CHAPTER 1

INTRODUCTION
1.1 INTRODUCTION
The performance and properties of composite materials depend on the
properties of the individual components and their interfacial compatibility.
To ensure appropriate interfacial interactions their surface properties must be
modified accordingly. Also, the use of thermoplastic polymers with
particulate fillers or short-fiber reinforcements has grown rapidly because of
their good processability and ability to be recycled. Fillers are added to the
polymeric matrix with the aim of improving its thermal and mechanical
properties.
There are, however, some adverse effects, i.e. toughness, and ultimate
elongation that polymers often suffer because of the addition of fillers. A
properly selected interface has a significant effect on the dispersion quality
and adhesion between the polymer and the filler. natural hard fibers are
gaining attention as a reinforcing agent in thermoplastic matrices. Low
density and a highly reduced wear of the processing machinery may be
mentioned as attractive properties, together with their abundance and low
cost. pointed out that these hard fibers posses mechanical properties that
make them a suitable candidate to reinforce thermoplastic resins.

1.2 INTRODUCTION TO COMPOSITE MATERIALS

Composites is defined as “the engineered materials made from two or
more constituent materials with significantly different physical or chemical
properties which remain separate and distinct on a macroscopic level within
the finished structure.
 Materials are selected for a given application based principally on the
material’s properties. Composites have high stiffness, strength, and tough-
ness, often comparable with structural metal alloys. Further, they usually
provide these properties at substantially less weight than metals their “spe-
cific” strength and modulus per unit weight is near five times that of steel or
aluminum. Composites can be excellent in applications involving sliding
friction, with tri biological (“wear”) properties approaching those of lubri-
cated steel.

Fig 1.1 Composite Material

In recent years, the interest in composite materials is increasing due to

its advantages as compared to monolithic metal alloys. Composites materials
can be defined as engineered materials which exist as a combination of two
or more materials that result in better properties than when the individual
components are used alone. Composites consist of a discontinuous phase
known as reinforcement and a continuous phase known as matrix. In
practice, most composites consist of a bulk material (the „matrix‟), and a
reinforcement of some kind, added primarily to increase the strength and
stiffness of the matrix.
Matrix Phase:
The matrix phase generally comprises the bulk part of a composite.
Materials in fibrous form are seen to be showing good strength property and
for achieving this property the fibers should be bonded by a matrix. Matrix
may consist of any of the three basic material types mainly Polymer,
ceramics or metals.

Reinforcement:
The reinforcement is generally responsible for strengthening the
composite and improves its mechanical properties. All of the different fibers
used in composites have different properties and so affect the properties of
the composite in different ways. It also provides stiffness to the composites.

1.3 Classification of Composites

Composite materials can be classified into many categories depending
on Reinforcing material type, matrix type etc. They are namely:

1.3.1 According to the type of matrix material they can be classified as

(a) Metal matrix composite:

It consists of a metallic matrix (Al, Mg, Cu, Fe).There are several
reasons for the re-emergence of interest in metal matrix composites, the most
important one being their engineering properties. They are of light weight,
and exhibit good stiffness and low specific weight as compared to other
metals and metal alloys. It is generally considered that these materials offer
savings in weights, at the same time maintain their properties. Although it
has many advantages, cost remains a major point of interest for many
applications.

(b) Polymer matrix composite:

Polymer matrix composites are considered to be a more prominent
class of composites when compared to ceramic or metal matrix composites
once in commercial applications. It comprises of a matrix from thermosetting
(unsaturated polyester, epoxy) or thermoplastic (nylon, polystyrene) and
embedded glass carbon, steel or Kevlar fibers (dispersed phase). The
industries supporting reinforced polymer markets include transportation,
marine accessories, electronic products etc.

(c) Ceramic matrix composite:

It comprises of a material consisting of a ceramic combined with a
ceramic dispersed phase. The availability of new technologies, processing
methods and the demand for high performance products, have together
promoted the growth of advanced ceramic products, but the brittleness of
ceramics still remains a major disadvantage.

