i
DESIGN AND FABRICATION OF CARBON FIBRE
REINFORCED LAPTOP BEZEL
A PROJECT REPORT
Submitted by
MURALIDHARAN.J.B (Reg. No. 201505067)
MURUGESH.M (Reg. No. 201505070)
RAMKUMAR.D (Reg. No. 201505093)
in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
MEPCO SCHLENK ENGINEERING COLLEGE, SIVAKASI
(An Autonomous Institution affiliated to Anna University Chennai)
March 2019
ii
BONAFIDE CERTIFICATE
Certified that this project report titled DESIGN AND FABRICATION OF CARBON FIBRE
REINFORCED LAPTOP BEZEL is the bonafide work of MURALIDHARAN.J.B
(Reg. No. 201505067) MURUGESH.M (Reg. No. 201505070), RAMKUMAR.D
(Reg.No.201505093), who carried out the Project work under my supervision. Certified further,
that to the best of my knowledge the work reported here in does not form part of any other project
report or dissertation on the basis of which a degree or award was conferred on an earlier occasion
on this or any other candidate.
Mr.P.BALAMURUGAN, M.E.,
Dr.P.Nagaraj, M.E., Ph.D.,
Internal Guide
Assistant Professor,
Department of Mechanical Engineering,
Mepco Schlenk Engineering College,
Sivakasi.
Head of the Department
Senior Professor,
Department of Mechanical Engineering,
Mepco Schlenk Engineering College,
Sivakasi.
Submitted for viva-Voce Examination held at MEPCO SCHLENK ENGINEERING
COLLEGE, SIVAKASI (AUTONOMOUS) on ……………..............
Internal Examiner
External Examiner
iii
ABSTRACT:
Laptops became a part and parcel of every business man’s life and their usage and
their importance cannot be matched with any of the other electronic gadgets of the similar type.
Though the laptops are having many advantages, there are certain disadvantages as well. It
becomes a difficult task in making a laptop case that protects the laptop from damage during
a fall, sudden impact etc. Laptop cases made up of metals or plastics are more prone to
scratches, dents, cracks etc..
Laptop’s have heating issues, which might cause skin burns and itching, are harmful
to the reproductive organs, can lead to pregnancy issues and are carcinogenic. The making of
the laptop cases with the composite materials will meet the requirements of a good laptop by
eradiating the above mentioned disadvantages.
Carbon fibre being strong will be the correct choice of material to be used for the
casing. In composites the carbon fibre is chosen as the reinforcement and the epoxy resin is
chosen as the matrix material. In order to increase the strength and the crack bridging properties
of the composite materials Tio2 is used as a filler material. The composite is manufactured
with 0%,0.5%,1% Tio2 with 60% volume fraction of fibre and 40% volume fraction of matrix
.The
material is tensile tested for knowing its properties, and subjected to flexure test for
knowing its flexure strength. The composite with 1 wt. % TiO2 showed 50% more tensile
strength. There comes a case where a laptop may fall into water and so water absorption test
was conducted for understanding the product’s water gain when it is immersed in water for
hours. This carbon fibre reinforced laptop casing will be a solution to all the problems
encountered with the existing laptop cases and will prevail in the market as a quality product.
iv
ACKNOWLEDGEMENT
We are extremely thankful to Dr.S.Arivazhagan, M.E., Ph.D., Principal, Mepco Schlenk
Engineering College, for permitting us to carry out this project and providing us with all facilities.
We are grateful to Dr.P.Nagaraj, M.E., Ph.D., Sr. Professor &Head, Department of Mechanical
Engineering, Mepco Schlenk Engineering College, for allowing us to work on this project and for
all his support and guidance.
We take immense pleasure in expressing our sincere gratitude to Dr.R.RAJKUMAR M.E, Ph.D.,
Professor, Department of Mechanical Engineering, for allowing us to use the compression
moulding machine, Shore-D-Hardness tester and also for his invaluable guidance and
encouragement towards the completion of the project.
We take pride in expressing our deepest gratitude to our project guide Mr.P.BALAMURUGAN
M.E., Assistant Professor, Department of Mechanical Engineering, for his invaluable guidance
and encouragement at every stage of this project.
We extend our hearty thanks to all staff members of Department of Mechanical Engineering for
their extended assistance and support.
We are very pleased to thank all the technicians for their great encouragement and help in all
occasions of our project.
v
TABLE OF CONTENTS
CONTENTS
PAGE
NO
Bonafide certificate
ii
Abstract
iii
Acknowledgement
iv
List of tables
vii
List of figures
vii
List of symbols
viii
CHAPTER 1
1.1
1
INTRODUCTION
Composites
1
1.1.1
Introduction
1
1.1.2
Constituents of composites
1
1.1.3
Classification of composites
1
1.2
Problem identification
4
1.3
Project objective
5
1.4
Methodology
5
CHAPTER 2
LITERATURE SURVEY
7
CHAPTER 3
MATERIALS USED
8
Carbon fibre
8
3.1
3.2
3.1.1
Carbon fibre mechanical properties
10
3.1.2
Carbon fibre physical properties
11
3.1.3
Advantage of carbon fibre
11
3.1.4
Disadvantage of carbon fibre
11
Epoxy resin
12
3.2.1
Types of epoxy resin
13
3.2.2
Epoxy resin properties
13
vi
3.3
3.4
3.2.3
Hardeners
14
3.2.4
Curing of epoxy resin
14
3.2.5
Advantages
14
3.2.6
Application of epoxy resin
15
Titanium dioxide – TiO2
15
3.3.1
15
Ball Milling
FTIR
18
DESIGN
20
4.1
Design calculations
20
4.2
Solid works modelling
22
SAMPLE PREPARATION
23
Preparation of samples
23
TESTING
26
CHAPTER 4
CHAPTER 5
5.1
CHAPTER 6
6.1
Tensile testing
26
6.2
Flexure testing
31
6.3
Water absorption testing
35
FABRICATION
CHAPTER 7
7.1
Fabrication of laptop Bezel
RESULTS
CHAPTER 8
37
37
40
8.1
Results and discussions
40
8.2
Cost estimation
41
CHAPTER 9
9.1
CONCLUSIONS
42
Conclusions
42
REFERENCES
43
URKUND REPORT
44
vii
LIST OF FIGURES
S. NO.
FIGURE
No.
1
1.1
Particle reinforced composite
2
2
1.2
Fibre reinforced composite
2
3
1.3
Structural composite
4
4
1.4
Methodology chart
6
5
3.1
Carbon fibre
10
6
3.2
Epoxy resin
13
7
3.3
Ball milling
16
8
3.4
SEM image denoting TiO2
17
9
3.5
FTIR setup
18
10
3.6
FTIR results
19
11
4.1
Solid works model of Laptop Bezel
22
12
6.1
Tensile testing specimen
26
13
6.2
Tensile testing apparatus
27
14
6.3
Tensile testing result for 1% TiO2
28
15
6.4
Tensile testing result for 0.5% TiO2
29
16
6.5
Tensile testing result for 0% TiO2
30
17
6.6
Flexure test specimen
31
18
6.7
Flexure testing result for 1% TiO2
32
19
6.8
Flexure testing result for 0.5% TiO2
33
20
6.9
Flexure testing result for 0% TiO2
34
21
6.10
Water absorption test specimens
36
22
6.11
Water absorption test results
36
23
7.1
Compression moulding machine
38
24
7.2
Compression mould die of dimensions 250 mm X 150 mm
39
25
9.1
Top panel and bottom panel
42
26
9.2
Fabricated model of laptop bezel
43
FIGURE NAME
PAGE No.
viii
LIST OF TABLES
S.No
TABLE No.
TABLE NAME
PAGE No.
1
8.1
Test results
40
2
8.2
Cost estimation
41
ix
LIST OF SYMBOLS
αc
:
coefficient of thermal expansion of the composite.
αm
:
coefficient of thermal expansion of the matrix.
αf
:
coefficient of thermal expansion of the fiber.
𝑉𝑓
:
Volume fraction of reinforcement (fiber).
𝑉𝑚
:
Volume fraction of matrix.
𝐸𝑚
:
Young’s modulus of matrix.
𝐸𝑓
:
Young’s modulus of reinforcement (fiber).
1
CHAPTER 1
COMPOSITES
1.1 COMPOSITES
1.1.1 INTRODUCTION
The existing engineering materials are not serving certain needs which are related with new
technologies. Engineers are looking for the materials that are able to satisfy all the needs that are
demanded by the recent technologies. When people are in search of new materials, then mixing one or
two materials will be the correct solution to the meet the demands of the society. The composite
technology will be the correct choice for mixing the materials with the different phases to arrive at the
multiphase materials. This multiphase materials will be of significant properties as expected by the
engineers and will be replacement for the conventional materials in meeting the needs of the growing
world.
1.1.2 CONSTITUENTS OF COMPOSITES
Composites are materials with two different constituents in them. They are generally made up of
two phases, namely the matrix and the reinforcement phases. The matrix is generally a thermosetting
compound. The thermosetting behavior of the matrix phase is attained by the addition of the hardeners.
The hardeners make a strong bonding between the resin molecules and thus form a strong link between
the resins. After the addition of the hardeners, the resin will form strong bonding and this action is called
the curing action and the time taken for curing is called the curing time. Additionally there are certain
compounds called the accelerators or catalysts. These compounds are responsible for the faster curing
of the resin and the hardener mixture.
1.1.3 CLASSIFICATION OF COMPOSITES
1.1.3.1 BASED ON THE MATRIX MATERIAL

