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I.
INTRODUCTION
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July 8, 2014, Coimbatore, India.
M.Prakash
PG Scholar, Manufacturing Engineering ,
Government College of Technology,
Coimbatore,India.
Prakash2521@gmail.com
buckling), Good corrosion resistance. Reasons for choosing
composite material
To improve fuel efficiency by reducing the mass of the
vehicle
To improve safety and crashworthiness
To enhance style and part consolidation
To improve aerodynamic design
Effect of Reduction in Weight on fuel Efficiency of the Vehicle.
The reduction in weight of the vehicle by 1 kg on the
cost of manufacturing in various industries like automobile,
aeronautical and space are as follows,
Automobile 5-7$/Kg
Aeronautical 500-700$/Kg
Space 5000-7000$/Kg
The table below shows the values of fuel consumption and fuel
efficiency for different design types and vehicle weights.
Table 1. Fuel Consumption in Vehicles
Design/Engine Type
State of the art
A)High strength
steel plus structural
bonding
B)Carbon fiber
composite for
structure and
closures
C1)Diesel Engine
C2)Full Hybrid(otto)
C3)Full Hybrid
(Diesel)
Vehicle
weight(Struct
ure and
closure)
500 Kg
Fuel
Consumption
(ltr.per
100Km)
10
350 Kg
9.58
4.20%
270 Kg
9.31
7%
7
6.5
30%
35%
5.5
45%
Fuel
efiiciency
increase
0%
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Reinforcement:
The reinforcing fibers or fabric provides strength and
stiffness to the composite, the matrix gives rigidity and
environmental resistance. The reinforcing fibers are found in
different forms, from long continuous fibers to woven fabric to
short chopped fibers and mat. Each configuration result in
different properties. The fiber carries the load and its strength is
greatest along the axis of fibers. Long continuous fibers in the
direction of load results in a composite with properties far
exceeding the matrix resin itself. The same material chopped
into short length yields low properties, as illustrated in figure 2.
Depending on the type of application and manufacturing
method, the fiber form is selected. The most widely used fiber
materials in fiber reinforced plastics are Glass, Carbon, Aramid,
and Boron.
COMPOSITE MATERIALS
Matrix:
Matrix surrounds the fiber and thus protects those
fibers against chemical and environmental attack. For fibers to
carry minimum load, the matrix must have a lower modulus and
greater elongation than the reinforcement. The matrix
determines the service operating temperature of a composite as
well as processing parameters for part manufacturing the various
types of thermoset resins and thermoplastic resins are used as
matrix.Thermoset materials once cured cannot be re-melted or
reformed. Thermoset offers greater thermal and dimensional
stability, better rigidity and higher electrical resistance the most
common resin materials used in thermoset composites are
Epoxy, Vinyl ester, Polyester, Phenolics and Polyamides.
Thermoplastics can be melted by heating and can be re-shaped.
These are ductile and flexible such that these composites do not
enjoy as high the level of integration as the thermoset
composites. Some of the thermoplastic resins are Nylon,
Polypropylene, Teflon and Polycarbonate.
A.Functions of Fibres and matrix
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Expanded energy
Tire resistance
Aerodynamic drag
Inertia (Linear And
Rotational)
city
25%
18%
Highway
33%
51%
57%
16%
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COMPOSITE MATERIALS
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The following are the force analysis being carried out as shown
in figure 2 to figure 6.
Impact analysis on LEFT Surface
Loading condition: point load, distributed load.
Impact analysis on TOP Surface
Loading condition: point load, distributed load.
Impact analysis on RIGHT Surface
Loading condition: point load, distributed load.
Impact analysis on FRONT Surface
Loading condition: point load, distributed load.
Impact analysis on BACK Surface
Loading condition: point load, distributed load.
In the below analysis, Bottom surface is not considered
as it is not exposed to the environment.
MILD STEEL/COMPOSITE MATERIAL (LEFT SURFACE)
LOADING CONDITION POINT LOAD
DISTRIBUTED LOAD
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DISTRIBUTED LOAD
DISTRIBUTED LOAD
DISTRIBUTED LOAD
DIE PREPARATION
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1.
2.
3.
Figure 11. Test Specimens
D.Inference
The glass-fiber-reinforced woven-fabric laminates have
been subjected to impact testing. After the impact testing the
following observations were made.
1. Delamination, fiber shear-out behavior was observed
in the test specimen.
2. No complete breakage was found in the test
specimen irrespective of the volume fraction.Based on the Test
results, the volume fraction (Resin-55%: Fiber- 45%) yields high
Impact Strength (25.6 N/mm2) is preferred for manufacturing of
the model (Roof Panel).
V.
MANUFACTURING
A.Die Preparation for Roof PanelThe die was prepared
according to the prototype where the dimensions are scaledown
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Hardener-Triethylenetetramine(TETA)
50
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With
the
Test
results
VI.
[2]
[3]
[4]
[5]
[6]
[7]
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