Mekanika Mikro

dan
Teknik Proses
Composites
 Our Team
Muhammad Saiful Rizal Rakhmad Rofiansyah

Intan Febrianti Nur Azizatur Rohmah

Fidhiyah Anas Novia Rizqi Rohmawati

Maudina Alfira Adzany Rizki Agung Rahmanto

Dewi Rahmita Aulia R. Irfani Mauludiyah Fitri

Agung Wijanarko Nur Aulia Pramesthi

Agenda

1 Mekanika Mikro Material Komposit

2 Teknik Proses
 MICRO
MECHANICS OF
COMPOSITE
MATERIAL
 MICRO MECHANICS OF
COMPOSITE MATERIAL

Mechanical Properties Fiber

Reinforced

Orientation of Distribution of
Fiber Fiber
Composition of
Fiber
Orientation of Fiber :
1. Aligned
Longitudinal direction (0ᵒ)
Transversal direction (90ᵒ)
2. Random

Size of Fiber :
1. Continue
2. Discontinue
Longitudinal Fiber Reinforced of Coamposite
Material

1. Has a force of addition / resultant component series

2. Has a same iso strain

Symbols :
cl, its mean longitudinal composites
m, its mean matrix
f, its mean fiber
Transversal Fiber Reinforced of Composite Material

1. Has a force of addition / resultant component paralels

2. Has a same iso stress

Symbols :
ct, its mean transversal composites
m, its mean matrix
f, its mean fiber
FABRICATION TECHNIQUES
 FABRICATION TECHNIQUES
• There are numerous methods for fabricating composite components
Fabrication Techniques of Composites

Open-Mold Closed Mold

Process Process
 FABRICATION TECHNIQUES
Open-Mold Process - Contact Molding/ Hand Lay Up

• Open mold process in one-sided molds is a lowcost

• Open mold process is common process for making fiberglass composite products.
Typically used for boat hulls and decks, RV components, truck cabs and fenders, spas,
bathtubs, shower stalls and other relatively large, noncomplex shapes.
• Open mold process involves either hand layup or a semi-automated alternative, sprayup
 FABRICATION TECHNIQUES
Contact Molding/ Hand Lay Up

Vacuum Bag

Open-Mold Pressure Bag

Process
Spray-Up

Filament Winding
 FABRICATION TECHNIQUES

Open-Mold Process - Contact Molding/ Hand Lay Up

• Hand Lay Up is the most basic fabrication method for thermoset composites
• This method consists of laying dry fabric layers, or “plies,” or prepreg plies, by hand onto
a tool to form a laminate stack. Resin is applied to the dry plies after layup is complete
(e.g., by means of resin infusion).
FABRICATION TECHNIQUES

Open-Mold Process - Contact Molding/ Hand Lay Up

 FABRICATION TECHNIQUES
Open-Mold Process - Contact Molding/ Hand Lay Up

• Proses pembutan komposit dengan metode ini yaitu dengan cara menuangkan resin
dengan tangan kedalam serat berbentuk anyaman, rajuan atau kain
• Kemudian memberi tekanan sekaligus meratakannya menggunakan rol atau kuas
• Proses tersebut dilakukan berulang ulang hingga ketebalan yang diinginkan tercapai
• Pada proses ini resin langsung berkontak dengan udara dan biasanya proses pencetakan
dilakukan pada temperatur kamar
• Pada metode ini jenis resin yang paling banyak digunakan adalah polyester dan epoxies
 FABRICATION TECHNIQUES
Open-Mold Process – Vacuum Bag

• Proses Vacuum Bag merupakan penyempurnaan dari proses Hand Lay Up

• Proses Vacuum Bag ini bertujuan untuk menghilangkan udara yang terperangkap dan
kelebihan resin
FABRICATION TECHNIQUES

Open-Mold Process – Vacuum Bag

 FABRICATION TECHNIQUES
Open-Mold Process – Vacuum Bag

• Pada Proses Vacuum Bag digunakan pompa vakum untuk untuk menghisap kelebihan
udara yang ada dalam wadah tempat diletakkannya komposit yang akan dilakukan proses
pencetakan
• Dengan divakumkan udara dalam wadah, maka udara yang ada di luar penutup plastik
akan menekan kearah dalam
• Hal ini akan menyebabkan udara yang terperangkap dalam specimen komposit akan dapat
diminimalkan
 FABRICATION TECHNIQUES

Open-Mold Process – Pressure Bag

• Proses Pressure Bag memiliki kesamaan dengan proses Vacuum Bag

• pada proses ini tidak menggunakan pompa vakum, melainkan menggunakan udara atau
uap bertekanan yang dimasukkan melalui suatu wadah elastis
• Wadah elastis ini yang akan berkontak dengan komposit yang akan dilakukan proses
• Biasanya tekanan yang diberikan pada proses ini adalah sekitar 30 sampai 50 psi
FABRICATION TECHNIQUES