1.3.2 According to the type of reinforcing material composites:

(a)Particulate composites:
The reinforcement is of particle nature (platelets are also included in
this class). It may be spherical, cubic, tetragonal, a platelet, or of other
regular or irregular shape, but it is approximately equiaxed. In general,
particles are not very effective in improving fracture resistance but they
enhance the stiffness of the composite to a limited extent.
 Particle fillers are widely used to improve the properties of matrix
materials such as to modify the thermal and electrical conductivities,
improve performance at elevated temperatures, reduce friction, increase wear
and abrasion resistance, improve machinability, increase surface hardness
and reduce shrinkage.
Some of the useful properties of ceramics and glasses include high
melting temp., low density, high strength, stiffness, wear resistance, and
corrosion resistance. Many ceramics are good electrical and thermal
insulators. Some ceramics have special properties; some ceramics are
magnetic materials; some are piezoelectric materials; and a few special
ceramics are even superconductors at very low temperatures. Ceramics and
glasses have one major drawback: they are brittle. An example of particle
reinforced composites is an automobile tyre, which has carbon black
particles in a matrix of poly-isobutylene elastomeric polymer.

(b) Fibrous composites:

Fibers, because of their small cross- sectional dimensions, are not
directly usable in engineering applications. They are, therefore, embedded in
matrix materials to form fibrous composites. The matrix serves to bind the
fibers together, transfer loads to the fibers, and protect them against
environmental attack and damage due to handling.
In discontinuous fibre reinforced composites, the load transfer function
of the matrix is more critical than in continuous fibre composites. An
example of particle reinforced composites is an automobile tyre, which has
carbon black particles in a matrix of poly-isobutylene elastomeric polymer.
1.4 ADVANTAGES OF COMPOSITE MATERIALS DESIGN
FLEXIBILITY
  Thermoset Composites give designers nearly unlimited flexibility in
designing shapes and forms. They be molded into the most intricate
components and can be made a wide range of densities and chemical
formulations to have precise performance properties.

 Because thermoset composites can be precisely molded, there is little

waste and therefore significantly lower overall material costs than
metals products.

1.5 THE MATRIX FOR COMPOSITES

The primary phase, having a continuous character, is called matrix.

Matrix is usually more ductile and less hard phase. It holds the dispersed
phase and shares a load with it Dispersed (Reinforcing) Phase The second
phase (or phases) is Embedded in the matrix in a discontinuous form. This
secondary phase is called dispersed phase. Dispersed phase is usually
stronger than the matrix, therefore it is sometimes called reinforcing phase.
In other way we can also define composite materials like fiber and resin and
if they get added make composites.

Fig 1.3 Fibers with fillers and resin make composite material

The other major constituent in fiber composites are the matrix, serves
two very important functions that is it holds the fibrous phase in place and
under an applied force it deforms and distributes the stress to the high
modulus fibrous constituent. The load is borne longitudinally by the
reinforcements. The choice of a matrix for a structural fiber composite is
limited by the requirement that it have a greater elongation at break than the
fiber.

1.5.1 Reinforcement In Composite Material

Tensile strength was more sensitive than compressive strength to lime

and coir fiber reinforced soft soil. The desired tension failure was caused by
the tensile stress acting perpendicular to the loaded diameter. The
combination of discrete coir fiber and lime resulted in a good earthen
reinforcement material.

The role of the reinforcement in a composite material is fundamentally

one of increasing the mechanical properties of the neat resin system. All of
the different fibers used in composites have different properties and so affect
the properties of the composite in different ways. However, individual fibers
or fiber bundles can only be used on their own in a few processes such as
filament winding.

For most other applications, the fibers need to be arranged into some
form of sheet, known as a fabric, to make handling possible. Different ways
for assembling fibers into sheets and the variety of fiber orientations possible
lead to there being many different types of fabrics, each of which has its own
characteristics.

1.5.2 Inter Phase

 When composite are manufactured a small region (1μm) known as the
fiber matrix Inter phase form between the fiber and the matrix. This region
exhibits properties distinguishably different from the properties of the bulk
matrix. The fiber matrix inter phase transfer stress between fiber and matrix,
the efficiency of this stress transfer process and a composite’s and durability
are controlled by this region’s properties.

The inter phase stiffness, fiber topography and fiber matrix chemical
bonding are critically important to the stress transfer process and composite
performance. The efficiency of this process is determined directly by
micromechanics test and quantified by a value termed the fiber matrix
interfacial shear strength.

In addition, micro mechanics test are used to probe a composite’s

strength, durability and failure behavior. The inter phase of composites is the
region where loads are transmitted between the reinforcement and the matrix.

