Kingdom of Saudi Arabia ‫المملكة العربية السعودية‬

Ministry of Higher Education ‫وزارة التعليم العالي‬

Qassim University ‫جامعـة القصيـم‬
College of Engineering ‫كليه الهندسة‬
Mechanical Engineering Dept. ‫قسم الهندسة الميكانيكية‬
Manufacturing Processes
ME 335 – (Fall 381)
Sheet No. 6
Processing of Polymers and Reinforced Plastics
Q1. Consider a composite consisting of reinforcing fibers with E f = 300 GPa. If the
allowable fiber stress is 200 MPa and the matrix strength is 50 MPa, what
should be the matrix elastic modulus so that the fibers and matrix fail
simultaneously?
Q2. A piece of thermoplastic is stretched under 5 MPa. After 30 days, the stress level
has decayed to half the original level. How long will it take for the stress level to
reach one tenth of the original value?
Q3. In processing a batch of polystyrene at 120 oC to make a certain part, it is found
that the polystyrene’s viscosity is twice that desired. Determine the temperature
at which this polymer should be processed.
Q4. Calculate the elastic modulus and percentage of load supported by fibers in a
composite with an epoxy matrix (E = 10 GPa), with 20% fibers made of high-
modulus carbon.
Q5. A fiberglass composite is composed of a matrix of vinyl ester and reinforcing
fibers of E-glass. The volume fraction of E-glass is 35%. The remainder is vinyl
ester. The density of the vinyl ester is 0.882 g/cm3, and its modulus of elasticity
is 3.60 GPa. The density of E-glass is 2.60 g/cm3, and its modulus of elasticity
is 76.0 GPa. A section of composite 1 cm by 50 cm by 200 cm is fabricated with
the E-glass fibers running longitudinal along the 200 cm direction. Assume
there are no voids in the composite. Determine the (a) mass of vinyl ester in the
section, (b) mass of E-glass fibers in the section, and (c) the density of the
composite.

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Sheet (No.6) Manufacturing Processes (ME335) Fall-381

Q6. By repeating problem (Q5), determine the modulus of elasticity in the

longitudinal direction of the glass fibers.
Q7. A composite sample of carbon reinforced epoxy has dimensions of 12 in by 12 in
by 0.25 in and mass of 1.8 lb. The carbon fibers have a modulus of elasticity of
50(106) lb/in2 and a density of 0.069 lb/in3. The epoxy matrix has modulus of
elasticity of 0.61(106) lb/in2 and a density of 0.042 lb/in3. What is the volume
fraction of (a) the carbon fibers and (b) the epoxy matrix in the sample?
Assume there are no voids in the sample.
Q8. By repeating problem (Q7), what is the predicted value for the modulus of
elasticity in the longitudinal direction?
Q9. A composite has a matrix of polyester with Kevlar-29 fibers. The volume
fractions of polyester and Kevlar are 60% and 40%, respectively. The Kevlar
fibers have a modulus of elasticity of 60 GPa in the longitudinal direction and 3
GPa in the transverse direction. The polyester matrix has a modulus of elasticity
of 5.6 GPa in both directions. Determine the modulus of elasticity for the
composite in the longitudinal direction.
Q10. An extruder has barrel diameter and length of 100 mm and 2.8 m, respectively.
The screw rotational speed = 50 rev/min, channel depth = 7.5 mm, and flight
angle = 17°. The plastic melt has a shear viscosity = 175 Pa-s. Determine:
(a) The extruder characteristic?
(b)The die characteristic (K) for a circular die opening with diameter = 3 mm
and length = 12 mm?
(c) The operating point (Q and p)?

2
Sheet (No.6) Manufacturing Processes (ME335) Fall-381

Data Sheet:

Table 10.2:
Glass-Transition and Melting Temperatures of Selected Polymers

3
 Sheet (No.6) Manufacturing Processes (ME335) Fall-381

vHW
Q  Qd  Qp t
P Qd 
vd 2

 2 HD2 N sin  cos  pDH 3 sin 2 

Q 
2 12l
F = d(mv)/dt Ac = Af + Am Ec = xEf +(1-x)Em
σc = xσf + (1-x)σm e = σ/E = F/AE Ff/Fm = AfEf/AmEm

4  k x D H VI
A

k px  p0e e
V Deq l v
UTS  UTS0 e  nP k  k0 1  P 
n  VwC
3
 L  VI
Vsint  Vgreen 1   ve
 L0  uA
−𝒕 𝝅𝑫𝟒𝒅
𝝈= 𝝈𝒐 𝒆 ⁄𝝀 log η = 12-[(17.5 ∆T)/(52+ ∆T)] 𝑲= 𝟏𝟐𝟖𝜼𝒍𝒅