experimental study on wear behaviour of sic filled …...that predominantly influence the specific...

http://www.iaeme.com/IJMET/index.asp 271 [email protected]

International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 2, February 2017, pp. 271–277 Article ID: IJMET_08_02_033

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=2

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication

EXPERIMENTAL STUDY ON WEAR BEHAVIOUR OF

SIC FILLED HYBRID COMPOSITES USING TAGUCHI

METHOD

T. Madhusudhan and M. SenthiL Kumar

Research Scholar, PRIST University, Thanjavur, Tamil Nadu, India

ABSTRACT

The popularity of composite materials usage is increasing due to its superior strength

characters racing the traditional materials in strength to weight ratio. The developments of new

materials are on the anvil and are growing day by day. In this work, two-body abrasive wear test

with different loads and abrading distances were performed at room temperature by using a pin on

a disk apparatus to determine the surface hardness strength of SiC filled Glass fiber reinforced

with epoxy resin hybrid composites. The results showed that the wear volume increased with

increasing abrading distance and the specific wear rate decreased with increasing abrading

distance and increased with load for SiC particle filled Hybrid composites. Among the filled Hybrid

composites tested, composites with 10% SiC by weight showed a better tribological behavior result.

Also, a taguchi’s experimental design approach to make a parametric analysis of wear behavior of

10% SiCG-J-E, 10%SiCG-S-E and 10% SiCG-R-E.hybrid composites were studied. The systematic

experimentation leads to identification of significant process parameters and material variables

that predominantly influence the specific wear rate.

Key words: SiC, Taguchi Method, Hybrid Composites.

Cite this Article: T. Madhusudhan and M. Senthil Kumar. Experimental Study on Wear Behaviour

of SiC Filled Hybrid Composites Using Taguchi Method. International Journal of Mechanical

Engineering and Technology, 8(2), 2017, pp. 271–277.

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=2

1. INTRODUCTION

Polymer matrix is one of those matrices which have the advantage of least weight and higher strength

which are establishing their applications in aerospace, automobiles; household articles e.t.c. Polymer

composites have the other advantage of tailor able properties promoting application. The decision of

material for a specific application depends on the variables like material expense, thickness, quality and

working conditions. Polymer composites which are used in sliding conditions are normally employed in

low energy transfer. The reason behind sudden increase in rate of wear may be due to material frictional

temperature reaching temperature of the model behind melting temperature under condition of load [1].

Wear is one of the important issues which will affect the shelf life of the component hence it need to

handled to enhance the life of ht e component. The frictions between the parts results in higher temperature

which will enhances the wear and leads to faster replacement of parts [2] & [3]. Polymer matrix

composites which have the advantage of light weight are the most suitable materials for weight sensitive

application in aerospace and automobile industries. Deuis et al. (1996) [3] explained the impact of volume

Experimental Study on Wear Behaviour of SiC Filled Hybrid Composites Using Taguchi Method


percentage, sliding conditions (time, distance, speed, etc.) and applied load that impacts the dry sliding

wear of the composites. Biswas and Satapathy (2010) [4] concluded that the particulate filled polymer

composites are encouraging building materials because of their reasonable determination of lattice and

fortifying strong molecule stage. It develops a composite a composite with a mixture that possesses a

material with better modulus than those of traditional monolithic material. Polymer composites have

replaced the traditional metal and ceramic materials in making high strength and low conductivity

applications like pump wear ring, bushings, line shaft bearings, inter-stage bushings and pressure reducing

bushings. Laguna-Camacho et al., (2015) [5] suggested that unreinforced epoxy polymer composites were

not satisfactory because of its high fragility. Use of ceramic filler materials like SiC or WC which increase

the wear properties. The consideration of ceramic fillers into polymers for commercial application rises,

and it enables good mechanical properties and good aesthetic sense . Silica assumes an imperative part in

enhancing electrical, mechanical and thermal properties of the material.. Fly ash has been used earlier as a

reinforcing material in polymeric materials, but a few investigations have been carried out on tribological

properties of the material by varying different parameters of pin on disc sliding wear. Xu et al. (2015) [6]

described that the sliding is mainly influenced by contacting parts and tribological behavior of the

materials. To make a suitable wear resistant composite, one has to evaluate the relation between varying

parameters and wear rate. This technique has effectively sought parametric evaluation in different wear

procedures of an extensive variety of polymer composites [7–10]. The use of SiC and WC as the filler in

epoxy polymer composites imparts good wear resistance and strength [11-14].In our investigation,

tribological behavior of the SiC reinforced epoxy polymer composite is measured to find out he factors

which influence the wear predominately

2. EXPERIMENTATION

2.1. Matrix, Reinforcement and Filler Details

Material composition used for preparation of hybrid composites are; Epoxy Resin (LAPOX L12) a high

viscous semi solid material chemical known as Diglycidyl Ether Bisphenol (DGEBA) having density of