Metal matrix composites

Polymer matrix composites
2

Ceramic matrix composites
1.1.3.2 BASED ON THE SIZE AND THE SHAPE OF THE DISPERSED PHASE

Particle reinforced composites

Fibre-reinforced composites

Structural composites
i) PARTICLE REINFORCED COMPOSITES
These composites are characterized by larger sized particles. These composites were developed
in the motive to produce a combination of properties and not for increasing the strength of the composite
materials. These composites are made up of all the three types of the engineering materials likely,
polymers, metals and the ceramics.
Fig. 1.1 Particle reinforced composite
ii) FIBRE-REINFORCED COMPOSITES
The above figure illustrates the fibre reinforced composite with particles in sphere shaped and
the matrix material which is used to bind the fibre to form the composite material.
3
Fig 1.2. Fibre reinforced composite
These composites are a combination of the softer matrix and the harder fibres. These composites
consists of the matrix materials which are not responsible for the load bearing nature of the composite
materials. It is the fibres which are responsible for bearing the loads that are applied to the composite
materials and the matrix materials will transfer the load from the point of application of the load, to the
fibres. The matrix phase protects the composite materials from the external environment so that the
composite material remains chemically stable Fibres may be either continuous or discontinuous in
structure. Continuous fibres provide better efficiency. The properties of these composites depend upon
the properties of the matrix and the reinforcement phases, the length of the fibres, fibre and the matrix
volume fraction, orientation of the fibres etc. The above mentioned parameters influence the following
properties

Density

Tensile strength and modulus

Compressive strength and modulus

Fatigue strength

Fatigue failure mechanisms

Electrical and thermal conductivities

Cost
iii) STRUCTURAL COMPOSITES
There are two different classes of the structural composites namely the laminar composites and
the sandwich structure. The laminar composites are a layer of materials and were designed in the motive
4
of increasing the corrosion resistance of the composite materials. Claddings and laminates are the best
examples of the laminar composites. The name itself suggests that the sandwich composites are thin
layer with a core in between them
Fig 1.3.Structural composite
Both the filler material and the facing material are not strong but both of them are possessed by
the composite materials. The face material will bear the loads applied and also any transverse bending
stresses. Examples of face materials include Al alloys, titanium, steel and plywood. The core separates
the faces and resists deformations that are aligned at 90 degrees with the face plane. Foamed polymers,
synthetic rubbers, inorganic cements, balsa wood are examples of the core materials. Applications of
Sandwich structures include roofs, floors, walls of buildings, and in aircraft for wings, fuselage and tail
plane skins.
1.2-PROBLEM IDENTIFICATION:

It becomes a difficult task in making a laptop bezel that protects the laptop from damage
during a fall, sudden impact etc.