1.5.3 Fiber Matrix Composites

Of all composite material, the fiber type specifically the inclusion of

fibers in a matrix has evoked the most interest among engineers concerned
with structural applications. Initially most work was done with strong, stiff
fibers of solid, circular cross section in a much weaker, more flexible matrix,
i.e., glass fibers in synthetic resins. Then development work disclosed the
special advantages offered by metal and ceramic fibers, hollow fibers, fibers
of noncircular cross section and stronger, stiffer and more heat resistant
matrices.

1.5.4 Types Of Polymeric Matrix

 A polymeric solid material may be considered to be one that contains
many chemically bonded parts or units that themselves are bonded together
to form a solid. There are many types of plastics such as polyethylene and
nylon.

Plastics can be divided into two classes that are thermoplastics and
thermosetting plastic (thermosets) depending on how they are structurally
chemically bonded.

1.5.4.1 Thermoplastics:

Thermoplastics require heat to make them formable and after cooling,

retain the shape they were formed into. These materials can be reheated and
reformed into new shapes a number of times without significant change in
their properties. Most thermoplastics consist of very long main chains of
carbon atoms covalently bonded together. Sometimes nitrogen, oxygen, or
sulfur atoms are also covalently bonded in the main molecular chain.

Pendant atoms or groups of atoms are covalently bonded to the main

chain atoms. In thermoplastic the long molecular chains are bonded to each
other by secondary bonds

1.5.4.2 Thermosetting Plastic:

Thermoset formed into a permanent shape and cured or “set” by

chemical reaction cannot be re melted and reformed into another shape but
degrade or decompose upon being heated too high a temperature. Thus,
thermosets cannot be recycled. The term thermosetting implies that heat is
required to permanently set the plastic. There are, however, many so called
thermosets that set or cure at room temperature by a chemical reaction only.
 Most thermosets consist of a network of carbon atoms covalently
bonded to form a rigid solid. Sometimes nitrogen, oxygen, sulfur, or other
atoms are also covalently bonded into a thermoset network structure.

1.5.4.3 Elastomers:

Elastomers or rubbers can be elastically deformed a large amount

when a force is applied to them and can return to their original shape or
almost when the force is released.

Natural rubber is obtained from the latex from tree Hevea Brasiliensis
and is over 98% polyisoprene. Polyisoprene exists in two forms and it is the
cis form that is the main constituent of natural rubber. Nowadays wide
ranges of synthetic rubber are available and these dominate market.

1.6 INTRODUCTION OF FIBER:

fiber is a natural or synthetic substance that is significantly longer than
is wide. Fibers are often used in the manufacture of other materials. the
strongest Engineering.

1.6.1 Classification Of Fiber

1.6.1.1 According to the general classification:

These are generally classified into two groups:-
 Synthetic Fibers
 Natural Fibers

Synthetic Fibers
 These are man made fibers which are a result of research by scientists
to improve natural occurring plant and animal fibers.
Before synthetic fibers were developed artificially manufactured fibers
were from cellulose which comes from plants. Nylon was the first synthetic
fiber.

Natural Fibers:
Natural fibers include those made from plant, animal and mineral
sources. Natural fibers can be classified according to their origin. Natural
fibers can be classified according to their origin.

 Fruit fibers are extracted from the fruits of the plant, they are light and
hairy, and allow the wind to carry the seeds.
 Bast fibers are found in the stems of the plant providing the plantits
strength Usually they run across the entire length of the stem and Are
therefore very long.
 Fibers extracted from the leaves are rough and sturdy and form part of
the plants transportation system, they are called leaf fibers.

1.6.1.2 According to the fiber placement directions:

1. Continuous fiber composites:

The fiber may be arranged either in a unidirectional orientation or in a

multi axial orientation. A laminate formed by continuous fibers has the
highest strength and modulus in the longitudinal direction of the fibers, but in
the transverse direction, its strength and modulus are relatively low.
 Fig: 1.6.1.2 Continuous fiber composites

2. Woven fiber composites:

The delimitation or separation of the laminates is still a major

problem due to the fibers not being as straight as in the continuous fiber
laminate. Hence, strength and stiffness are sacrificed. However, the woven
fiber composites are not relevant to delimitation because they do not have
dependent laminate.

Fig: 1.6.1.3 Woven fiber composites

3. Chopped fiber composites:

With random orientation of fibers, it is possible to obtain nearly

uniform mechanical and physical properties in all direction. Chopped fiber
composites are used extensively in high-volume applications such as
building materials, because of low manufacturing cost.

