Vol.04,Special Issue 06, (IC-IREASM-2019) October 2019, Available Online: www.ajeee.co.in/index.php/AJEEE
SEM ANALYSIS AND SLIDING WEAR TEST ON EPOXY REINFORCED GLASS FIBRE COMPOSITE WITH THE FILLERS OF BLACK GRANITE POWDER, WHITE GRANITE
POWDER AND STONE POWDER
1D.K.Jawad, 2Dr. A.Ramesh
1,2Department of Mechanical Engineering, JJTU, Jhunjhunu, Rajasthan-333001 Abstract - SEM analysis and wear teston Epoxycompositereinforced Glass fibre with the fillers of Black Granite Powder, White Granite Powder and Stone Powdery considering ten test samples of three variations of 5%, 10% and 15% weight percentages of fillers. Scanning electron microscopy (SEM) used to analyse the composite microstructures. An experimental study on Sliding Wear test conducted to determine the wear, coefficient of friction and friction force by using a wear testing machine and the wear behaviour of reinforced Epoxy with Glass fibre and filler matrixwere examined and the specific wear rates of the Glass epoxy composite with and without fillers were investigated.
Keywords: Epoxy, Glass fire, Black Granite powder (BGP), White Granite powder (WGP), Stone powder (SP), Wear, Specific wear rate, Coefficient of friction, Sliding Distance.
1 INTRODUCTION
Polymer is a synthetic organic material consists of small molecules identified as monomers, Epoxy is a versatile class of molecule containing one oxygen atom bonded with two carbon atoms and these carbon atoms already have bonded by other means, glass fibre consisting extremely small fibre layers of glass and granite and stone powder are the industrial wastage obtained after grinding the granite and stones.
Epoxy material reinforced with synthetic fibres such as glass fibre is an enormous achievement in the field of materials. The combinations of polymer based on composite materials have started new ways for the polymer fabrication and have allowed the manufacture of new products with optimal properties [2].
Fillers of Granite and Stone powders come under the class of ceramic, these are added in the form of powder that means consisting of extremely small grains and each grain form as a crystalline that bonds well with Glass fibre Epoxy and enhances mechanical properties such as tensile, flexural, impact, hardness strengths and also increases the dimensional stability, resistance to wear, work at high temperatures, weathering resistance.
It is commonly recognised to use the SEM apparatuses straightforward to operate; it is asignificantfeature in the study of micro structure sat the failure parts of the all tested samples[18].
There are extensive technical applications in which friction and wear are important considerations. Polymer composites containing different fillers and reinforcements[17].
One of the essential characteristics of materials are wear and friction. Wear is defined as the destruction to a solid surface, generally relating continuous loss of material, due to sliding motion between that surface and contacting substance or substances [12].
To improve the friction and wear properties of polymer materials is to improve their hardness, tensile, flexural and impact strengths and to reduce their adhesion to the contacting part material for this generally using the fibre reinforcements with the glass fibre and ceramic fillers in the powdered form [9].
2. METHODOLOGY:
2.1. Work Sample Preparation:
A Teflon glass mould of size 30×20×3mm3 has prepared, cut the required size of glass fibre then apply the silicone mould release spray on the inner surface of Teflon glass mould and then apply first layer of Epoxy as shown in Fig.1, paste the first layer of glass fibre on it and apply the second layer of Epoxy on glass fibreas shown in Fig.2 then paste the second layer of glass fibre on Epoxy paste and then apply the third layer of Epoxy on Glass fire after that action allow sample to be cure at room temperature up to 48 hours then remove the sample from the mouldas shown in Fig.3 and then based on ASTM standards cut the required sizes of samples by the using vertical band saw machine.
