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INVESTIGATIONS ON TRIBOLOGICAL BEHAVIOR OF

NATURAL FIBER RESIN COMPOSITE FOR BRAKE PAD

A PROJECT REPORT
Submitted By,
APINASH G (15AUR003)
GOKULPRASATH K (15AUR016)
KATHIRESWARAN P (15AUR025)

In partial fulfilment of the requirements for the award of the degree


Of
BACHELOR OF ENGINEERING
In

AUTOMOBILE ENGINEERING
DEPARTMENT OF AUTOMOBILE ENGINEERING
SCHOOL OF BUILDING AND MECHANICAL SCIENCES

KONGU ENGINEERING COLLEGE


(Autonomous)
PERUNDURAI ERODE – 638 060
APRIL 2019

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DEPARTMENT OF AUTOMOBILE ENGINEERING
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI ERODE – 638060

BONAFIDE CERTIFICATE

This is to certify that the project report entitled INVESTIGATIONS ON


TRIBOLOGICAL BEHAVIOR OF NATURAL FIBER RESIN COMPOSITE FOR
BRAKE PAD is the bonafide of project work done by APINASH G (15AUR003),
GOKULPRASATH K (15AUR016), KATHIRESWARAN P (15AUR025) in partial
fulfilment of the requirements for the award of the Degree of Bachelor of Engineering in
Automobile Engineering of Anna University, Chennai during the year 2019 - 2020.

SUPERVISOR HEAD OF THE DEPARTMENT


Mr. P.Senthilkumar, M.E., Dr. P. Somasundaram, M.E, Ph.D.,
Assistant Professor, Professor and Head,
Department of Automobile Engineering, Department of Automobile Engineering,
Kongu Engineering College, Kongu Engineering College,
Perundurai - 638060. Perundurai - 638060.
Erode, Tamil Nadu Erode, Tamil Nadu.

Submitted for the end semester viva voce examination held on ___________

INTERNAL EXAMINER EXTERNAL EXAMINER

EXTERNAL DECLARATION:

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DEPARTMENT OF AUTOMOBILE ENGINEERING
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI ERODE – 638060
APRIL 2019
DECLARATION

We affirm that the project report titled, INVESTIGATIONS ON TRIBOLOGICAL


BEHAVIOR OF NATURAL FIBER RESIN COMPOSITE FOR BRAKE PAD, being
submitted in partial fulfilment of the requirements for the award of Bachelor of Engineering
and it is the original work carried out by us. It has not formed the 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.

Date:
APINASH G (15AUR003)
GOKULPRASATH K (15AUR016)
KATHIRESWARAN P (15AUR025)

I certify that the declaration made by the above candidates is true to the best of my
knowledge.

Date: Name and signature of the supervisor


with seal

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ABSTRACT

Brake pads are the main components that play important role in safety riding. It is
used for reducing velocity and stopping the vehicle as expected. Generally, there are two
basic materials for brake pads namely asbestos and non-asbestos. Asbestos brake pads are
carcinogenic. This research aims to develop an eco-friendly alternative composite material
for brake pads. The composite consists of jute and coir fibres, glass fibre and vinyl ester
resin. Initial study of this research is to measure coefficient of friction and wear rate of the
alternative composite material along with the tensile and compressive strength for brake pads.
Wear rate and coefficient of friction of the alternative composites brake pads are equal to the
commercial ones.

Keywords:
Jute fibre, Coir fibre, Glass fibre, Vinyl ester resin, Hand lay technique.

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ACKNOWLEDGEMENT

First and foremost, our sincere thanks to the almighty, who has blessed us to
accomplish the project successfully. Then, we thank our correspondent
Thiru. A. Venkatachalam and all the members of Kongu Vellalar Institute of Technology
Trust for providing us with a plethora of facilities to complete our project in a successful
manner.

We wish to express our sincere thanks to our beloved Principal


Prof. S. Kuppuswami B.E., M.Sc. (Engg), Dr. Ing (France) for allowing us to have the extensive
use of college facilities to do this project.