Fig: 1.6.1.4 Chopped fiber composites

4. Hybrid fiber composites:

Mixed chopped and continuous fibers, or mixed different fiber types

such as glass/carbon fiber and natural/synthetic as well. Hybrid fiber
composites provide the chance of achieving a balance of mechanical
properties and cost.

Fig 1.6.1.5 Hybrid fiber composites

 CHAPTER 2

LITERATURE REVIEW

Natural fibers exhibit many advantageous properties, they are a low-

density material yielding relatively lightweight composites with high specific
properties Satyanarayana et al. 1986. These fibers also assignment cost
advantages and ease of processing along with being a highly renewable
resource, in turn reducing the dependency on foreign and domestic petroleum
oil. This paper emphance that increasing demand for environmentally
friendly materials and the desire to reduce the cost of traditional fibers (i.e.,
carbon, glass and aramid) reinforced petroleum-based composites, new bio-
based composites Narendra Reddy, Yiqi Yang et al.2003, have been
developed. Researchers have begun to focus attention on natural fiber
composites (i.e., bio composites), which are composed of natural or synthetic
resins, reinforced with natural fibers and fillers. The conventional composites
replace a few of the steel, iron structures. In automobiles the FRP composites
replace the bumpers. The main advantage of the conventional composites is
that they have enough strength with less weight. Weight reduction, corrosion
resistance, easy and convenient fabrication made the industries to go for
composite materials.The fiber treated with filler takes the load and the resin
binds the filler and fibers to make the composite in the desired shape. The
resin fiber and filler together make the composite material. The epoxy resins
are epoxy, polyester etc. These composites are good at engineering
applications and they are efficiently used in industry. The bio degradable
composites degrade in the atmosphere easily. The biodegradable composites
are fabricated by the natural fibers, natural fillers and natural resins.
 CHAPTER 3
MATERIALS AND EXPERIMENTEL PROCEDURE

3.1 MATERIAL USED

3.1.1 Coir Fiber

Coconut fiber is extracted from the outer shell of a coconut. It is

the natural fiber of the coconut husk where it is a thick and coarse but
durable fiber. The common name, scientific name and plant family of
coconut fiber is Coir, Cocos nucifera and Arecaceae (Palm), respectively.
There are two types of coconut fibers, brown fiber extracted from matured
coconuts and white fibers extracted from immature coconuts.

Brown fibers are thick, strong and have high abrasion resistance.
White fibers are smoother and finer, but also weaker. Both brown and white
coir consist of fibers ranging in length from 4-12 in (10-30 cm). Those that
are at least 8 in (20 cm) long are called bristle fiber. Shorter fibers, which are
also finer in texture, are called mattress fiber. A 10-oz (300-g) coconut husk
yields about 3 oz (80 g) of fiber, one-third of which is bristle fiber. Industries
based on coir have developed in many coconut producing countries
especially India, Tanzania, Kenya, Bangladesh, Burma, Thailand, Sri Lanka,
Nigeria, Ghana etc.
 Fig: 3.1.1.1 Coconut Tree, Coconut and Coconut fibers

Chemical Composition of Coconut / Coir Fiber:

 Lignin - 45.84%
 Cellulose - 43.44%
 Hemi-Cellulose - 0.25%
 Pectin’s and related Compound - 3.00%
 Water soluble - 5.25%
 Ash - 2.22%

Physical Properties of Coconut / Coir Fiber:

 Length in inches 6-8
 Density (g/cc) 1.40
 Tenacity (g/Tex) 10.0
 Breaking elongation% 30%
 Diameter in mm 0.1 to 1.5
 Rigidity of Modulus 1.8924 dyne/cm2
 Swelling in water (diameter) 5%
 Moisture at 65% RH 10.50%
Application of Coconut Fiber
 Brown coir is used in sacking, brushes, doormats, rugs, mattresses, in-
sulation panels and packaging. In Europe, the automobile industry up-
holsters cars with pads of brown coir bonded with rubber latex.
 Geotextiles made from coir mesh (at left) are durable, absorb water,
resist sunlight, facilitate seed germination, and are 100% biodegrad-
able.
 Coir peat, a residue of milling, is gaining economic importance as
mulch, soil treatment and a hydroponic growth medium.