Fig.1. Cutting the Glass fibre and applying the first layer of Epoxy
Fig.2. Pasting the first layer of Glass fibre and applying the second layer of Epoxy
Fig.3. Pasting the second layer of Epoxy and curing the sample at room temperature
Fig.4. Composites without fillers and all composites
Vol.04,Special Issue 06, (IC-IREASM-2019) October 2019, Available Online: www.ajeee.co.in/index.php/AJEEE
Fig.5. Scanning Electron Microscopic machine
The SEM scans a high-energy electron beam acrossthe surface of a specimen and measures one of a numberof signals resulting from the interaction between thebeam and specimen.
The SEM imagesare monotonous as they reflect the electron on each pixel. They can be colourless to improvevisual refinement of ingredients through changes in image intensity [24].
2.3 Wear test procedure:
Fig 6. Pin on disc Wear testing Machine
Fig.6 show sapin- on-disk wear testing machine, in which the wear test were conducted.
The specimen pin (30×13×3mm3) was rotated against hardened and polished carbon steel disk. All Tests In This Study Were Conducted at room temperature. During the test, the wear, friction coefficient and friction force was recorded and graphed.
To describe the tribological behaviour of polymer materials in the laboratory, standard tests are used. The pin-on-disc test, one of the most frequently used test configurations.
2.4 Mathematical Formula for Sliding wear test:
The specific wear rate WSof the material to be optimized, by using the equation WS= 𝛥𝑚
𝜌𝐹𝑁 𝐿(mm3/N m) (1)
whereΔmis the mass loss before and after sliding, L the sliding distance, ρthe density of the composite, and FN is the normal load.
3. RESULTS AND DISCUSSION
3.2 SEM analysis Results:
Fig.7. SEM images of glass fibre Epoxy without filler and with 5% of Black granite powder
Fig.8. SEM images of glass fibre Epoxy with 10% of and with 15% of Black granite powder
Fig.9. SEM images of glass fibre Epoxy with 5% and 10% of White granite powder
Fig.10. SEM images of glass fibre Epoxy with 15% of white granite powder and with 5% of Stone powder
5SP 5% of Stone Powder and 95% of Glass Epoxy
Vol.04,Special Issue 06, (IC-IREASM-2019) October 2019, Available Online: www.ajeee.co.in/index.php/AJEEE
Fig.11. SEM images of glass fibre Epoxy with 10% and 15% of Stone powder Fig.7 shows 50µm resolution microstructure image of Epoxy without filler it depicts Epoxy bonded with Glass fibre, where Epoxy is loosely coupled with glass fibre forms a less dense and less crystalline microstructure and forms a spherules microstructure and also depicts 5% BGP bonded with Epoxy and glass fibre forms a dense and crystalline structure.
Fig.8. shows the 50µm resolution image of 10% and 15% of BGP fillers with Glass fibre Epoxy, a clear vision of glass fibre and Epoxy with 10% of BGP forms a strong bond of more dense and better crystalline microstructure, in next image consisting 15% of BGP forms a dense crystalline microstructure.
Fig.9. shows the 50µm resolution image of 5% and 10% of WGP fillers with Glass fibre Epoxy. In 5% of WGP forms a dense and crystalline microstructure, on the other hand the next image of 10% WGP shows the clear view of glass fibre and well bonded with epoxy forms a more and better dense crystalline microstructure.
Fig.10. shows the 50µm resolution image of 15% of WGP and 5% of SP fillers with Glass fibre Epoxy, the 15% of WGP forms a dense and crystalline microstructure, the next image of 5% SP shows the clear visibility of glass fibre and well bonded with epoxy forms a more and better dense crystalline microstructure.
Fig.11. shows the 50µm resolution image of 10% and 15% of SP fillers with Glass fibre Epoxy. It depicts a denser and good form of crystalline microstructure.
3.3 Wear test results:
After wear testing operation, machine generates the wear testing result, Coefficient of friction and frictional force. Even negligible amount of wear occurred to all the samples, with the fillers 10% of BGP, 5% of WGP and SP showed better wear resistance properties with that of that glass fibre Epoxy without fillers.
Fig.12. depicts wear of samples in µm with respect to the machining time up to the 300 seconds. It has observed BGP and WGP with percentages of 10 and 5 showed better results.