We solemnly express our gratitude to our beloved Dean


Dr. K. Krishnamurthy M.E., PhD, for his guidance, support and encouragement.

The Head of the Department of Automobile Engineering,


Dr. P. Somasundaram M.E, Ph.D., for his guidance, support and encouragement.

We specially thank our guide Mr. P. Senthilkumar M.E., for his continuous support
for the successful completion of the project. We also thank our project coordinators and the
review committee for their suggestions and encouragement.

We express our sincere thanks to all teaching and non-teaching staff members of
Automobile Engineering department.

We also extend our gratitude to our beloved parents and friends.

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CONTENTS

CHAPTER NO. PARTICULARS PAGE NO.


1. Introduction 1
1.1 Asbestos 1
1.1.1 Hazardous of Asbestos 2
1.1.2 Risk of exposure 3
1.1.3 Affecting health conditions 3
1.2 Jute 5
1.2.1Composition and properties of Jute 6
1.3 Coir 7
1.3.1 Composition and properties of Coir 8
1.4 Glass fibre 9
1.5 Vinyl Ester Resin 11
2. Literature Review 12
3. Methodology 21
3.1 Alkali treatment 21
3.2 Hand lay-up method 21
3.3 Fibre material preparation 22
3.3.1 Brake pad composition 22
3.3.2 Mechanical testing 22
4. Results and conclusions 25
4.1 Wear test 25
4.2 Tensile test 30
4.3 Compressive test 33
5. Conclusion 34
5.1 Scope for future research 34
5.2 Applications 36
References 37

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LIST OF FIGURES

FIGURE No. TITLE PAGE No

1.1 Classification of fibres 5


3.1 Pin on Disc-Friction and Wear tester 23

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LIST OF TABLES

TABLE No. TITLE PAGE No.

1.1 Chemical composition of Jute fibre 7


1.2 Composition of Coir fibre 9
1.3 Properties of Glass fibre 10
4.1 Wear test result at 50cm/sec sliding 25
velocity
4.2 Wear test result at 100cm/sec sliding 26
velocity
4.3 Weight loss result at 50cm/sec sliding 28
velocity
4.4 Weight loss result at 100cm/sec sliding 29
velocity
4.5 Tensile test result 32
4.6 Compressive test result 33

LIST OF GRAPHS

GRAPH No. TITLE PAGE No.

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4.1 Coefficient of friction at different loads at 26
50cm/sec sliding velocity
4.2 Coefficient of friction at different loads at 27
100cm/sec sliding velocity
4.3 Weight loss result at 50cm/sec sliding velocity 28
4.4 Weight loss result at 100cm/sec sliding 29
velocity
4.5 Tensile test observed between Displacement 33
(mm) and Bearing Load (N)

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CHAPTER 1
INTRODUCTION

A brake plays a vital role in any automotive vehicle to slow down the
vehicle or to stop the vehicle completely. During the applying of brake, friction
between restraint and rotating disc causes to prevent the vehicle by changing
mechanical energy of the vehicle into energy. Therefore, the restraint ought to
quickly absorb heat, should withstand for higher temperatures and should not
wear. The brake pad material ought to maintain a sufficiently high friction
constant with the brake disc, not decompose or break down in such a way that
the friction coefficient with the brake disc is compromised at high temperatures
and exhibit a stable and consistent friction constant with the brake disc.

1.1 ASBESTOS:

Asbestos is one of the fibrous materials to build as the commercial uses


of manufacturing materials. Asbestos refers to a set of six naturally occurring
fibrous minerals. It has six primary chemical sub-classifications of chrysotile,
crocidolite, amosite, anthophyllite, tremolite, and actinolite. Among these,
chrysotile and amosite asbestos are the most common uses of material
selections.
Boasting excellent heat and fire-resistant properties, asbestos has a
history that dates back to the ancient Greek island of Ewoia. As a matter of fact,
the word “asbestos” comes from a Greek word meaning “inextinguishable.”
Even centuries ago, people were awed by this mineral for which they found
many uses. Legend has it that an early Roman emperor used to marvel at the
fact that he could throw his asbestos tablecloth into the fire after meals and it
would emerge clean and unscathed.