Soil treatment material

Sacking
 Geotextiles

Fig: 3.1.1.2 Application of coir fiber

Table.3.1 Chemical composition of natural fibers

Species Cellulos Hemicellulose Lignin Ash

e ( wt % ) ( wt (Wt %)
( wt % ) %)
Pine (softwood) 40-45 25-30 26-34 -
Maple (hardwood) 45-50 22-30 22-30 -
Banana 63-64 19 5 -
Coir 32-43 0.15-0.25 40-45 -
Sisal 63-64 12 10-14 -
Jute 61-71.5 12-20.4 11.8-13 2
Kenaf 31-39 21.5 15-19 -
Hemp 70.2-74.4 17.9-22.4 3.7-5.7 -
Bagasse 40-46 24.5-29 12.5-20 1.5-2.4
Groundnut shell 35.7 18.7 30.2 5.9
Rice husk 31.3 24.3 14.3 23.5
Pineapple 81 - 12.7 -
3.1.2 Epoxy Resin

Epoxy resins are low molecular weight pre polymers or higher

molecular weight polymers which normally contain at least two epoxide
groups. The epoxide group is also sometimes referred to as a glycidyl or
oxirane group.

A wide range of epoxy resins are produced industrially. The raw

materials for epoxy resin production are today largely petroleum derived, al-
though some plant derived sources are now becoming commercially avail-
able (e.g. plant derived glycerol used to make epichlorohydrin).
Epoxy resins are polymeric or semi polymeric materials, and as such
rarely exist as pure substances, since variable chain length results from the
polymerization reaction used to produce them. High purity grades can be
produced for certain applications, e.g. using a distillation purification
process.
One downside of high purity liquid grades is their tendency to form
crystalline solids due to their highly regular structure, which require melting
to enable processing.

3.1.2.1 Properties of Epoxy Resin:

 High Shear Strength Adhesives:

Master Bond offers a range of one and two part epoxies with exceptionally
high shear strength properties. These compounds can withstand exposure to
many chemicals, resist high and low temperatures and have superior gap fill-
ing capabilities. Shear strengths in excess of 10,000 psi have been achieved
with fiber reinforced epoxy compounds truly an amazing accomplishment.
 High Tensile Strength Epoxy Compounds:

Superior tensile strength adhesives from Master Bond are employed in many
critical bonding applications. These compounds feature high reliability and
dependability even upon exposure to hostile environmental conditions. De-
signed for easy application, both single and two component products are
available for use.

 Strength Properties of Epoxy Compounds:

Master Bond epoxies feature outstanding physical strength properties for
high performance bonding, sealing, coating, potting and encapsulation. Our
polymer compounds are formulated to meet challenging physical strength
requirements.

 High Compressive Strength Adhesive Systems:

Advanced formulations feature outstanding resistance to compressive forces.

Products are designed for service in structural bonding applications. Specific
grades offer compressive strengths as high as 15,000 and 20,000 psi at room
temperature.

3.1.2.2 Application

Epoxy has a wide range of applications,

 Including metal coatings,

 Use in electronics / electrical components,

 High tension electrical insulators, fiber-reinforced plastic materials.

  Adhesives and

 Composite materials such as those using carbon fiber and fiberglass

reinforcement

Fig 3.1.2 Epoxy Resin

3.1.4 HADNER:

We are engaged in offering a quality range of Araldite HY 951

Hardener to our clients at market leading prices

Applications: Araldite HY 951 is a hardener which is used with the epoxy

resin which is used for the encapsulation or coating of low voltage and
electronic components

Features:
 ARADUR HY 951 Viscosity at 25°C: 10-20 mPa*s
 Specific Gravity at 25°C : 0.98 g/cm³
 Appearance : Clear liquid
 Flash point : 110°C
 Mix ratio : 100:10
Properties: Aradur HY 951 is good mechanical strength, good resistance to
atmospheric and chemical degradation, excellent electrical properties.

3.2 EXPERIMENTAL PROCEDURE

3.2.1 Selection of Matrix

Epoxy resin used - Araldite LY556
Density - 1.15 to 1.20 [g / cm3]
Hardener used - HY951
Density - 1.13 [g / cm3]
Curing temperature - Room temperature
The Epoxy resin and Hardener are mixed by 10:1 weight ratio.