1120 gm/cm3 and a room temperature curing hardener K-6 chemical called as Tryethylel tetramine (TETA)

having density of 954 gm/cm3 was used. Epoxy resin has established itself as suitable matrix material

exhibiting good mechanical properties, significant thermal stability, lower shrinkage, high corrosion &

moistures resistance, good wet ability e.t.c. As a filler material silicon carbide (SiC) is used in this

experiment has density of 3.21 gm/cm3. SiC silicon carbide a ceramic abrasive material, has higher thermal

stability. Glass fiber of 360gsm with density 2.54 gm/cm3

was used. Glass fiber is easily available and has

higher tensile modulus when compared to other fibers used as reinforcements. Glass fibers were used in

the form of woven glass fabric which is bi directional. Sisal fibers are the natural fibers which are recently

finding their application in composite material as they are less harmful to the environment as well for

human usage. In the present study uni-directional sisal fibers are used which has the density of 1.4gm/cm3.

Jute fiber is another natural fiber which is finding application in polymer composites. In the present study

treated bi-directional woven jute fabric is used, which has the density of 1.46 gm/cm3. Rubber particles are

also used as the reinforcement along with other fiber in this study. The density of the rubber particles used

in the experiment is 0.83gm/cm3.

2.2. Fabrication of Composite Specimens

The most common method used for fabrication of polymer composites is hand-layup technique.

Fabrication process is done in three stages (i) preparation of resin by adding filler material to it and

mixing it uniformly by using mechanical stirrer. (ii) Removing the moisture content in the fabric by

placing on floor under hot sun (iii) mixing of hardener to the filled epoxy resin. To start with the filler

material i.e. SiC 10% of total weight of the composites is mixed with resin by using mechanical stirrer. In

second stage the moisture content in the fabric is removed for proper bonding between the matrix and the



fiber. In third stage the hardener is added to the epoxy in the ratio 100:38 on weight basis. The hardener

mixed epoxy resin is applied on the glass fabric. Using roller the excessive resin and entrapped hole or air

bubble is removed from the adjacent layer. The layer is built up till the thickness of 3mm and tabs are used

for maintaining uniform thickens throughout the laminate. The laminates are cured at room temperature

and pressure of 14bar for 24-48 hours.

The fiber to matrix ratio is 60:30:10 for 10% SiC filled composites. The laminates are fabricated to the

dimension of 150mmx150mmx3mm and specimens are cut using wire saw machine as per the required

size

The raw material used for fabrications of composites by hand layup technique are, glass fabric, jute

fabric, rubber particles and sisal fiber, epoxy resin. Glass-jute fabric with epoxy resin in 60% fiber, 30%E,

10%SiC). Other different material combinations used in present studies are Glass fabric -sisal with epoxy

resin in the ratio 60:30:10 and Glass fabric- rubber powder with epoxy resin in the ratio 60:30:10 was used.

The specimens used for wear test are cut to the standard dimension of 10 mmX10mmX3mm. Two body

abrasive wear test was conducted on a pin-on-disc apparatus at normal room temperature.

3. TRIBOLOGICAL CHARACTERISTICS TEST

As the name indicates it deals with study of wear behavior and parameters affecting it. The composites

materials which are fabricated by land layup technique are subjected to different kinds of tribological test.

To analyses the wear properties of the composites two body abrasive wear test was conducted using the pin

on disc apparatus. Wear test doesn’t have any standard dimension as there are no imposed constraints..

Two body abrasive wear test is conducted based on the L9 orthogonal array as per taguchi design. The

specimen is attached to the flat surface of the pin and 100 grit SiC sand paper is used on the surface of the

disc. For each trail the fresh sand paper is used. The different test parameters used in two body abrasive

wear test are material combination, sliding distance, speed of rotation of disc, and loading condition.

Table 1 Operating Conditions

Control factors Levels

I II III *Material 1 2 3

Speed Rpm 300

400

500

Load N 20 30 40

Distance(m) 25 50 75

*Materials are: 1-10%SiCG-J-E, 2-10%SiCG-S-E, 3- 10%SiCG-R-E.

3.2. Analysis of Wear by Taguchi Technique

The experiments were conducted as per the standard orthogonal array. The selection of the orthogonal

array was based on the condition that the degree of freedom for the orthogonal array should be greater than

or equal to sum of those wear parameters.