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Although asbestos fibers are microscopic in nature, they are extremely
durable and resistant to fire and most chemical reactions and breakdowns. These
properties of asbestos were the reasons that supported its use for many years in
a number of different commercial and industrial capacities.
The strength of asbestos, combined with its resistance to heat, allowed it
to become the material of choice in a variety of products, including, but not
limited to, roofing shingles, floor tiles, ceiling materials, cement compounds,
textile products, and automotive parts.
However, despite its many uses, even the early civilizations surmised that
asbestos was the cause of the pulmonary problems being exhibited by those who
worked in the mines where asbestos was extracted or those who spun and wove
asbestos into fabric. In particular, Roman philosopher and naturalist Pliny the
Elder noted that slaves who mined asbestos suffered from a sickness of the
lungs and died at an early age.

1.1.1 HAZARDNOUS OF ASBESTOS:

The use of asbestos sharply declined in the late 1970s when it became
evident that asbestos posed a threat to human health and safety. Today, asbestos
is classified as a known human carcinogen. The durability property makes
asbestos a desirable one to manufacturer even then hazardous. Asbestos fibers
are microscopic (roughly 0.02 the diameter of a human hair), and therefore, are
easily inhaled. Once inhaled, the fibers cling to the respiratory system, including
the lining of the lungs and inner cavity tissue. As asbestos fibers are typically
quite rigid, they become lodged in the soft internal tissue of the respiratory
system and are not easily expelled or broken-down by the body.
Hundreds of thousands of people were exposed to asbestos in some
capacity as a result of the mineral’s extensive use in domestic, commercial, and
industrial products. There is no safe type of asbestos and no safe level of
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exposure. Nearly all those with exposure history are potentially at risk of
serious respiratory health complications.
Asbestos is now strictly regulated as exposure to this toxic mineral can
now be directly and scientifically linked to a number of lung and respiratory
health conditions.

1.1.2 RISK OF EXPOSURE:

There were hundreds of exposures. Asbestos was used in thousands of


commercial products and industrial capacities and those working with the
material in these industries are potentially at risk of harmful exposure.
Industries in which asbestos use was particularly prevalent include shipbuilding,
commercial product manufacturing, power plants, and construction. Workers
employed in these industries prior to 1980s likely encountered asbestos
products.
While asbestos exposure is hazardous, not all asbestos products are
inherently hazardous. Because asbestos must be inhaled to represent a health
risk, only loose asbestos fibers or those in the air supply (a condition known as
friable) represent a true hazard. Stable asbestos compounds, such as intact
cement, tiles, or other products are generally not an immediate hazard. Exposure
to friable asbestos fibers was common when grinding, chipping, demolishing, or
retrofitting asbestos products. Each of these functions could potentially release
asbestos into the air supply where it would be easily inhaled.

1.1.3 AFFECTING HEALTH CONDITIONS:

There are three major lung conditions traced directly to asbestos


exposure. These are lung cancer, mesothelioma, and asbestosis. Lung cancer
risk, typically associated with tobacco use, is known to be exacerbated by