3.2.2 Types of Composition Used For Matrix

1. SAMPLE A - Coir fiber 10% + Resin 90%
2. SAMPLE B - Coir fiber20 %+ Resin 80%
3. SAMPLE C - Coir fiber 30% + Resin 70%

3.2.3 Raw Material Used In Hand Lay-Up Method

MATRIX - Epoxy LY556
REINFORCEMENT - Coir fiber
HARDENER - Araldite HY951

3.2.4 Preparation of Epoxy And Hardener

The matrix used to fabricate the fiber specimen was epoxy LY556 of
density 1.13 g/cm3 at 25°C mixed with hardener HY951 of density 0.97 to
0.99 g/cm3. The weight ratio of mixing epoxy and hardener was followed as
per the supplier Norms that is 100ml of epoxy resin with 10ml.

3.2.5 FABRICATION OF COMPOSITE (hand lay-up method):

 Hand Lay-up method is followed for fabrication.
 A 3mm thick silicon rubber mould is been created with 300mm length
and width.
The composite is been fabricated further as shown.

Fig 3.2.5 Hand lay-up method

3.2.6 Hand lay-up method procedure:

The releasing agent used is hard wax which is applied over the mould
such that the wax is equally spread and it is dried for about half an hour.

 Epoxy and hardener are thoroughly mixed in a separate beaker. The

composite material is prepared by using Hand Layup Technique.

 While performing hand layup technique care should be taken to avoid

formation of voids within the composite.
 After that mould was kept for about 24 hours to get hardened. After 24
hours the mould was kept in an oven for 20 minutes such that the
releasing agent gets melted and it will be easy to remove the composite
material from the glass mould.

 And then the composite material was kept in the oven for about one hour
for curing purpose.

 After curing the material is kept under weights so that the material gets a
uniform shape like the shape of the mould cavity.

Applying wax Resin weighing Fiber weighing

 Hand compacting

Fig 3.2.6 Fabrication of Specimen

 CHAPTER 4
TESTING AND RESULT
4.1 SPECIMEN TESTING:
4.1.1 Tensile Test:

ASTM D3039 tensile testing is used to measure the force required to

break a polymer composite specimen and the extent to which the specimen
stretches or elongates to that breaking point. Tensile tests produce a stress-
strain diagram, which is used to determine tensile modulus. The data is often
used to specify a material, to design parts to withstand application force and
as a quality control check of materials. Since the physical properties of many
materials can vary depending on ambient temperature, it is sometimes
appropriate to test materials at temperatures that simulate the intended end
use environment.

Specimen size:

The most common specimen for ASTM D3039 is a constant

rectangular cross section, 25 mm (1 in) wide and 250 mm (10 mm) long.
Optional tabs can be bonded to the ends of the specimen to prevent gripping
damage.

Fig 4.1.1 Tensile Test Specimen

Test procedure:

Fig 4.1.2 Tensile Testing machine

Specimens are placed in the grips of a Universal Test Machine at a

specified grip separation and pulled until failure. For ASTM D3039 the test
speed can be determined by the material specification or time to failure (1 to
10 minutes). A typical test speed for standard test specimens is 2 mm/min
(0.05 in/min).

An extensometer or strain gauge is used to determine elongation and

tensile modulus. Depending upon the reinforcement and type, testing in more
than one orientation may be necessary.

State-of-the-art equipment including Align-pro for reduced bending.

Data: From tensile test results the Tensile strength (N/mm2)

4.1.2 Flexural Test:

Flexural Properties of Composites by ASTM D7264Intertek provides

flexural properties testing for various polymer matrix composites, using
ASTM D7264.
 ASTM D7264 outlines testing of flexural properties of polymer matrix
composites using a bar of rectangular cross section supported on a beam and
deflected at a constant rate. Fabric-reinforced textile composite materials are
also referenced within the ASTM D7264 method. Flexural properties of
many materials can vary depending on temperature, rate of strain and
specimen thickness, it may be appropriate to test materials at varied
parameters.

Specimen size:

Standard specimen thickness is 4 mm (0.16 in), standard specimen

width is 13 mm (0.5 in) and standard specimen length is 20% longer than the
support span. If the standard specimen is not available, alternative specimen
sizes may be used.

Fig 4.1.2 Flexural Test Specimen

Test procedure:

Fig 4.1.3 Flexural Testing machine

Procedure A: Outlines a three point loading system for center loading. Most
commonly the specimen lies on a support span and the load is applied to the
center by the loading nose producing three-point bending at a specified rate.

Procedure B: Outlines a four point loading system for two equal loading
points. For the four point flexural test, the specimen lies on a span and stress
is uniformly distributed between the loading noses.