Laptop cases made up of metals or plastics are more prone to scratches, dents, cracks.
5

Laptop’s have heating issues, which might cause following problems,
o
It is harmful to the reproductive organs.
o
There might be potential harm of cancer.
o
It can lead to pregnancy issues.
o
It can cause skin burns and itching.
1.3 PROJECT OBECTIVE:
In recent years it has become a fashion that many of the business personnel’s and many of the
employees are keener in using the laptops for their uses than the personal computers. There are many
issues concerned with the usage of the laptop computers. The main objective of the project are the
following,

To reduce the thermal conductivity of the laptop’s bottom panel and also to enhance the thermal
properties of the laptop material.

To increase the strength of the laptop panel.

To improve the crack bridging properties of the composite material used in the laptop application
by the addition of the TiO2.

To introduce a laptop material which is of lesser cost than that of the existing laptop panel
materials.
1.4 METHODOLOGY:
The composite is a combination of two materials namely the matrix and the reinforcement. It is
hard to make laptop panels which are strong enough to withstand tensile and the flexural loads. Carbon
fibre being strong is the reinforcement and the epoxy resin is chosen as the matrix material. For
improving the crack bridging properties TiO2 is chosen as the filler material. Three samples with 0%,
0.5%,1% TiO2 were made. The specimens were cut and were tested for tensile strength, flexure strength
and water absorption test. The composite sample with 1%TiO2 gave better results in all the tests and so
the composite laptop panel was manufactures with carbon fibre, epoxy resin with 1% TiO2 content in it.
Finally the product was coated with the epoxy resin to get an aesthetic look.
6
`
START
DESIGN AND FABRICATION OF CARBON FIBRE REINFORCED
LAPTOP BEZEL
PROBLEM IDENTIFICATION
LITERATURE REVIEW
SELECTION OF MATERIAL-Carbon fibre and
epoxy resin
SYNTHESIS OF TiO2 POWDER-BALL MILLING
SELECTION OF MANUFACTURING TECHNIQUE
SELECTION OF SUITABLE TESTING
METHODS
VALIDATION OF EXPERIMENTAL RESULTS
& DISCUSSIONS
CONCLUSIONS
END
Fig 1.4 Methodology
7
CHAPTER 2
LITERATURE SURVEY
2.1 LITERATURE SURVEY

Prashanth Banakar et.al., in their paper, “Preparation and characterization of the carbon fiber
reinforced epoxy resin composites” have discussed the strength and stiffness properties of
carbon fiber reinforced composites by conducting tensile and flexural test experiments .they
conducted these tests with different specimens by changing the orientation of the carbon fibre
in 30˚, 45˚, 90˚ angles and they found that when fibres oriented at 90˚ angle showed higher
tensile and flexural strength.

D.Jagannatha et.al., in “Mechanical properties of carbon/glass fiber reinforced epoxy hybrid
polymer composites” have discussed about the fabrication of carbon fiber and glass fiber
reinforced hybrid composites by vacuum bag method and experimentally evaluated the
mechanical properties like micro hardness, tensile and flexural strength of hybrid composites
as per ASTM standards. They found that the micro hardness of carbon fiber reinforced
composite is higher than the other composites. The inclusion of carbon fiber mat reinforced
polymeric composite significantly enhanced the ultimate tensile strength, yield strength and
peak load of the composite. the ductility of carbon fiber reinforced composite is higher than
the other composites.

D T Arun Kumar et.al., in their paper ,“ Study of Mechanical Properties of Carbon Fiber
Reinforced Polypropylene” reported that tensile strength of polypropylene reinforced with
10 percent of short carbon fiber was comparable with that of carbon steel. Further they
concluded that increase in fiber length can enhance thermal stability of the composites.
Carbon fiber is known for its high specific modulus, strength, stiffness etc.
8

Md. Abdur Razzaque Sarker in his journal “Optical properties of al- and
Zr-doped rutile single crystals grown by tilting-mirror-type floating zone method and study
of structure-property relationships by first principle calculations ”journal of inorganic
chemistry volume 2014, article ID 274165, 11 pages has studied the properties of rutile and
anatase structures of TiO2. He also analyzed the FTIR peak values of TiO2 the range of 4004000 cm-1 and arrived at peak values of 450 cm-1,600 cm-1and 1100 cm-1.
9
CHAPTER 3
MATERIALS USED
3.1 CARBON FIBRE
Carbon fibres possess a carbon content of about 95% and are a combination of amorphous carbon
and graphite carbon. They possess high tensile modulus and it is due to the graphite form in which carbon
atoms are arranged in parallel layers in a crystal.
Carbon fibres are manufactured from two types of precursors:
(i)
PAN (Poly Acrylonitrile)
They are generally characterized by high tensile strength, high modulus and ultrahigh modulus.
(ii)
Pitch, a petroleum by-product.
They have very high modulus but their tensile strength and strain-to-failure are lower than those of
PAN and are cheaper than PAN.
Carbon fibres are of 5–10 micrometers in diameter and are composed of carbon atoms. High
stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low
thermal expansion are the advantages of the carbon fibres. These properties have made carbon fibre very
popular in aerospace, civil engineering, military, and motorsports, along with other competition sports.
They are expensive than other fibres like glass and plastic fibres.
To produce a carbon fibre, the carbon atoms are bonded together in crystals that are more or less
parallel in alignment to the long axis of the fibre and this crystal alignment gives the fibre high strengthto-volume ratio. Several thousand carbon fibres are bundled together and are called the tow, which may
be woven into a fabric or used by itself.
Carbon fibres are usually combined with other materials to form a composite. When carbon fibres
are impregnated with a thermosetting plastic resin and are kept in an oven, it forms carbon-fibrereinforced polymer (often referred to as carbon fibre) which has a very high strength-to-weight ratio,
10
and although brittle, it is extremely rigid. Carbon fibres are also combined with other materials, such as
graphite, to form reinforced carbon-carbon composites and they possess a very high heat tolerance.
Fig 3.1 Carbon fibre
3.1.1 CARBON FIBRE MECHANICAL PROPERTIES
 Carbon fibres are extremely thin strands of carbon atoms in a long chain.
 Five times as strong as steel.
 Weighs around two-thirds less.
 High strength-to-volume ratio.
 High strength and weightless.
 Lighter than metal but provides more protection than plastic.
11
 High melting point (3650 – 3700 ºC), carbon fibre is resistant to fire.
 Waterproof compound so the bezels are also water-resistant.
 Durable as they are not prone to wear and tear.
 Creates a unique and beautiful surface finish.
3.1.2 CARBON FIBRE PHYSICAL PROPERTIES
Molecular Weight
12.01
Appearance
Black solid
Melting Point
3652 - 3697 °C (sublimes)
Boiling Point
4200 °C
Density
2.267 g/cm3
Heat of Vaporization 128 K-Cal/gm atom at 4612 °C
Thermal Conductivity 119-165 W/m/K
3.1.3 ADVANTAGES