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exposure to asbestos. Symptoms include coughing, chest pain, and difficulty
breathing. Mesotheliomas a rare and aggressive cancer of the lung and inner
body’s cavity lining- a thin membrane known as the mesothelium.
Mesothelioma is typically recognized as the most clearly attributable disease
resulting from asbestos exposure.
Mesothelioma originates in three locations. Pleural mesothelioma forms
in the lining of the lungs and is the most common form of the disease.
Peritoneal and pericardial mesothelioma are less common and form in the lining
of the abdominal cavity and lining of the heart, respectively.
Asbestosis is a degenerative and progressive non-malignant long-term
respiratory condition. Asbestosis results from the formation of scar tissue
plaques on the visceral surface of the pleura.
In past years amphibole is employed in restraint. But asbestos causes
carcinogenic effects on human health. It ends up in the investigation on new
materials significantly agricultural residues or wastes area unit currently rising
as new and cheap materials within the restraint development with business
viability and environmental acceptability for brake pad which possesses all the
required properties. There are a unit tinny, semi metallic and organic brake pad
materials. Generally, brake pad consists of a composition of reinforced fibres,
binder, fillers, friction additives. These entire constituents area unit mixed or
amalgamated in varied composition and brake pad material is obtained
victimization totally different producing techniques. Reinforced fibres increase
mechanical strength to the friction material. The purpose of a binder is to take
care of the restraint structural integrity underneath mechanical and thermal
stresses. It holds the elements of a brake pad along and to stop its constituents
from crumbling apart. Fillers in a brake pad are present for the purpose of
improving its manufacturability as well as to reduce the overall cost of the brake
pad.

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There are so many natural fibres which are obtained from nature, such as
sisal, coconut, banana, wool, coir, jute, flax, hemp, cotton, kenaf, abaca, ramie,
silk, pineapple. Natural fibres are classified as animal cellulose fibre sand which
are further divided into bast, leaf, seed and fruit fibres, etc. as shown in figure.

Fig 1.1
(Classification of fibres)

1.2 Jute:
Jute is commonly used natural fibre as reinforcement in green
composites. Jute is type of bastfibres from Tiliaceae family and having
scientific name is Corchorus capsularis because it is extracted from plants of
corchorus, it is the low-cost natural fibre and it is presently the bast fibre with
the maximum production volume. Jute is intuitive to the Mediterranean but now
a day’s Bangladesh, India, China, Japan, Thailand, Indonesia, and Brazil
provide the finest type for the growth of jute. Overall world production of jute
fibre is around 2300x10³ to2850x10³ tones. Jute can grow 2–3.75 m in height
and are very brittle, with a low extension to break because of the high lignin

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content (up to 12–16%). Jute fibres have a less resistance to moisture, acid and
UV light.
Conversely, their fine texture as well as their resistance to heat and fire
are providing a wide range of applications in industries such as textile,
construction, and automotive.

1.2.1 COMPOSITION AND PROPERTIES OF JUTE FIBRE:


Climatic circumstances, phase and the degradation procedure affect the
configuration of fibre sand the chemical composition. The main chemical
constituent of living tree is water, and all the plant cell walls contain mostly
cellulose and hemi-cellulose that are contained with lignin, with smaller
aggregate of protein and starch. Basically, natural fibres are contained of
cellulose, hemicelluloses, lignin and other waxy material in which cellulose is
the main constituent of natural fibre. The stems of the plant are made from cells
and cell walls, these cells could be instituted by the leaves or the sources of
plants. It was induced by enzymes, such as cellulose. So that, cellulose makes
up the preponderance of fibre and offers strength properties to the fibre.
As, the all-natural fibres are lingo cellulosic in nature, they possess better
acoustic insulation properties along with the thermal properties as compared to
the other synthetic fibres. Mechanical properties of synthetic fibres are better as
compared to natural fibres, but that can be further enhanced by different surface
treatment of fibres as alkali treatment, silane treatment etc. Natural fibres are
possessing high specific modulus, high specific strength, low density etc. are the
reasons, of high demand in the industries for the improvement of the composite
materials.
The required mechanical characterisation of jute fibres is mentioned in
table below. The tensile strength of glass fibre is more than that of plant fibres,
but the specific modulus of natural fibres is higher than that of glass fibres. Due
to these reasons, the natural fibres are widely used for the different applications