In the present investigation an L9 orthogonal array was chosen. The parameters chosen for wear test

are; speed, load, material and abrading distance. The experiment consists of 9 tests and was assigned as

shown in table 2. The experimental results are analyzed using taguchi method and the influential

parameters affecting wear have been identified.



Table 2 Standard orthogonal L9 array with output results for normal specimens.

*Materials are: 1-10%SiCG-J-E, 2-10%SiCG-S-E , 3- 10%SiCG-R-E.

3.3. Taguchi Analysis: Wear Versus Speed, Load, Material, Distance

Table 3 Wear Response for Signal to Noise Ratio

Level Material Load N Speed Rpm Distance m

1 12.86 15.81 12.31 15.66

2 16.91 14.28 14.76 13.24

3 12.05 11.60 14.69 12.82

Delta 4.95 4.13 2.47 2.81

Rank 1 2 4 3

Signal to Noise Ratios Smaller is better

Figure 1 Plots of SN ratio

321

1 7

1 6

1 5

1 4

1 3

1 2

1 1

403020 500400300 755025

material

Mean o

f SN

rati

os

load speed distance

Main Effects Plot for SN ratiosData Means

Signal-to-noise: Smaller is better

Experiments Material Speed Load Distance Wt.Loss SNRA

1

1 300 20 25 0.1798 14.9042

2 2 300 30 50 0.2120 13.4733

3 3 300 40 75 0.3061 10.2827

4 2 400 20 75 0.1177 18.5845

5 3 400 30 25 0.1024 19.7940

6 1 400 40 50 0.2416 12.3381

7 3 500 20 50 0.2001 13.9751

8 2 500 30 75 0.3271 9.7064

9 1 500 40 25 0.2417 12.3345

http://www.iaeme.com/IJMET/index.

4. RESULTS

Analysis was made using minitab-

speed, load, material and abrading distance on wear loss analysis of variance performed on the

experimental data.

In this work, an experimental investigation has been conducted to evaluate the mechanical and

tribological properties of fiber reinforced

carbide (SiC) particles. The following main conclusions can be drawn from

From Taguchi wear response it is evident that material plays a

distance and speed of rotation of disc

(10%SiCG-R-E), load 40N, speed 3

4.1. SEM Analysis

Figure


IJMET/index.asp 275

-17 software in order to find statistical significance of



properties of fiber reinforced Hybrid, epoxy matrix filled with different proportions of Silicon

carbide (SiC) particles. The following main conclusions can be drawn from the experimental data.

wear response it is evident that material plays a significant role followed by

distance and speed of rotation of disc plays least role. From the main effects plot for

), load 40N, speed 300 rpm and distance 75 m gives minimum wear loss.

ure 2 SEM images of taguchi experimental trials

[email protected]

17 software in order to find statistical significance of various factors like



epoxy matrix filled with different proportions of Silicon

the experimental data.

significant role followed by load,

plays least role. From the main effects plot for SN ratio, material 3

5 m gives minimum wear loss.



SEM images for taguchi experiment were conducted for wear specimens. The figure 3.2A shows the

result of 10%SiC-G-J-E with load of 20N, at a speed of 300rpm & at 25mm abrading distance. Wear test

for the specimen was conducted on pin on disc using SiC sand paper of 100 grit size. The figure shows

worn out glass and sisal fibers. Figure 3.2 B shows the results of 10%SiC-G-S-E with speed of 300rpm,

load 30N and abrading distance of 50m. Images reveal the presence of voids and wear out of the top layer

of the laminate. Figure 3.3 C shows the results of 10%SiC-G-R-E with speed of 300rpm, load 40N and

abrading distance of 75m. The results show the wear out of glass fibers and rubber particles on its surface

is the reason behind maximum wear loss. Figure 3.3 D shows the results of 10%SiC-G-S-E with speed of

400rpm, load 20N and abrading distance of 75m. Here the results shows the wear of sisal fibers on its

surface. Figure 3.3 E shows the shows the results of 10%SiC-G-R-E with speed of 400rpm, load 30N and

abrading distance of 75m. Results show the wear out of rubber particles on its surface no fiber is exposed

on the wear surface, which could be the reason for least wear. Figure 3.3 F shows the results of 10%SiC-G-

J-E with speed of 400rpm, load 40N and abrading distance of 50m the images reveal broken fibers and few

layers of worn-out fibers. Figure 3.3 G shows the results of 10%SiC-G-R-E with speed of 500rpm, load

20N and abrading distance of 50m. The images reveal presence of few voids and distribution of rubber

particles on the surface of the polymer composites. Figure 3.3 H shows the results of 10%SiC-G-S-E with

speed of 500rpm, load 30N and abrading distance of 75m the images reveal few voids and fibers layer after

worn-out of the top surface. Figure 3.3 I show the shows the results of 10%SiCG-J-E with speed of

500rpm, load 40N and abrading distance of 25m. Images show the presence of many voids and the

deposited debris on the surface of the voids.