High stiffness

Less specific gravity

Can withstand at high temperature

Negative coefficient of thermal expansion
3.1.4 DISADVANTAGES

Low strain-to-failure,

Low impact resistance

High electrical conductivity

High cost.
12
3.2 EPOXY RESIN
Epoxy resin is combination of two substances namely resin and hardener that when combined
form a material with great durability. They have several types which are used for adhesion, casting and
coating.
Epoxy is commonly used as adhesives. Epoxy resin adhesives are considered as very powerful
bonding agent allowing two objects to unite inseparably. It is called “super glue” because of its ability
to join almost any type of materials permanently. It can be applied in wood, glass, stone, metal and
plastic. Homes and businesses take advantage of this type of epoxy. Repairing a broken object at home
and construction of cars and furniture are just some of the many uses of epoxy as adhesives.
Epoxy is the cured end product of the epoxy resin and the epoxide functional group is
colloquially called the epoxy. They are class of reactive polymers called the polyepoxides, polymers
with the epoxide groups. These resins may be reacted with themselves through catalytic
homopolymerisation or with the co-reactants like polyfunctional amines, phenols, alcohols and thiols.
These co-reactants are called as the hardeners and this cross-linking reaction ais referred to as curing.
These reactions of the polyepoxides with themselves or the hardeners will result in the formation of the
thermosetting polymer. The thermosetting polymers possess favorable mechanical properties and high
thermal and chemical resistance. Epoxy possess wide range of applications. They are used in
electronics/electrical components, high tension electrical insulators. They also find their usage in paint
brush manufacturing, fibre reinforced plastic materials, in structural adhesives and also they are
sometimes used as glue.
`
Fig 3.2 Epoxy resin
13
3.2.1 TYPES OF EPOXY RESIN
There are two main types of epoxy resin, namely

Glycidyl epoxy resin

Non-Glycidyl epoxy resin
The Glycidyl epoxy is further classified into

Glycidyl-ether

Glycidyl-ester

Glycidyl-amine
3.2.2 EPOXY RESIN PROPERTIES
 Biocompatibility.
 Environmentally friendly.
 Flame resistant.
 Food Safe.
 Superb mechanical strength.
 Epoxy also has excellent resistance to chemicals.
 It resists heat.
 Epoxy is resistant to cold, radiation, and steam.
 It has excellent gap filling properties.
3.2.3 HARDENERS (CURING AGENTS)
Various curing agents for epoxy resin is available, which depends on the process and properties
required. The common curing agents for epoxy are amines, polyamides, phenolic resins, Anhydrides,
14
isocyanates, and polymer captans. The choice a=of resin and hardener depends on the application,
properties desired and the process selected
3.2.4 CURING OF EPOXY RESINS
It is a chemical reaction in which the epoxide group in epoxy resin reacts with hardener
(which is also called curing agent) to form highly cross-linked, three dimensional network. In order to
convert the epoxy resin to a hard, infusible and rigid material, the hardener is required. Epoxy resins
cure easily at any temperature around 5-1500 C depending on the choice of curing agent.
3.2.5 ADVANTAGES

Good adherence to metal and glass fibers

Curing agents, and modifiers are available

Absence of volatile matters during curing

Low shrinkage during curing

Excellent resistance to chemicals and solvents
`
3.2.6 APPLICATIONS OF EPOXY RESIN

Besides this versatility feature, properly cured epoxy resins have other attributes:

Excellent chemical resistance, particularly to alkaline environments.

Outstanding adhesion to a variety of substrates.

Very high tensile, compressive, and flexural strengths.

Low shrinkage on cure.

Excellent electrical insulation properties and retention thereof on aging or exposure to difficult
environments.

Remarkable resistance to corrosion.

A high degree of resistance to physical abuse.

Ability to cure over a wide range of temperatures.