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in composite materials. Fibre characteristics are the major parameters for
enhancing the performance of the natural fibre reinforced polymer-based
composites. It has been observed that one of the studies in moisture content is
having a wide impact on the biological performance of natural fibre reinforced
polymer composites. Factors in consideration of fibre chemical properties
consist of crystalline cellulose content, cell number, aspect ratio and micro-
fibrillar angle. Lesser micro-fibrillar angle and Greater cellulose content are
vital for high fibre strength. Natural fibres are generally characterized by their
aspect ratio. The tensile strength, young’s modulus and density of jute fibres are
the main parameters of the physical and mechanical properties as per the
research.
Cellulose Hemicellulose Lignin Pectin Moisture Wax Other
(%) (%) (%) (%) (%) (%)
61-71 13.6-20.4 12.0-13.0 ~0.2 ~12.6 0.5 ~0.5-2.0
61-71.5 13.6-20.6 12.0-13.0 2.3 ~1.7
61-71.5 12.0-13.0 13.6-20.4 0.2 12.6 ~0.5 ~8.0
61 20.4 13 12.6
45-63 12.0-25 4.0-10.0 12.0-13.0 ~0.5 ~8.0
71 14 17 0.5
61-71 14-20 12.0-13.0
61-63 13 5.0-13.0 0.5
61-71 14-20 12.0-13.0
58-63 21-24 12.0-14.0
61-73.2 13.6-20.4 12.0-16.0
72 13 13
Table 1.1
(Chemical composition of Jute fibre)
1.3 COIR:
Coir is a hard, versatile, natural fibre available in large quantities
(World: 0.78 million tons/year; India: 0.165 million tons/year) and is a
renewable resource. Coir fibre is obtained by de-husking coconut and separating
it from the pithy material of the fibrous mesocarp by a process of retting.
Retting, being a biological process, may be carried out at any time during the

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year either in freshwater or saline water, flowing water or stagnant water, deep
back waters. The husks may be placed for retting either in the upright position
in coir nets or in pits. It has been reported (CSIR1960) that the retting is quicker
in the summer months but the colour of the fibre is brown. The fibres obtained
from the husks retted in saline water are stronger and have a good colour
(golden yellow); in fibres obtained from husks placed in freshwater, the retting
is incomplete resulting in same amount of pith adhering to the fibre. Fibres
obtained from retting in stagnant water were found to be weak. Husks soaked in
the back waters and placed upright in coir nets yielded better quality fibres, both
in terms of strength and colour for grading purposes.
The coir fibre is multicellular (the fibre contains 40 to 400 or more cells
in its total cross-section) and its cross-section is polygonal or round. The
individual cell size is 13-15μm in diameter (Bergen & Krause 1940) and the
length to diameter ratio of the cell is of the order of 35. The walls are thin to
fairly thick with lens-shaped silicified stigmata (15μm in diameter) on their
surface. These are delicate thickenings with a few of them are circular or spiral
in shape. There is a central cavity in each cell called lumen, which is medium to
large in size (polygonal, rounded to elliptic in shape). The surface of the
individual cell is smooth or rough with certain defects like cross-markings,
while the surface of the fibre is coated with waxy materials called cuticle.

1.3.1 COMPOSITION AND PROPERTIES OF COIR FIBRE:


The chemical constituents of pure coir fibre have been found (Menon
1935, 1939) to be cellulose, lignin, hemicelluloses, pectin, ash and water
soluble. The relative percentages of the chemical constituents in the fibre and
the nature of the lignin complex have been studied and are found to be vary
with the age of the nut from which the fibre is extracted (Menon 1939). It has
also been pointed out that aromatic components of a pectic nature present in the
husks, serve as lignin precursors (Bergen & Krause 1940). The ageing of the

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fibres is found to render the fibres stiffer and tougher and leads to an increase in
the lignin content.

Total Hot
Maturity Hemi Ligni Cellulos water water Ash
Cellulos n e solubl solubl
e e e
Very young nuts 0.25 41.02 36.11 15.5 4 -
Young nuts 0.15 40.52 32.86 16 2.75 -
Matured nuts 0.25 45.84 43.44 5.25 3 0.13
Table 1.2
(Composition of coir fibre)

Coir fibre has the highest toughness compared to all other natural fibres.

