SYNOPSIS

ANNASAHEB DANGE COLLEGE OF ENGINEERING AND

TECHNOLOGY, ASHTA

DEPARTMENT OF MECHANICAL & AUTOMATION

ENGINEERING
1. Name of Program : B.E. Mechanical & Automation Engineering
2. Name of student with roll number : 1) Dhekolkar Pankaj P. (10404)
2) Gandhi Nivedhan S. (10405)
3) Khanderao Ajinkya S. (10409)
4) Kulkarni Rushikesh P. (10410)
5) Patil Ajay T. (10414)
6) Tipre Parth M. (10425)
3. Name of guide : Mr. J.H. Mulla (Asst. Prof)
4. Title of Project Work : Design and construction of impact testing
machine for FRP components
 5. Synopsis of project work
5.1. Introduction
Fiber-reinforced plastic (FRP) (also called fiber-reinforced polymer, or fiber-reinforced
plastic) is a composite material made of a polymer matrix reinforced with fibers. The
fibers are usually glass, carbon, aramid, or basalt. Rarely, other fibers such as paper,
wood, or asbestos have been used. The polymer is usually an epoxy, vinyl ester, or
polyester thermosetting plastic, though phenol formaldehyde resins are still in use.
FRPs are commonly used in the aerospace, automotive, marine, and construction
industries. They are commonly found in ballistic armor as well.
Impact force is a force that delivers a shock or high impact in a relatively short period
of time. It occurs when two entities collide. This collision is the result of one object
falling onto, or slamming into, another object. Impact force is given by Newtons
second law of motion. An impact test measures how much energy is absorbed when an
object fractures or breaks under a high-speed collision. The safety of many consumer
products depends on their resistance to breaking. But impact resistance is difficult to
quantify. An impact testing may be used to validate design of prototype to ensure they
meet product durability and safety requirements.
Current limitations
The behaviour of materials is different when they are subjected to dynamic
loading. The testing of materials under dynamic conditions needs an efficient
and reliable equipment to experimentally examine and quantify the dynamic
behaviour of materials under low velocity impact loads. The range of such
impact loads vary from a few m/s to several hundred m/s (such as a bullet
impact). It is not possible with any one apparatus to cover a velocity range such
as this. Various devices such as explosive or air gun rigs are employed for high
velocity impact tests. Drop weight machines are in use to conduct test at low
velocity impact loads.
6. Literature Review
Following is a list of Authors & researchers who had already worked on FRPs and
impact and burst tests on FRP composite pipes.
F. Taheri-Behrooz, M.M. Shokrieh and H.R. Abdolvand designed and manufactured a
Drop Weight Impact Tester Machine in Iran University of Science and Technology
which measures the energy absorption of composite materials under impact load. The
output of the machine is used to draw load-time graph and calculate the amount of
energy absorbed by the specimens. The machine was equipped with various sensor
systems to measure the velocity of the impactor just before it contacts the specimen and
the amount of contact force, and with a data acquisition system to record the force and
time history. Capability of testing according to many different types of standards and
capability of studying behaviour of the specimen after impact are two important
characteristics of this machine. This designed system, after manufacturing and
calibration, was installed and successfully utilized.
Anmol Sharma, Karthik D, Hemanth Kumar and Naveen H developed an impact testing
as a facility to provide experimental data of impact loads on the composite specimens
that absorb kinetic energy during collision. Material standard has been considered while
developing the machine. The modelling of the set up was done using CATIA software.
Fabrication and construction was done at relatively low cost to produce a functional
equipment. The equipment is equipped with load cell to detect the impact load on the
specimen and it will be will be digitally shown. Winch has been used to lift the impactor
assembly.