Open-Mold Process – Pressure Bag

 FABRICATION TECHNIQUES

Open-Mold Process – Spray Up

• Proses Spray Up merupakan metode open-mold process yang dapat menghasilkan bagian-
bagian yang lebih kompleks dari pada proses Hand Lay Up
FABRICATION TECHNIQUES

Open-Mold Process – Spray Up

 FABRICATION TECHNIQUES
Open-Mold Process – Spray Up

• In an open-mold spray up application, the mold is first treated with mold release
• The gel coat sprayed into the mold after the mold release has been applied.
• The gel coat then is cured and the mold is ready for fabrication to begin.
• In the spray up process, catalyzed resin (viscosity from 500 to 1,000 cps) and glass fiber
are sprayed into the mold using a chopper gun, which chops continuous fiber into short
lengths, then blows the short fibers directly into the sprayed resin stream so that both
materials are applied simultaneously.
• In the final steps of the spray up process, workers compact the laminate by hand with
rollers.
 FABRICATION TECHNIQUES
Open-Mold Process – Filament Winding

• Filament Winding is a continuous fabrication method that can be highly automated and
repeatable, with relatively low material costs
• Golf club shafts, Fishing rods, pipe, pressure vessels and other cylindrical parts are some
composite that manufactured by this process.
FABRICATION TECHNIQUES
Open-Mold Process – Filament Winding
 FABRICATION TECHNIQUES
Open-Mold Process – Filament Winding

• Pada proses ini, fiber tipe roving atau single strand dilewatkan melalui wadah yang berisi
resin, kemudian fiber tersebut akan diputar sekeliling madrel yang sedang bergerak dua
arah, arah radial dan arah tangensial
• Proses ini dilakukan secara berulang hingga didapatkan lapisan serat dan fiber sesuai yang
diinginkan
• Resin termoseting yang biasanya digunakan pada proses in adalah : poliester, vinil ester,
epoxies, dan venolat.
 FABRICATION TECHNIQUES

Compression Molding

Closed Mold
Injection Molding
Process

Continuous Pultrusion
 FABRICATION TECHNIQUES
Closed Mold Process – Compression Molding

• Compression Molding is a high-volume thermoset molding process that employs

expensive but very durable metal dies
• It is an appropriate choice when production quantities exceed 10,000 parts
FABRICATION TECHNIQUES
Closed Mold Process – Compression Molding
 FABRICATION TECHNIQUES
Closed Mold Process – Compression Molding

• Proses ini menggunakan hidraulik sebagai penekannya

• Fiber yang telah bercampur dengan resin dimasukkan kedalam rongga cetakan, kemudian
dilakukan penekanan (compression) dan pemanasan.
• Resin termoset yang biasa digunakan dalam proses Compression Molding ini adalah :
poliester, vinil ester, epoxies, dan fenolat
 FABRICATION TECHNIQUES
Closed Mold Process – Injection Molding

• Injection Molding is a fast, high-volume, lowpressure, closed process using, most

commonly, filled thermoplastics, such as nylon with chopped glass fiber
• Injection speeds are typically one to five seconds, and as many as 2,000 small parts can be
produced per hour in some multiple-cavity molds.
FABRICATION TECHNIQUES
Closed Mold Process – Injection Molding
 FABRICATION TECHNIQUES
Closed Mold Process – Injection Molding

• Injection Molding juga dikenal sebagai reaksi pencetakan cairan atau pelapisan tekanan
tinggi
• Fiber dan resin dimasukkan kedalam rongga cetakan bagian atas, kondisi temperatur
dijaga supaya dapat tetap mencairkan resin
• Resin cair beserta fiber akan mengalir kebagian bawah, kemudian injeksi dilakukan oleh
mandrel ke arah nozel menuju cetakan
 FABRICATION TECHNIQUES
Closed Mold Process – Continuous Pultrusion

• Continuous Pultrusion In this relatively simple, low-cost, continuous process, the

reinforcing fiber (usually roving, tow or continuous mat) is typically pulled through a
heated resin bath and then formed into specific shapes as it passes through one or more
forming guides or bushings
• The material then moves through a heated die, where it takes its net shape and cures.
• Further downstream, after cooling, the resulting profile is cut to desired length. Pultrusion
yields smooth finished parts that typically do not require postprocessing
• A wide range of continuous, consistent, solid and hollow profiles are pultruded, and the
process can be custom-tailored to fit specific applications.
FABRICATION TECHNIQUES
Closed Mold Process – Continuous Pultrusion
 FABRICATION TECHNIQUES
Closed Mold Process – Continuous Pultrusion

• Fiber jenis roving dilewatkan melalui wadah berisi resin, kemudian secara kontinyu
dilewatkan ke cetakan pra cetak dan diawetkan (cure), kemudian dilakukan pengerolan
sesuai dengan dimensi yang diinginkan.
• Atau bisa disebut juga sebagai penarikan serat dari suatu jaring atau creel melalui bak
resin, kemudian dilewatkan cetakan yang telah dipanaskan
• Fungsi dari cetakan tersebut adalah mengontrol kandungan resin, melengkapi pengisian
serat, dan mengeraskan bahan menjadi betuk akhir setelah melewati cetakan
Thank You