1.4 GLASS FIBRES:

More than 95% of the fibres used in reinforced plastics are glass fibres,
because of reason as they are more expensive compared to natural fibre, simple
to manufacture and acquires high strength and stiffness with respect to the
plastics which are reinforced. Glass fibre are low in density, resistance to
chemicals, insulation capacity are other bonus characteristics. Major demerit of
glass fibre is that they will prone to break when subjected to high tensile stress
for continuous loading. Glass fibres are offered in the form of tapes, cloth,
mates continuous & chopped filaments, roving and yarns. By adding chemicals
to silica sand glasses fibres improve vastly in performance when a fine metal
outline is included with refractory ceramics by improving their impact
resistance and thermal fatigue properties which ensure high strength, light
weight and good fatigue resistance. Better flexural properties are observed in
some metal fibres reinforced plastic composites which also improve strength
and weight, than glass fibres. Temperature, moisture and other factors also
dictate the tolerance levels of glass fibres and the demerit further mixed by the

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fact that the brittleness of glass does not make room for earlier warning before
the anamorphic failure. But this may be simply overlooked in sight of the fact
the wide range of glass fibre variety lend themselves affably to fabrication
processes like filament winding lay-up, matched die-mounding and so on.
However, their poor tolerance of high temperature and the resultant steep
variations of thermal coefficient of expansion with the resins are an obstacle
that limits their application.
Glass fibre (or glass fibre) is a material consisting of numerous extremely
fine fibres of glass. Glass fibre when used as thermal insulating material is
manufactured with bonding agent to trap many small air cells, resulting in the
characteristically air-filled low-density "glass wool" family of products. Glass
fibre is light weight, extremely strong and robust. Its bulk strength, stiffness and
weight properties are also equivalent when compared to metals. The E-glass
fibre with random orientation was used as a reinforcing material. This kind of
glass combines the characteristics of C-glass with very good insulation to
electricity. Properties of E-Glass fibre are given in the table below

Fiber Tensile Compressive Density  Thermal Softening


type strength  strength  (g/cm3) expansion T
(MPa) (MPa) (µm/m°C) (°C)

E-glass 3445 1080 2.58 5 846

S-2 4890 1600 2.46 2.9 1056


glass

Table 1.3
(Properties of glass fibre)
1.5 VINYL ESTER RESIN:
Vinyl ester resin, or often just vinyl ester, is a resin produced by the
esterification of an epoxy resin with acrylic or methacrylic acids. Vinyl esters

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are halfway between polyesters and epoxies as far as typical properties and
toughness, and they are a step up on a cost basis. Their longer double bonded
vinyl groups that link the ester groups together contribute a flexible nature to
the resin. That flexible nature produces parts that withstand impacts and
repeated flexing without developing cracks.
Vinyl esters provide excellent resistance to water, organic solvents and
alkalis, but less resistance to acids than polyesters. Vinyl esters are stronger than
polyesters and more resilient than epoxies. Moulding conditions for vinyl esters
are similar to those for polyesters.

 Vinyl ester is formulated for maximum corrosion resistance to most fuels,


vapours, and chemicals.
 It's heat resistant and blended for durability.
 It features excellent impact strength and high tensile elongation.
 It's low viscosity, so it's easy to pour and just right for vacuum infusion.

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CHAPTER2

LITERATURE REVIEW

K.K. Ikpambese et-al [1] prepared brake pad material using natural fibre called
as palm kernel fibres for its eco-friendly nature with CaCO3, graphite and Al2O3
as other constituents. Epoxy resin is used as binder. Composition of 40% epoxy-
resin, 10% palm wastes, 6% Al2O3, 29% graphite’s, and 15%CaCO3gave better
properties than other composition. The results were compared with commercial
asbestos, palm kernel shells. Result shown that palm kernel fibres can be
suitable for replacement of asbestos brake pads with epoxy resin as a binder.