Superior fatigue strength.
15
3.3 Titanium-di- oxide (TiO2)
TiO2 is a chemical compound which has unique O-Ti-O bonds. It exists in nature in two phases
namely, anatase and the rutile phase. The rutile phase is the most common phase of TiO2. TiO2 exists in
nature only in the form of rutile phase. Rutile TiO2 is the commercially available TiO2. TiO2 is used as
a filler in many of the composites. It is being used because of its excellent crack bridging properties and
also its influence in other vital properties of the composite materials. It when added, will enhance the
strength of the composite materials. And also it gives better results in the tensile and the flexure testing
of the composite materials.
3.3.1 BALL MILLING
In the journal “Water absorption behavior, mechanical and thermal properties of nano TiO2
enhanced glass fibre reinforced polymer composites”, Ramesh Kumar Nayak has studied the
mechanical, thermal and the water absorption behavior of the TiO2 powders. He used the TiO2 powders
in the size of about 100 nm. The TiO2 powder was in the size of about 10 micro meter and thus we were
in the need of reducing its size. The ball milling machine is the choice for reducing the size of the TiO2
powder. The ball milling setup consists of a single rotor with four magnetic bars. Inside the cylinder
there are about 50 balls present which are made up of Titanium Carbide. Once the setup is switched on,
the rotor rotates at the specified rpm and the balls are raised by the magnetic bars and thus released from
a certain height, so that the powders size is reduced. The above process for reducing the size of the
powder is done in 4 stages for about six hours with each stage possessing 4 cycles. In each cycle the
milling setup is run for about 15 minutes with a pausing time of about 5 minutes. After the completion
of the ball milling process the size of the powder was measured, to ensure if the required size of the
powder, to be used in the manufacturing of the composites is attained. The size of the powder was
measured by studying the SEM image of the TiO2 powder. After the ball milling process the size of the
TiO2 powder was reduced to about 198 nm. This size was sufficient enough for achieving the surface
16
properties of the nano materials and were ready to be mixed with the resin, to be used in the
manufacturing of the composite material.
Fig 3.3 Ball milling apparatus-1
17
Fig 3.3 Ball milling apparatus-2
Fig 3.4 SEM image denoting TiO2 size
The above figure shows the SEM image of the ball milled TiO2 indicating its size i.e. 198 nm
18
3.4 FTIR
Fig 3.5 FTIR setup
Md. Abdur Razzaque Sarker Optical Properties of Al- and Zr-Doped Rutile Single Crystals
Grown by Tilting-Mirror-Type Floating Zone Method. TiO2 exists in two different phases. They are the
rutile and the anatase phases. Rutile is the most commonly available form of TiO2 powder. Rutile TiO2
is having excellent optical, mechanical and chemical properties.
There are two different grades of TiO2 available in the market, grade A and grade B. Grade A
TiO2 is white in colour and possesses excellent crack bridging properties. The confirmation of TiO2 was
done with the help of the Fourier Transform Infrared setup. The setup consists of an infrared source, a
transmitter, a receiver and a monitor to visualize the results. The powder is placed in the cup and the
setup is switched on. Either the transmittance or the absorbance peak for the powder is fetched as a
result. The obtained results are compared with the standard absorbance or the transmittance peaks for
the TiO2 powder. The standard absorbance peak for the TiO2 powder is given below
19
Fig 3.6 FTIR result
In the above given standard absorbance peak diagram it is clear that the absorbance peaks for the
TiO2 powders are at 400 cm-1 ,800 cm-1 and at 1100 cm-1 , From the experimental results it is found that
the absorbance peaks were absorbed at 450 cm-1 ,499 cm-1 and at 1045 cm-1 . As the peak values obtained
experimentally lie nearer to the standard absorbance peak values, it is confirmed that the TiO2 used is
pure in nature.
20
CHAPTER 4
DESIGN CALCULATIONS
4.1- DESIGN CALCULATIONS
Coefficient of Thermal Expansion (CTE) in longitudinal direction (along the fibres)
𝛼𝑐
=
(𝛼𝑚 ∗ 𝐸𝑚 ∗ 𝑉𝑚 + 𝛼𝑓 ∗ 𝐸𝑓 ∗ 𝑉𝑓)
(𝐸𝑚 ∗ 𝑉𝑚 + 𝐸𝑓 ∗ 𝑉𝑓)
𝑉𝑓 = 0.54, 𝑉𝑚 = 0.46, 𝐸𝑚 = 3.42 GPa, 𝐸𝑓 = 228 GPa, 𝛼𝑚 = 2.8 * 10-6 /˚C , 𝛼𝑓 = 5.06 * 10-4 /˚C .
𝛼𝑐
=
[(2.8 ∗ 10-6 ∗ 3.42 ∗ 0.46) + (5.06 ∗ 10-4 ∗ 228 ∗ 0.54)]
[(36.3 ∗ 0.4) + (228 ∗ 0.6)]
𝜶𝒄 = 6.23 * 10-2 /˚C
Where αc
– coefficient of thermal expansion of the composite.
αm – coefficient of thermal expansion of the matrix.
αf - coefficient of thermal expansion of the fibre.
𝑉𝑓 - Volume fraction of reinforcement (fibre).
𝑉𝑚 - Volume fraction of matrix.
𝐸𝑚 - Young’s modulus of matrix.
𝐸𝑓
- Young’s modulus of reinforcement (fibre).
Coefficient of Thermal Expansion (CTE) in transverse direction (perpendicular to the fibres)
αc = [((1+μm) αm * 𝑉𝑚) + (αf* 𝑉𝑓)]
𝑉𝑓 = 0.54, 𝑉𝑚 = 0.46, 𝛼𝑚 = 2.8 * 10-6 /˚C, 𝛼𝑓 = 2.05 * 10-3 /˚C , μm = 0.3
αc = [((1+0.3) 2.8 *10-6 * 0.46) + (2.05*10-3 * 0.54)]
αc = 1.11 *10-3 /˚C.
21
Where αc – coefficient of thermal expansion of the composite.
αm – coefficient of thermal expansion of the matrix.
αf - coefficient of thermal expansion of the fibre.
𝑉𝑓 - Volume fraction of reinforcement (fibre).
𝑉𝑚 - Volume fraction of matrix.
μm - Poisson’s ratio for matrix.
𝑉𝑓 = 0.54, 𝑉𝑚 = 0.46, 𝐸𝑚 = 3.42 GPa, 𝐸𝑓 = 228 GPa
By the Rule of mixtures,
 𝐸𝑐 = 𝐸𝑚 𝑉𝑚 + 𝐸𝑓 𝑉𝑓 .
 𝐸𝑐 =(3.42 * 0.46) + (228 * 0.54)
 𝐸𝑐 = 124.7 GPa.
Where, 𝑉𝑓 - volume fraction of reinforcement (fibre).
𝑉𝑚 - Volume fraction of matrix.
𝐸𝑚 - Young’s modulus of matrix.
𝐸𝑓 - Young’s modulus of reinforcement (fibre).
𝐸𝑐 - Young’s modulus of the composite.
22
4.2- SOLIDWORKS MODELLING:
Fig 4.1 Solid works model of laptop bezel
23
CHAPTER 5
SAMPLE PREPARATION
5.1 PREPARATION OF SAMPLES
Sample 1:
Composition - carbon fibre + epoxy resin

For preparation of sample 1, carbon fibre was cut into required dimension
(150 mm x 250 mm)

5 layers of carbon fibre with similar dimension were taken

Epoxy resin and hardener were mixed in ratio of 10:1

PVA is used as a removing agent.