5. CONCLUSIONS

The taguchi wear test conducted on the polymer composites for different materials reveal that; material

was predominantly influencing the wear character, followed by load on the material, later abrading

distance and then by speed of rotation of disc. The least wear rate was the found for the material with

10%SiCG-R-E with load of 40N speed 300rpm and abrading distance of 75m. Taguchi material analysis is

best suited to minimize the number experiments.

REFERENCES

[1] K. Mao, P. Langlois, Z. Hu, K. Alharbi, X. Xu, M. Milson, et al. The wear and thermal mechanical

contact behaviour of machine cut polymer gearsWear, 333 (2015), pp. 822–826

[2] A. Routa, A. Satapathy Analysis of dry sliding wear behaviour of rice husk filled epoxy composites

using design of experiment and ANN Procedia Eng, 38 (2012), pp. 1218–1232

[3] L. Deuis, C. Subramanian, M. YellupAbrasive wear of aluminium composites – a review Wear, 201

(1996), pp. 132–144

[4] S. Biswas, A. Satapathy A study on tribological behavior of alumina-filled glass-epoxy composites

using Taguchi experimental design Tribol. Transact, 53 (2010), pp. 520–532

[5] J.R. Laguna-Camacho, C.A. Márquez-Vera, A.A. Patiño-Valdez, G. Juarez-Morales, I. Hernández

Romero, R.E. Contreras-Bermúdez, et al. A study of the erosive wear damage on a recycled polymer

coating Wear, 332–333 (2015), pp. 836–843

[6] W. Xu, X. Ma, N. Tang, L. Zhu, W. Li, Y. Ding Effect of post-welding heat treatment on wear

resistance of cast-steel die with surfacing layer Manuf. Rev, 2 (2015), p. 25

[7] A. Satapathy, A. Patnaik, M.K. Pradhan A study on processing, characterization and erosion behavior of

fish (Labeo-rohita) scale filled epoxy matrix composites Mater. Des, 30 (2009), pp. 2359–2371

[8] Rashmi, N.M. Renukappa, B. Suresha, R.M. Devarajaiah, K.N. Shivakumar Dry sliding wear behaviour

of organo-modified montmorillonite filled epoxy nanocomposites using Taguchi's techniques Mater.

Des, 32 (2011), pp. 4528–4536



[9] T.S. Kiran, M. Prasanna Kumar, S. Basavarajappa, B.M. Viswanatha Dry sliding wear behavior of heat

treated hybrid metal matrix composite using Taguchi techniques Mater. Des, 63 (2014), pp. 294–304

[10] A. Pattanaik, M.K. Mohanty, M.P. SathpathyEffect of mixing time on mechanical properties of epoxy-

fly ash composite J. Mater. Metall. Eng, 5 (2015), pp. 11–17

[11] Chisholm, N., Mahfuzi, H., Rangari, V., Rodgers, R., Jeelani, S., 2004, Synthesis and mechanical

characterization of carbon/epoxy composites reinforced with SiC nano particles, NSTI Nanotechnol. 3,

p. 302.

[12] Suresha, B., Chandramohan, G., Renukappa, M.N., Siddaramaiah, 2007. Mechanical and tribological

properties of glass–epoxy composites with and without graphite, J Appl Polym Sci. 103, p. 2472.

[13] Suresha, B., Chandramohan, G., 2008, Three-body abrasive wear behaviour of particulate-filled glass–

vinyl ester composites, J Mater ProcTechnol. 200, p. 306.

[14] Bijwe, J., Jhon Rajesh, J., Jeyakumar A., Gosh A., Tewari US. 2007. Influence of solid lubricants and

fiber reinforcement on wear behavior of polyethersulphone, Tribol Int. 33, p. 697.

[15] Chandra Shekar, N B D Pattar and Y Vijaya Kumar, Design and Study of the Effect of Multiple

Machining Parameters in Turning of AL6063T6 Using Taguchi Method. International Journal of

Design and Manufacturing Technology. 7(3), 2016, pp. 12–18.

[16] K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar, Studies on Tribological

Properties of SiC and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method.

International Journal of Mechanical Engineering and Technology, 7(6), 2016, pp. 199–208

experimental study on wear behaviour of sic filled …...that predominantly influence the specific...

Documents