International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 01, January 2019, pp. 543–549, Article ID: IJMET_10_01_056
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=01
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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EFFECT OF PROCESS PARAMETERS ON WEAR BEHAVIOR AND
WATER ABSORPTION OF UHMWPE FABRIC REINFORCED EPOXY
COMPOSITES
P.RajendraPrasad*
Research Scholar, School of Mechanical Engineering, Reva University, Bangalore, INDIA.
Assistant Professor, Department of Mechanical Engineering, G.Pulla Reddy Engineering
College, Kurnool, INDIA,
J.N.Prakash
Research Supervisor, School of Mechanical Engineering, Reva University, Bangalore, INDIA
3
L.H.Manjunath
School of Mechanical Engineering, Reva University, Bangalore, INDIA.
*Corresponding author
ABSTRACT
The use of artificial fiber reinforced composites are widely used in many applications
such as automobile, aircraft manufacturing because they are cost effective and offers high
strength, and weight ratio compared to other composites with similar applications. In this
work, epoxy was selected as a matrix material to prepare a composite specimens
reinforced with UHMWPE fabric with varying layers. Composite specimens are prepared
by varying the number of fabric layers and Taguchi’s L9 orthogonal array method is used
to study the Tribological behavior. The test specimen of composite material had been
prepared using hand layup technique and the samples were tested for wear properties
using the equipment DUCOM made pin on disc experimental setup. The weight was
measured before and after the experiment is conducted. The effects of the Tribological
operating parameters applied load, sliding velocity and sliding distance on the frictional
and wear performance of UHMWPE fabric reinforced composites are demonstrated.
Moreover, water absorption tests were conducted to know their effect over a period of
time for both the aerial densities 200gsm and 240gsm of the fiber mats. It was observed
that the wear response of the specimens is influenced by the applied load, sliding distance
and the speed.
Keywords: Woven fabric, textile composites, UHMWPE, orthogonal array, and Hand
lay-up.
Cite this Article: P.RajendraPrasad, J.N.Prakash and L.H.Manjunath, EFFECT OF
PROCESS PARAMETERS ON WEAR BEHAVIOR AND WATER ABSORPTION OF
UHMWPE FABRIC REINFORCED EPOXY COMPOSITES, International Journal of
Mechanical Engineering and Technology, 10(01), 2019, pp.543–549
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P.RajendraPrasad, J.N.Prakash and L.H.Manjunath
1. INTRODUCTION
From decades the customary metals or materials have been supplanted by Polymer matrix
composites (PMC) in view of simplicity of processing, productivity and low cost. Because of
their splendid formability, low specific weight, high stiffness to weight and high strength to
weight proportions the fiber-reinforced polymer (FRP) [1-3] composites are used in various fields
of Engineering and structural applications such as ship superstructures, marine, auto mobile,
machine parts, and the modern aerospace industries [3].
The Fiber-reinforced polymer (FRP) composites are made of two constituents i.e.
thermosetting or thermoplastic resins [11] as matrix material, and fiber or fabric as reinforcement
[2]. The fiber or fabric provides a load-bearing capacity while the resin contributes to transfer of
loads to the fiber. Resins also protect the fibers from environmental factors such as humidity,
high temperature, and chemical attack [2, 3]. The FRP composites possess desired Mechanical
properties like Tensile, Flexural and Impact strengths, and Tribological properties.
The
Mechanical properties of FRP composites depend on the properties of the fiber and matrix
constituents, as well as the interface between the fiber and matrix [4]. The Thermosets (epoxies
& phenolics) and Thermoplastics are used as matrix, and Fiber glasses, Carbon fiber, Kevlar
(Aramid) fiber, and Ultra-high molecular weight polyethylene (UHMWPE) fiber are used as
reinforcement [3].
The UHMWPE fiber or high modulus fiber considered as third generation high-performance
fiber [5-9] after Kevlar and carbon fiber because of remarkable physical and mechanical
properties such as high specific weight, high modulus, high stiffness, high cut proof and abrasion
resistance, good UV resistance, water resistant, and non-chemical reactive [3,10]. Due to these
exceptional properties the UHMWPE fiber reinforced composites are extensively used in
aerospace, automobile [11], and sports utilities industries [3].
Ultra–high molecular weight polyethylene (UHMWPE) woven fabric reinforced polymer
(WFRP) composite laminates or textile composites are increasingly used in defense industries
and marine construction due to their exceptional properties like highest strength to weight ratio,
and outstanding features like environmental resistance and long life, these would be the better
replacement to traditional materials like metals and ceramics.
In this work UHMWPE fabric reinforced polymer composites were synthesized and wear and
friction properties of the specimens were investigated. The water absorption test also conducted
to investigate the water resistance in the composite specimens.
2. MATERIALS AND METHODS
2.1. Materials
The Epoxy resin (LAPOX L-12) of medium viscosity is used as matrix material, and a room
temperature curing polyamine hardener (K-6) both are supplied by ATUL Limited (Polymers
division), Gujarat, India. The properties of epoxy resin and hardener are given in table 1. The
Ultra-high molecular weight polyethylene (UHMWPE) fabric of 200 gsm and 240 gsm areal
densities are used as reinforcement material supplied by Huaheng High Performance Fiber
Textile Co. Ltd (China), the details of fabrics given in table 2.