Since, compression moulding machine was used the volume of the mould was calculated.
Volume of mould:

Next, the volume of carbon fibre, epoxy resin and hardener used was calculated based upon
the volume of mould.
Volume of carbon fibre, epoxy resin and hardener:

Next, a layer of OHP sheet along with PVA was placed on the bottom of mould.

After that mixed epoxy resin and hardener was applied above the PVA layer.

Above that a layer of carbon fibre was placed.

Similarly, 5 layers of carbon fibre are placed by applying resin

Finally, the top layer of mould is covered by OHP sheet along with PVA

After that, the mould was placed in the compression moulding machine for 8 hrs.

After 8 hrs. the composite sample was removed.
24
SAMPLE 2:
Composition – carbon fibre + epoxy resin + 0.5 % TiO2

For preparation of sample 1, carbon fibre was cut into required dimension
(150 mm x 250 mm)

5 layers of carbon fibre with similar dimension was taken

Epoxy resin and hardener was mixed in ratio of 10:1

PVA is used as a removing agent.

Since, compression moulding machine was used the volume of the mould was calculated.
Volume of mould:

Next, the volume of carbon fibre, epoxy resin and hardener used was calculated based upon
the volume of mould.
Volume of carbon fibre, epoxy resin and hardener:

Next, a layer of OHP sheet along with PVA was placed on the bottom of mould.

After that mixed epoxy resin, hardener along with 0.5 % TiO2 was applied above the PVA
layer.

Above that a layer of carbon fibre was placed.

Similarly, 5 layers of carbon fibre place by applying resin

Finally, the top layer of mould is covered by OHP sheet along with PVA

After that, the mould was placed in the compression moulding machine for 8 hrs.

After 8 hrs. the composite sample was removed.
SAMPLE 3:
Composition – carbon fibre + epoxy resin + 1 % TiO2

For preparation of sample 1, carbon fibre was cut into required dimension
25
(150 mm x 250 mm)

5 layers of carbon fibre with similar dimension were taken

Epoxy resin and hardener were mixed in ratio of 10:1

PVA is used as a removing agent.

Since, compression moulding machine was used the volume of the mould was calculated.
Volume of mould:

Next, the volume of carbon fibre, epoxy resin and hardener used was calculated based upon
the volume of mould.
Volume of carbon fibre, epoxy resin and hardener:

Next, a layer of OHP sheet along with PVA was placed on the bottom of mould.

After that mixed epoxy resin, hardener along with 1 % TiO2 was applied above the PVA layer.

Above that a layer of carbon fibre was placed.

Similarly, 5 layers of carbon fibre were placed by applying resin

Finally, the top layer of mould is covered by OHP sheet along with PVA

After that, the mould was placed in the compression moulding machine for 8 hrs.

After 8 hrs the composite sample was removed.
26
CHAPTER 6
TESTING
6.1 TENSILE TESTING
Fig 6.1 Tensile testing specimen
The testing procedure includes the performing of the tensile testing, flexural testing and water
absorption testing of the composite material .There are certain ASTM standards to be followed for the
conducting of the specimen testing of the composite material. The standard dimension for the tensile
testing of the composite material is 220 mm x 25 mm x 3 mm. The standard dimension for the flexure
testing of the composite material is 127 mm x 12 mm x 3 mm. The standard specimen size for the water
absorption testing of the composite material is a 2-inch diameter circular disc .The specimens for the
tensile, flexural and water absorption testing are cut from the samples prepared.
27
Fig 6.2 Tensile testing apparatus
The samples were prepared using the compression moulding machine. The volume of the mould
was calculated from the dimensions of the mould. From that volume the calculations for the amount of
the epoxy resin and hardener to be mixed to fill that empty space in the mould are calculated.
After the preparation of the sample it is necessary that it should be cut into required dimensions
for the tensile testing of the composite material. The specimens were cut by using the switch board
cutting machine into the required dimensions.
The tensile testing of the specimen was done in order to know the material properties. The
young’s modulus of the material is found from the tensile testing results. The specimen is held in
between two jaws, one fixed and the other being movable. The load is applied until the material fails
and the load at which the material fails is noted. The ultimate tensile strength of the material could be
found from the value of the load and the cross sectional area of the material. As the composites are
brittle in nature there is no possibility for the indication of the necking formed and thus the material fails
suddenly at the ultimate tensile load. Due to the non-uniform distribution of the fibre and the matrix
there is no such surety that the material will fail at the centre of the specimen. The composite material
28
will fail at the point where it is weak and therefore it may fail either at the centre or at one of the ends.
The SEM image of the failure region will give us the morphology of the composite material. The
following graphs shows the stress vs strain curves of the composite material for the three different weight
percentages of the TiO2 .
Fig 6.3 Tensile test result for 1% TiO2 Specimen
The above graph indicates the tensile strength of the composite material with 60% volume
fraction of the carbon fibre and 40% volume fraction of the matrix material. The ultimate tensile strength
of the material exists at 105 MPa.
29
Fig 6.4 Tensile test result for 0.5% TiO2 Specimen
The above graph indicates the tensile strength of the composite material with 60% volume
fraction of the carbon fibre and 40% volume fraction of the matrix material. In addition to the fibre and
the matrix material 0.5 wt % of the TiO2 powder is used as the filler material. The ultimate tensile
strength of the material is at 110 MPa.
Fig 6.5 Tensile test result for 0% TiO2 Specimen
30
The above graph indicates the tensile strength of the composite material with 60% volume
fraction of the carbon fibre and 40% volume fraction of the matrix material. In addition to the fibre and
the matrix material 1 wt % of the TiO2 powder is used as the filler material. The ultimate tensile strength
of the material exists at 165 MPa.
The three point bending test is called the flexural test and it is conducted to know the bending
strength of the material. The flexure testing specimen is kept over two knife edged supports. A point
load is applied at the centre of the specimen and thus the bending of the composite material is studied.
From the load applied and the area of the application of this load the bending stress is calculated and
this value becomes the indication of the bending strength of the material.
There is a possibility for the laptop to be fallen into water and thus it is necessary to check if the
material used in the laptop is hydrophilic or not. In order to ensure that, it is necessary that we conduct
the water absorption tests for the specimens. The standard dimension for the water absorption test is a
2-inch diameter disc with 3 mm thickness. The specimen is cut from the samples and they are immersed
in water for hours. For every 24 hours the specimen is checked for its weight gain. The results are plotted
in the graph with % gain in water content in the ordinate and the wt % of TiO2 in the abscissa
6.2 FLEXURE TESTING
It’s common that the material may be subjected to bending because of the application of a sudden
load. In case of a laptop it is possible that keeping an object over it unknowingly may lead to bending
of the laptop casings. This reduces the lifetime of the laptop by forming.
31
Fig 6.6 Flexure test Specimens
The above figure illustrates the specimens for the flexure testing of the composite materials.
There are three different specimens made. The three combinations are carbon fibre with 0%, 0.5%, 1%
TiO2 respectively. All the three specimens were cut using the switch board cutter machine. The
specimens were taken for the flexure testing to know the bending strength of the composite materials.
32
Fig 6.7 Flexure test result for 1% TiO2 Specimen
The above figure illustrates the flexure testing report of the specimen with 1%TiO2. The results
obtained for the below given combination of carbon fibre, epoxy resin,TiO2 are as follows,