Data: From tensile test results the following calculations can be made:

Maximum Flexural load in kN

4.1.3 Impact Test:

Specimen size:

The standard specimen for ASTM is 64 x12.7 x 6mm (2½ x ½ x 1/8 inch).
The most common specimen thickness is 3.2mm (0.125 inch), but the
preferred thickness is 6.4 mm (0.25 inch) because it is not as likely to bend
or crush. The depth under the notch of the specimen is10.2 mm (0.4
inches).The standard specimen for ISO is a Type 1A multipurpose specimen
with the end tabs cut off. The resulting test sample measures 80 x 10 x 4 mm.
The depth under the notch of the specimen is 8mm.

Fig 4.1.3.1 Impact Test Specimen

Test Procedure

Fig 4.3.1.2 Impact Test

 The specimen is clamped into the pendulum impact test fixture with
the notched side facing the striking edge of the pendulum. The pendulum is
released and allowed to strike through the specimen. If breakage does not
occur, a heavier hammer is used until failure occurs. Since many materials
(especially thermoplastics) exhibit lower impact strength at reduced
temperatures, it is sometimes appropriate to test materials at temperatures
that simulate the intended end use environment.

Data:

ASTM impact energy is expressed in J (or ft-lb) by the thickness of the

specimen.

4.1.4 TEST RESULTS OF SAMPLE MATERIALS:

Samples Samples Tensile test Flexural test Impact Hardness

(Breaking test Test in
Names (In %) (Breaking
load in KN)
load in KN) in joules BHN
ASTM
ASTM D ASTM D ASTM E
D790
638 256 407

A CF(10)+ E(90) 0.335 0.689 3.33 40,43,45

B CF(20)+ E(80) 0.482 0.846 3.33 51,53,56

C CF(30)+ E(70) 0.940 1.214 3.83 62,65,68

Table 4.1.4 Test results of specimen Materials

4.2 CALCULATIONS

4.2.1 Calculation Of Process Sheet

Density of Coir Fibre = 1.05×10-3 gm/mm3
Density of Epoxy Resin = 1.2×10-3 gm/mm3
Total Volume of Plate = Length × Breadth × Thickness
= 300 × 300 × 3
= 270000 mm3
Volume of Matrix = 270000 × (70/100)
= 189000 mm3
Mass of Matrix = Volume × Density
= 189000 × 1.2 × 10-3
= 226.8 gm
Volume of coir Fiber (10%) = 270000 × (10/100)
= 40500 mm3
Mass of coir Fiber (10%) = Density × volume
= 1.05 ×10-3 ×40500
= 42.525 gm
Total Mass of the Plate = 52.65 gm

4.2.2 Calculation For Mechanical Properties

1 .Tensile Load

Tensile Load = 0.9403 KN

Total Tensile Strength of composite = load / area

= 0.9403 / (12.5 x 3)

= 25 N/mm2
2 .Flexural load

Flexural load = 1.214 k N

Total Flexural strength of composite = {3PL / (2 x b x t2 )}

Where; P = load = 1214 N

b = breadth =12.5mm

t = thickness = 3mm

L = length = 130mm

= (3 x 1214x 130/(2 x12.5 x 9))

= 2104.267 N/mm2.
3. Impact strength
Total Impact strength of composite = 3.833 J

4.3 COMPARISON OF TESTING RESULT

Fig:1 comparison of Tensile, flexural, and impact test

4.4 ADVANTAGES OF THIS PROJECT:

 Cheaper when compared to existing materials,

 Reusable material,

 Long life product,

 less weight,

 Easy available materials are used,

 Less time to manufacture ,

 No need of skill labor to design this,

 Capable of operating at elevated temperatures.

 Material cost also very less when compared to others.

CHAPTER 5
 CONCLUSION

Scope and Objective of the Project to analyze mechanical propertics of

composite materials such as coir fiber treated with coir and epoxy resin in
mechanical testing. Then the results of mechanical testing like tensile,
flexural and impact values are compared to existing to find suitable new
material.
For the mechanical test the sample A, mixed 10% of coir fiber and and
90% of epoxy resin is added as a composite. In sample B, mixed 20% of coir
fiber and 80% of epoxy resin is added. In sample C, mixed 30% of coir fiber
and 70% of epoxy resin is added.
Among this, sample C is good mixture because of increase the tensile
test, flexural test and impact test is more than compare to other samples.

It is cheaper than existing material and less weight. Due to limited

resource available we have made a prototype specimen. Further research
being done to check the feasibility for mass production of the model.
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ProductDetails

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