J.D. Winkel, D.F. Adams deals drop weight impact test system developed to investigate
the impact performance of thin, simply-supported composite laminates. System
calibration, data acquisition and data reduction techniques developed for this impact
test system, which makes use of a piezoelectric force transducer. Composite material
plates were tested to identify performance differences between cross-ply and fabric
material forms. The six composite material systems investigated included cross-ply and
fabric laminates of Hercules AS4 graphite, DuPont Kevlar 49 and Owens-Corning E-
glass fibres impregnated with a Hercules 3501-6 epoxy resin.
7. Relevance:
An impact test measures how much energy is absorbed when an object fractures or
breaks under a high-speed collision. The safety of many consumer products depends on
their resistance to breaking. But impact resistance is difficult to quantify. Impact test is
considered to be one of the basic mechanical tests. Impact testing is performed to
determine the energy absorbed or the energy required fracturing a unit under test. An
impact testing may be used to validate design of prototype to ensure they meet product
durability and safety requirements.
A simple and direct way to measure the force is to measure the acceleration of the drop
mass. The product of acceleration and mass provides the force of impact. An
accelerometer is going to be fixed on the impactor assembly to measure the acceleration
of the dropped mass (impactor). This sensor is connected to data acquisition system,
which will condition data and display it on computer. All the calculations and result
plotting will be carried on computer. In this experimental setup, we are going to use the
Arduino Uno R3 kit and ADXL335 3-axis accelerometer.
Further tests are carried out on other samples to get more accurate value. Both the mass
and the drop height can be varied. The impact energy is the kinetic energy of the mass
at impact. The energy absorbed by the test specimen is the impact energy required to
just fracture or break the specimen. The impact testing can have a load cell attached to
it so that impact force can be determined.
8. Problem Statement
The machines main objectives include conducting automatic impact and burst tests on
pipes made by FRP components. The machine is required to calculate the impact
tolerable by the pipes, the maximum energy absorbable by the pipes when subjected to
impact forces, and the maximum pressure of the flowing fluid permissible by the pipe
before bursting, and should be feasible for FRP pipes of any dimensions. Moreover, the
whole machine is to be designed at considerably lower budget than its random
alternatives already available in the market at very high costs.
9. Present Theory and Practices
Currently the various machines or methods available for impact testing of FRP
components are restricted to just calculating the maximum impact force resistible by
the component before failure.
Disadvantages of present practice
1. Cant determine the energy absorbed by the FRP components due to impact.
2. Cant be used to test FRPs of various dimensions.
3. Separate machines were used for impact and burst tests.
4. Human errors are possible.
5. Chances of inaccurate results.
6. Chances of leakage of fluid during the burst tests leading to false results.
10.Proposed work
Objective:
1. Measurement of force of impact on composite pipe.
2. Measurement of energy absorbed by composite pipe during impact.
3. To conduct burst test on the composite pipe.
4. Reduce the human errors by implementing the automation.
5. Attempt to improve accuracy of results.
Advantages
1. It increases the speed and accuracy of testing.
2. It incorporates two tests in the same machine.
3. It can test any FRP composite pipe of any dimensions.
4. The load to be applied on the sample can be easily varied.
5. Improved quality or increased predictability of quality.
6. Improved consistency, of processes or product.
7. Increased consistency of results.
8. Reduced direct human involvement, thus reduction in chances of error.
11.Activity Chart

