO standards report impact strengths in
kJ/m2, where the impact energy is divided by the cross sectional area at the
notch. ASTM standards call for values to be reported in J/m, where the impact
energy is divided by the length of the notch. Factors that affect the impact
energy of a specimen will include yield strength and ductility, notches and
temperature and strain rate. For each case, a total of five samples are tested at
30 C .

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(a)

(b)

(c)
Figure 4.3

(a) Schimadzu universal tensile testing machine (b) Flexural

testing machine (c) Impact testing machine

4.6

SCANNING ELECTRON MICROSCOPY

Fractrography study of the broken specimen after the tensile,

flexural and impact test are carried out using Joel Scanning Electron
Microscope. Fractured specimens from tensile, flexural and impact test are
coated with gold and kept in ionizer. Images of the fractured specimens are
taken by subjecting to the voltage of 10 kV 15 kV.

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4.7

WEAR
A progressive loss of material from its surface is termed as wear. In

other words wear is the response of material to external load and temperature
as a result. Wear of the component will occur whenever two surfaces are in
contact directly. If the components material loss is high during contact it
losses its life prematurely. Abrasion wear can be computed by subjecting the
sample to test under Pin on disk method or abrasion test apparatus. Figure 4.4
shows the experimental set up of abrasion test.

Figure 4.4 Abrasion Testing machine

4.8

WEAR

BEHAVIOR

WOVEN

BANANA

AND

KENAF

FABRIC REINFORCED HYBRID COMPOSITE

4.8.1

Preparation of Composite materials for wear tests

A wooden mold of dimension (150 mm 150 mm 10 mm) was

used for casting the composite plate. The first groups of samples were

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manufactured with 20, 30 and 40 % volume fraction of fibers. For different
volume fraction of fibers, a calculated amount of polyester resin and hardener
(ratio of 10:1 by weight) was thoroughly mixed with gentle stirring to
minimize air entrapment. For quick and easy removal of composite sheets,
mold release sheet was put over the glass plate and a mold release spray was
applied at the inner surface of the mold. After keeping the mold on a glass
sheet a thin layer (approximately 2 mm thickness) of the mixture was poured.
Then the required amount of fibers was distributed on the mixture. The
remainder of the mixture was then poured into the mold. Care was taken to
avoid formation of air bubbles. Pressure was then applied from the top and the
mold was allowed to cure at room temperature for 72 hr. This procedure was
adopted for preparation of 20, 30 and 40 % fiber volume fractions of
composites. After 72 hours, the samples were taken out of the mould, cut into
different sizes and kept in air tight container for further experimentation.
4.8.2

Plan for Experimentation

Design of experiment is a powerful analysis tool for modeling and

analyzing the influence of control factors on output performance. The most

important stage in the design of experiment lies in the selection of the control
factors. Therefore, a number of factors are included so that non significant
variables can be identified at earliest opportunity. The wear tests are carried
out under operating conditions given in Table 4.3. The tests are conducted at
room temperature as per experimental design. Three parameters viz., abrasive
grit size, normal load and sliding distance each at three levels, are considered
in this study. Planning of the experiments has been done using the above
method.

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Table 4.3 Control Factors
Control factors
Sliding distance
Load
Abrasive grit size
Fiber content
4.8.3

Level 1

Level 2

Level3

25
10
100
20

50
20
320
30

75
30
400
40

Abrasive Wear Test

Abrasive wear tests were conducted on a pin-on-disk machine to

under abrasive mode. The SiC waterproof emery paper (Grade 100, 320 and
400) was affixed on the disk. Cylindrical specimens of dimensions 8 mm in
diameter and 20 mm in thickness were injection molded. The friction force
was measured by using a force transducer fixed on the loading lever arm. A
non-contact laser displacement transducer was used to measure the linear
wear during the tests. Friction force and linear wear were measured
continuously and data were stored using a personal computer based data
acquisition system. Friction and wear tests were conducted at normal loads 10
to 30 N. Tests were performed at a constant sliding velocity of 0.2 m/s. Tests
were conducted under laboratory conditions (32 C 3 C, RH 57% 5%).
The sliding surfaces of the pins were well cleaned before testing. The initial
mass of pins was measured using an electronic balance of 0.1 mg accuracy
and the dimensions of pins were measured using a digital micrometer of
accuracy 1 mm. Tests were run up to a sliding distance of 180 m. After the
test the pin was cleaned and the specimen mass was measured. Three tests
were conducted under each test condition and the average values of measured
friction force, temperature, linear wear and mass loss were used for further
analysis. The specific wear rate K (g/m), is the ratio of the weight loss to the
sliding distance. The worn-out surfaces were observed using scanning
electron microscope.