Volume fraction of fibre- 0.54

Volume fraction of matrix- 0.46

Weight percent of TiO2 – 1%

Flexure strength – 472 Mpa

Maximum deflection-9.71 mm
Fig 6.8 Flexure test result for 0.5% TiO2 Specimen
33
The above figure illustrates the flexure testing report of the specimen with 0.5 %TiO2. The results
obtained for the below given combination of carbon fibre, epoxy resin, TiO2 are as follows,

Volume fraction of fibre- 0.54

Volume fraction of matrix- 0.46

Weight percent of TiO2 – 0.5%

Flexure strength – 1002 Mpa

Maximum deflection-4.52 mm
Fig 6.9 Flexure test result for 0% TiO2 Specimen
34
The above figure illustrates the flexure testing report of the specimen with 0%TiO2. The results
obtained for the below given combination of carbon fibre, epoxy resin,TiO2 are as follows,

Volume fraction of fibre- 0.54

Volume fraction of matrix- 0.46

Weight percent of TiO2 – 0%

Fracture strength – 346 Mpa

Maximum deflection-9.45 mm
6.3 WATER ABSORPTION TEST
STANDARD: ASTM D570
Water absorption is used to determine the amount of water absorbed under specified conditions.
Factors affecting water absorption include: type of plastic, additives used, temperature and length of
exposure. The data sheds light on the performance of the materials in water or humid environments
For the water absorption test, the specimens are dried in an oven for a specified time and
temperature and then placed in a desiccator to cool. Immediately upon cooling, the specimens are
weighed. The material is then emerged in water at agreed upon conditions, often 23°C for 24 hours or
until equilibrium. Specimens are removed, patted dry with a lint free cloth, and weighed.
35
SPECIMENSIZE:

Two inch diameter disks, 0.125" or 0.250" thick

Water
absorption
is
expressed
as
increase
in
weight
percent.
Percent Water Absorption = [(Wet weight - Dry weight)/ Dry weight] x 10
PROCEDURE

The samples were cut into standard dimension for water absorption test (Two inch diameter
disks, 0.125" or 0.250" thick)

Three samples were cut, one with 0%Tio2 next with 1% Tio2 and the other with 0.5% Tio2

The three samples were soaked in bore water and after 24hrs, Change in weight of the
samples were noted