The maximum wear rate occurs to 15% of BGP with the readings of 147µm and minimum wear rate occur to 10% of BGP with the reading of 30µm among all the test samples. Glass fibre Epoxy with and without fillers are having very good wear resistance properties even 147µm is a negligible wear and is approximately equal to 15% of 1mm.
Fig.13. shows the Wear of samples based on Sliding distance, the maximum wear happened to 15% of BGP and minimum wear was to 10% of BGP.
All the samples having low coefficient of friction, the advantages of low coefficient of friction are less noisy in operation, reduced wear, extend the operational life and also better operational efficiency. Fig.14. shows Coefficient of friction against Sliding distance at a normal load of 30N and speed 500RPM the maximum coefficient of friction recorded as 0.35 to 15% of SP and minimum coefficient of friction recorded in between 0.2 to 0.25 and the samples are 10% of BGP, 5% of WGP and also glass Epoxy without filler.
Fig.12. Wear of samples with respect tothe time at normal load of 30N and speed of 500RPM
Fig.13. Wear of samples Vs. Sliding Distance at normal load of 30N and speed of 500RPM
Fig.14. Coefficient of friction Vs. Sliding Distance at normal load of 30N and speed of 500RPM
Fig.15 depicts Specific Wear Rate against sliding Distance by applying the normal load of 30N and set the speed of 500RPM, it has shown the maximum specific wear rate is up to 0.0004mm3/N-m of the 15% of BGP Glassfibre Epoxy sampleat 500m of Sliding Distance and minimum specific wear rate is about 0.0001mm3/N-m of the 10% of BGP Glass Epoxy sampleat 500m of Sliding Distance, 0.0002mm3/N-m recorded by the sample of glass fibre Epoxy without filler and the fillers of 5% WGP Glass fibre Epoxy sample recoded the better Specific wear rate as 0.00015mm3/N-m.
The Specific wear rate at various loads of 30N, 40N, 50N and at a speed of 500RPM with respect to all samples as shown in Fig.16 the maximum specific wear rate is about 0.004mm3/N-m recorded to a sample of 15% BGP Glass fibre Epoxy and the minimum specific wear rate is up to the 0.004mm3/N-m recorded to a sample of 10% BGP Glass fibre Epoxy.
Vol.04,Special Issue 06, (IC-IREASM-2019) October 2019, Available Online: www.ajeee.co.in/index.php/AJEEE
Fig.15. Specific Wear Rate of samples Vs. Sliding Distance at normal load of 30N and speed of 500RPM
Fig.16. Specific Wear Rate of samples regarding to weight % of Samples at 30N, 40N, 50N and speed of 500RPM
4 CONCLUSION
SEM analysis of Glass fibre Epoxy with fillers of BGP, WGP and SP formed a better crystalline microstructure with that of Glass fibre Epoxy without fillersthat forms a less dense, amorphous and less crystalline microstructure. In case of sliding wear test 10% of BGP and 5% of WGP showed better wear resistance properties with that of Glass Epoxy without fillers.
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AUTHORS PROFILE:
D.K.Jawad, Completed Diploma in Automobile Engineering in 1995 at Govt. polytechnic, Anantapur, B.Tech. Mechanical Engineering in 2000 from Kakatiya Institute of Technologyand Science,
affliated To Kakatiya University,Warangal and M.Tech. in Advanced Manufacturing Systemin 2015 from Kasireddy Narayan Reddy College of Engineering Affliated To JNTUH, Hyderabad. Mail ID: [email protected]
Ph: +91-9701704000
Dr. A. Ramesh, completed Diploma in Mechanical Engineering in 1985, B.E. in Mechanical Engineering in 1989 under Bangalore University, M.E. in Metal Casting
Engineering, 1995, from Bangalore University, Ph.D. in Mechanical Engineering in the year 2004 from Mysore University and Sir having the 30 years of Teaching Experience in Engineering Colleges.
Mail ID: [email protected]