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EFFECT OF PROCESS PARAMETERS ON WEAR BEHAVIOR AND WATER ABSORPTION OF
UHMWPE FABRIC REINFORCED EPOXY COMPOSITES
Table 1: Properties of Epoxy resin and Hardener
Typical values
Description
Epoxy
(L-12)
Appearance
Clear viscous
liquid
Hardener
(K-6)
Pale yellow
liquid
1.1-1.2
0.95-1.1
9000-12000
5-15
180-190
-
Density at 25 ºC
(g/cm3)
Viscosity
(mpa.s at 25ºC)
Epoxy
Equi. Wt (g/eq)
Table 2: Details of Fabric
Parameter
Areal density (gsm)
Weave
Fiber count (cm)
Yarn denier
Thickness (mm)
UHMWPE Fabric
200
240
Plain
Plain
15.5X12
10X9
600D
1000D
0.42
0.48
2.2. Processing of composites
The composites are prepared as laminates with fixed dimensions of 160 x 160 x 3 mm3. The
matrix is prepared by mixing epoxy (LAPOX L-12) and 10% hardener (K-6). Hardener is added
to the resin system shortly before use to initiate the polymerization reaction. A glass mould with
the aforementioned dimensions is placed and a layer of wax is coated over it which acts as
releasing agent. Resin is applied on top of the layer of fiber and it’s ensured that the fiber is
completely wet. Another layer of fiber is placed on top. These steps are repeated until the desired
thickness was obtained. Another plastic sheet is placed on top. Pressure is applied using weights
over the mould in order to ooze out the excess matrix and to apply load uniformly. These steps
were followed to make the three different layered composites.
The composite material reinforced with UHMWPE and epoxy matrix was analyzed for wear
with ASTM G99. Wear and Friction monitor- TR 201 (Pin on disc) wear apparatus is shown in
Figure.1 and its specifications are shown in Table.3.
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Figure.1 Wear and Friction test experimental set up with specimen
Table 3. Tribological test specification
Pin size
2mm - 10mm
Wear
2000 micrometer
Disc size
6mm X 100mm
Frictional Force
100N
3. RESULTS AND DISCUSSION
Wear and frictional force tests were performed as per Taguchi’s L9 orthogonal array. Taguchi’s
method is used when the numbers of inputs are too large to allow for exhaustive testing of every
possible input. Three layers of composites were processed and planned to study the wear
properties with varying parameters of Load (N), Speed (rpm) and Time (min) which was listed
in Table 4.
Table 4. Wear Test process conditions
S. No.
Load (N)
Speed (rpm)
Time (Min)
1
2
3
4
5
6
7
8
9
10
10
10
20
20
20
30
30
30
500
600
700
500
600
700
500
600
700
5
10
15
10
15
5
15
5
10
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EFFECT OF PROCESS PARAMETERS ON WEAR BEHAVIOR AND WATER ABSORPTION OF
UHMWPE FABRIC REINFORCED EPOXY COMPOSITES
Table 5. Experimental design and its response on single layered composite specimen
240 gsm weight loss (milligrams)
S. No.
1
2
3
4
5
6
7
8
9
200 gsm weight loss (milligrams)
1 layer
2 layers
3 layers
1 layer
2 layers
3 layers
0.0863
0.0892
0.0941
0.0895
0.0995
0.0877
0.0917
0.0899
0.0914
0.0864
0.0892
0.0942
0.0894
0.0994
0.0877
0.0916
0.0896
0.0913
0.0862
0.0891
0.0943
0.0896
0.0995
0.0874
0.0915
0.0894
0.0912
0.0895
0.0897
0.0941
0.0915
0.0924
0.0931
0.0924
0.0914
0.0922
0.0897
0.0892
0.0942
0.0914
0.0924
0.0936
0.0928
0.0915
0.0924
0.0895
0.0898
0.0943
0.0914
0.0925
0.0934
0.0926
0.0918
0.0921
Wear tests were conducted on the composite specimens to tests the wear resistance of the
specimens using pin-on-disc test apparatus. A total of 54 tests were conducted to know the wear
behavior against the EN32 material. The weight loss obtained for all these samples with different
process parameters is very minute as shown in Table 5. Only one conclusion can be drawn from
the data that as the time of the contact increases, wear (weight loss) increases, that too only a
minute increment.
3.1. Water Absorption Tests
The effect of number of layers on the water absorption UHMWPE reinforced composites for both
the areal densities increased in immersion time is shown in Figure 2 & 3. It is evident from the
figures that the rate of moisture absorption increases with increase in number of layers. Another
effect of increasing water absorption rate of composites is the nature of UHMWPE fiber, voids
inside the composites lead to the formation of micro channels. After immersion time in water, the
presence of these micro voids and cracks in the composite surface results in the movement of
water molecules to the material by capillary action [12].
Water absorption (%)
0.9
0.8
240 gsm 1 layer
0.7
240 gsm 2 layers
240 gsm 3 layers
0.6
0.5
0.4
0.3
0.2
0.1
0
0
1
2
3
4
Days
5
6
7
8
Figure.2 Effect of layers on water absorption with 240 gsm
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0.7
200 gsm 1 layer
0.6
Water Absorption (%)
200 gsm 2 layers
0.5
200 gsm 3 layers
0.4
0.3
0.2
0.1
0
0
2
4
Days
6
8
Figure.3 Effect of layers on water absorption with 200 gsm
4. CONCLUSIONS
Composite laminates are prepared for both areal densities of 200 gsm and 240 gsm UHMWPE
plane woven fabric reinforcement by varying the number of layers. A total of 3 laminates were
prepared for each areal density with 1, 2 and 3 layers of UHMWPE fabric. Both water absorption
and wear tests were conducted for all the six samples. Wear tests were performed by varying the
process parameters on pin-on-disc test apparatus and only a minute weight loss is observed for
all the samples, for 200 gsm the weight loss is little higher when compared to the 240 gsm fabrics
reinforced composite laminates. For water absorption 3 layered samples has more absorption than
the other two samples and 200 gsm samples has less water absorption capability than the 240 gsm
samples for all the layered samples.
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