The same procedure were repeated for a week and respective values were obtained
Fig 6.10 Water absorption test specimens
36
WATER ABSORPTION TEST RESULTS
10
8
6
4
2
0
DAY 1
DAY 2
DAY 3
1%
0.50%
DAY 4
0%
Fig 6.11 Water absorption test results
DAY 5
37
CHAPTER 7
FABRICATION
7.1 FABRICATION OF LAPTOP BEZEL
The Composites were manufactured using the compression moulding technique. In the journal
by T D Jagannatha he conducted the experiment considering the four weight fractions of the carbon
fibre which are 15%, 30%, 45% and 60%. These weight fractions were determined by taking into
account the density, specific gravity and the mass of the carbon fibre and the epoxy matrix. In order to
improve the crack bridging properties of the composite materials and in order to increase the tensile
strength and the flexural strength of them, TiO2 was used as the filler material. As in the journal by T D
Jagannatha it was clear that the composite with 60% weight fraction of the carbon fibre showed
enhanced tensile ,flexural and water absorption behaviour, the same was chosen as the weight percentage
of the fibre in the composition to be used in the manufacturing of the laptop casing. In the journal by
Ramesh Kumar Nayak et.al. they studied the water absorption behaviour, mechanical and the thermal
properties of nano TiO2 enhanced glass fibre reinforced polymer composites and they found that the
increase in the weight percentage of TiO2 in the composite material enhanced the tensile, flexural and
the water absorption behaviour of the composite material. The composites were manufactured
considering three weight fractions of the TiO2 particles. They were manufactured with the 0% wt
fraction, 0.5% and 1% of TiO2 .The tensile test was conducted to know the properties of the composite
materials. Then it was subjected to the flexure testing and better results were obtained for the composite
material with 1 wt % of TiO2. Based on the results it was concluded that composites with 1 wt% TiO2
was chosen as the amount of the filler material to be used in the manufacturing of the casing.
The required weight fractions of the epoxy resin and the hardener were mixed in a basin. The required
sizes of the fibre mats were cut and were prepared to be used in the mould. The die was prepared by
coating poly vinyl alcohol, the releasing agent so that the composite material does not stick to the mould.
The layers of the fibre mats were placed on the mould. The mixture of the resin and the hardener is now
uniformly brushed over the carbon fibre mat and the next layer of the fibre mat is placed above the
previous layer and this procedure is repeated for the next three layers of the fibre and totally a laminae
38
consisting of five layers of the carbon fibre is made using the compression moulding process. The above
mentioned procedure is for the manufacturing of the samples without TiO2 content in its matrix material
.The above procedure is repeated with two different combinations of the TiO2 filler material. The
composite is manufactured with 0.5% and 1% TiO2 content.
Fig 7.1 Compression moulding machine
39
Fig 7.2 Compression molding die of dimensions 250 mm X 150 mm
The above figure denotes the die that was used for the compression moulding of the samples.
The size of the die is 250 mm X150 mm.
40
CHAPTER 8
EXPERIMENTAL ANALYSIS
8.1 RESULTS AND DISCUSSIONS
Table 8.1 Test results
SAMPLES
CARBON
CARBON
CARBON
FIBRE+EPOXY
FIBRE+EPXOY+0.5%TiO2 FIBRE+EPOXY+1%TiO2
105 MPa
110 MPa
165 MPa
346 MPa
1002 MPa
472 MPa
8.8 wt%
6 wt%
4.2 wt%
75 HD
76 HD
78 HD
TESTS
TENSILE
TESTING
FLEXURE
TESTING
WATER
ABSORPTION
HARDNESS
The above table illustrates the flexure testing results of the three different specimens with the
three different combinations of carbon fibre, epoxy resin, TiO2. All the three different specimens were
tested for their tensile properties, flexure properties and their water absorption capabilities. In case of
tensile testing, the composite with 1% TiO2 showed better results during the test. It showed the maximum
tensile strength of about 165 MPa. In case of the flexure testing of the composite material the composite
specimen with the 0.5% TiO2 content showed the higher flexure strength when compared with the other
two combinations. In case of the water absorption test the composite with the 1% TiO2 content showed
the minimum water absorption capabilities when compared with the other combinations of the TiO2. And
41
also when the samples were tested for the hardness, the specimen with 1% TiO2 showed the higher
hardness values when tested with the Shore-D hardness tester.
From the above results it was concluded that the composite with the 1% TiO2 content showed the
better results when compared with the other combinations of the TiO2. The application does not demand
for the better results in the flexure testing of the composite materials and also as the 1% TiO2 content
composite specimen showed better results in the tensile testing, water absorption testing and in the water
absorption testing the composite sample with the 1% TiO2 content was chosen as the correct choice for
the manufacturing of the product which is the laptop bezel.
8.2 COST ESTIMATION:
Table 8.2 Cost estimation
Sl.no
Material
Quantity
Amount in Rs./
1
Epoxy
200 ml
150
2
Carbon fibre mat
½ Sq.m
1500
3
Hardener
100 ml
25
Total = Rs.1675
42
CHAPTER 9
CONCLUSIONS
9.1 CONCLUSIONS:
The Laptop bezel was made using the composite material with carbon fibre, epoxy resin combination
and by using TiO2 as a filler material. Initially
Finally the Skyfie, a device used to take selfies without the aid of the selfie sticks is made and is ready
to serve its purpose .The device flies in the air and it is used to take selfies as it flies in the air. The
Skyfie with the phone slot could now be used by the people of different age groups Thus the objective
of the project is achieved and it was made successfully.
Fig 9.1Top panel and bottom panel
43
Fig 9.2 Fabricated model of laptop bezel
44
REFERENCES:







G.R.Headifen, E.P.Fahrenthold, “Mechanical and electrical properties of glass and carbon fibre
reinforced composites” Journal of energy resources technology, Volume 113, issue 3, April
2008.
Y.Takao, M.Taya, “Thermal expansion coefficients and thermal stresses in an aligned short fibre
composite with application to a short carbon fibre / aluminium ”, volume 52,issue 4,July 2009
Prashanth Banakar, H.K.Shivananda, “Preparation And Characterization Of the Carbon Fiber
Reinforced Epoxy Resin Composites” IOSR Journal of Mechanical and Civil Engineering
(IOSRJMCE) ,ISSN : 2278-1684 Volume 1, Issue 2 , PP 15-18, May-June 2012.
T. D. Jagannatha and G.Harish ,“Mechanical properties of carbon/glass fiber reinforced epoxy
hybrid polymer composites” International journal of mechanical engineering and robotics
research, ISSN 2278 – 0149 Vol. 4, No. 2, April 2015.
Md. Abdur Razzaque Sarker ,“Optical Properties of Al- and Zr-Doped Rutile Single Crystals
Grown by Tilting-Mirror-Type Floating Zone Method and Study of Structure-Property
Relationships by First Principle Calculations”, Journal of Inorganic Chemistry, 11 pages Volume
2014, Article ID 274165,
Arun Kumar D T and Kaushik V Prasad, “Study of Mechanical Properties of Carbon Fiber
Reinforced Polypropylene” International Journal of Engineering Research & Technology
(IJERT) ISSN: 2278-0181 IJERTV4IS100500Vol. 4 Issue 10, October-2015.
C.Pradere, C.Sauder, “Transverse and longitudinal coefficient of thermal expansion of carbon
fibers at high temperatures (300–2500 K)”, Volume 46, Issue 14, Pages 1874-1884, November
2008.
Urkund Analysis Result
Analysed Document:
Submitted:
Submitted By:
Significance:
FINAL YEAR REPORT.docx (D49312920)
3/19/2019 7:48:00 AM
balamurugan910@mepcoeng.ac.in
9%
Sources included in the report:
jai thesis.docx (D40050090)
https://en.wikipedia.org/wiki/Carbon_(fiber)
http://mobilecaseshq.com/pros-and-cons-carbon-fibre-case/
https://en.wikipedia.org/wiki/Epoxy
http://www.carbontechnology.co.uk/composites.htm
https://www.sciencedirect.com/topics/chemistry/epoxy-resin
http://www.thegreenbook.com/types-of-epoxy-resins.htm
https://marketdesk.us/report/global-epoxy-hardener-market-2018-99s/
Instances where selected sources appear:
12
DESIGN AND FABRICATION OF CARBON FIBRE REINFORCED
LAPTOP BEZEL A PROJECT REPORT
Submitted by
MURALIDHARAN.J.B (Reg. No. 201505067) MURUGESH.M (Reg. No. 2015)
RAMKUMAR.D (Reg. No. 201505093)
in partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING in
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING MEPCO SCHLENK ENGINEERING
COLLEGE,
SIVAKASI (An Autonomous Institution affiliated to Anna University
Chennai)
March 2019