Activity Chart

4
3
2 2
2
2
4
3
2

2 2 2

15 JUL-7AUG 15 SEP- 31 DEC 15 JAN- 31 MAR

Phases of Dissertation Series 2 Phases of Dissertation

PHASE 1 - Duration of Dissertation phase 1 (15 July -7thAug)

PHASE 2 - Duration of Dissertation phase 2 (15st Sep -31stDec)
PHASE 3 - Duration of Dissertation phase 3 (15th Jan-31st Mar)
G1 - Gap of 15 days for Pending work & Review of work done after
 dissertation phase 1
G2 - Gap of 15 days for Pending work & Review of work done after
dissertation phase 2
Further the phases can be elaborated as project methodology as follows:

11.1. Project planning

The progress of developing the project will be smooth and easier with well-defined and
proper management. Planning is important as only sufficient time and resources are
provided. The major considerations of the planning of the project are as below:
Knowing the period required for completing the project.
Fact-finding and research procedure.
Defining the amount of resources that are available.
Determining the materials and objects to be used.
Before beginning the construction of the project, the above planning must be made.
However, the different planning and progress need to be re-figuring out when the
project come to midterm. The considerations are:
Problem solving and troubleshooting procedure
Improvement making steps and error finding
Maintenance process and project testing.
Project standard confinement (after modification).
Immediate actions need to be taken and project planning has to be followed up on time
when problems are encounter. For instance, when the initial planning need to takes
place immediately to acquire replaced equipment. Proper planning and good
management are needed for project to accomplish on time.
 11.2. Design
An impact testing machine based on dropped weight principle was selected since it is
able to provide impact velocity by using earth gravity. In the design, a specimen was
fixed on top of a mild steel base. An impactor was elevated and then released at a certain
height above the specimen. The impactor would hit the specimen with an impact speed
that depends on the dropping height. The kinetic energy of the impactor was then
absorbed by the progressive folding of the specimen, which reduced the kinetic energy
of the impactor until it finally stopped. The crushing force of the specimen during the
impact was sensed by using the load cell which was placed between the specimen and
the steel base. The crushing force data was later used in the numerical analysis. From
the design principle and requirements, the drop weight impact testing was designed.
The impact testing machine can be divided into 4 subsystems namely the frame that
consists of guide columns; base plate; impactor assembly that consists of weighing
masses, impactor head and clamp and the load cell with display.
11.3. Design principle and calculations:
A machine based on the impacts produced by dropped mass works on the principle of
free fall under which is given by:
v= (2gh) ... (4.4.1)
where, g = Acceleration due to gravity (m/s2)
h = Drop height (m)
The maximum energy that that can be stored in the dropped mass is its potential energy
which is given by
Potential Energy, E = mgh
where, m = Drop mass (kg)
This energy has to be absorbed by any specimen under test.
Impact calculations:
The impactor assembly will consist of an impactor head weighing masses. This
mechanism ensures that the impactor assembly always moved along the guide column
during the experiments. The impactor head was designed to be the part of the impactor
assembly that it the specimen. The mass of the impactor frame, impactor head i.e. dead
weight does not cross 3kg. The mass of the impactor assembly could be adjusted by
adding several weighing masses. Although the total length of the guide columns is
1.5m, the maximum dropping height is around 1.2m since some space should be
provided for the specimen, load cell, clamp and impactor assembly itself.
 11.4. Fabrication and Assembly
The main components include will be: Frame, base part, Impactor assembly, Sensors
and control panel assembly, adjustable holder etc.
11.5. Testing and calibration
The performance of the machine will be evaluated and tested by calculating the impact
load and impact energy by using load cell by varying different masses and different
height on standard FRP composites whose statistics would be already known.
Necessary calibrations and adjustments to the machine will be made before approval.
11.6. Final approval and results
The machine will be finally used for conducting impact and burst tests of FRPs pipes.
12.Plan of proposed work

Sr.
Activity/Month Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar April
No.

1 Problem Search

Literature
2
Review
Design of
3 machine
components
Prototype
testing & final
4
machine
assembly.

5 Testing

6 Result Analysis
7 Draft of Report
Submission of
8
final Report
13.Expenditure
Tentative expenditure of project Rs. 30,000/-
14.References
[1] F. Taheri-Behrooz, M.M. Shokrieh and H.R. Abdolvand, Designing and manufacturing of
a drop weight impact test machine.
[2] Ambur, D.R., Prasad, C.B. & Waters, W.A. A dropped-weight apparatus for low-
speed impact testing of composite structures. Experimental Mechanics, 35(1), 77-82.
[3] Barr, B. & Baghli, A. A repeated drop-weight impact testing apparatus for
concrete. Magazine of Concrete Research, 40(144), 167-176.
[4] Ghasemi-Nejhad, M.N., & Parvizi-Majidi, A. Impact behaviour and damage
tolerance of woven carbon fibre-reinforced thermoplastic composites. 21, 155-168.
[5] Gunawan, L., Dirgantara, T. & Putra, I.S. Development of a dropped weight impact
testing machine. International Journal of Engineering & Technology, 11(6), 120-126.
[6] J.D. Winkel, D.F. Adams "Instrumented drop weight impact testing of cross-ply
and fabric composites" Composites Volume 16, issue 4, october 1985, pages 268-278.
Date:-
Place:- Ashta

Sr. No. Name Roll No. Signature

01 Dhekolkar Pankaj Pudlik 10404
02 Gandhi Nivedhan Sudhakar 10405
03 Khanderao Ajinkya Sharad 10409
04 Kulkarni Rushikesh Prakash 10410
05 Patil Ajay Tanaji 10414
06 Tipre Parth Mohan 10425

Mr. J. H. Mulla Prof. Dr. S. A. Patil

Project Guide, MAE Head of Department, MAE