C.M.Ruzaidi et-al [2] incorporated the waste materials, palm slag as filler
material along with CaCO3 and dolomite in brake pad material to increase the
performance to cost ratio. The final compositions are made using steel fibres,
phenolic resin and other friction additives. Results shown that even though the
dolomite brake pad composite had the highest strength, it showed poor wear
behaviour compared to CaCO3 and palm slag. Thermal stability of the palm slag
material shown the better performance compared to the other two filler material
in the range of 60˚C to 1000˚C. It is proven that phenolic resin cannot be used at
high temperatures since curing of binder starts at a temperature of 145˚C caused
for the weight loss.

C.M.Ruzaidi et-al [3] has studied the mechanical properties and wear
behaviour of brake pads produced from palm slag. In this paper the composite
formed after the hand hydraulic pressing is further compacted and cured by
using a hot press at 150˚C with different pressures: 10, 20, 40, and 60 tons of
compression molding pressure for 5 minutes. Result shown that hardness and
compressive strength is higher for the composite material which is pressed less

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than 60 tons of compression and wear rate is low for the same. Based on the
mechanical properties and wear behaviour, this research indicated that palm
slag can be used effectively as an alternative to other fillers in brake pad
composites. The compactness of the palm slag brake pad composite, a result of
the processing compression load, plays an important role in enhancing the
mechanical properties and wear behaviour of the product.

A.O.A. Ibhadode et-al [4] used palm kernel shells, agro waste material as
friction lining material for the brake pads. Among other agro wastes like
hyphened the abaca kernel shell; and deled palm kernel shell shown better
performance after a series of tests. The mechanical properties and physical
properties compare well with commercial asbestos-based friction lining
material. Its performance under static and dynamic conditions compare well
with the asbestos-based lining material. However, further refinement of the
palm kernel shell lining formulation is recommended in order to have a
comparable wear rate at higher vehicular speeds.

IDris et-al [5] made a replacement brake pad victimization banana peels waste
to replaced amphibole and phenolic as a binder was investigated. The rosin was
varied from five to thirty skyscrapers with interval of five skyscrapers.
Morphology, physical, mechanical and wear properties of the brake pad were
studied. The results shown that compressive strength, hardness and relative
density of the made samples were seen to be increasing with accumulated in
skyscraper rosin addition, whereas the oil soak, water soak, wear rate and share
burn shrunken as skyscraper rosin accumulated. The samples, containing 25 wt
% in un-carbonized banana peels and 30 wt% carbonized gave the better
properties in all. The result of this analysis indicates that banana peels particles
are often effectively used as a replacement for amphibole in brake pad
manufacture.

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Poh Wah lee et-al [6] studied the friction and wear performance of Cu-free and
Sb-free environmentally friendly automotive brake friction materials with
natural hemp fibres and geo polymers as a fraction replacement of synthetic
kevlon fibres and phenol resins respectively. Using geopolymer in the brake
materials reduced the amount of phenol resin, which will release volatile
organic compounds when pads are subjected to temperatures higher than 300˚C.
The dynamometer result shown that the modified samples had better
performance when compared to the T-baseline (Cu, Sb based). However, the
modified samples exhibit higher wear rate than the T-baseline. +

Yun Cheol Kim et-al [7] investigated the tribological properties of phenolic
resin, potassium titanate whiskers, and cashew nut shell liquid (CNSL) cured by
aldehyde using a pad-on-disk type friction tester. Mixture of aramid pulp, rock
wool, potassium titanate is used as fibre. But in this study, only the effects of
phenolic resin, potassium titanate, and CNSL on the physical properties of the
friction material were investigated. The average coefficient of friction is
decreased when the amount of potassium titanate is increased. Phenolic resin
increased coefficient of friction but causes for the high noise propensity. While
noise occurrence reduced by increasing the CNSL and potassium titanate as
friction material.

C.M.Ruzaidi et-al [8] investigated the development of asbestos free brake pad
composites using different fillers (palm slag, calcium carbonate and dolomite)
with phenolic as binder, metal fibre as reinforcement, graphite as lubricant and
alumina as abrasive. Three types of composites were prepared by compression
molding of mixture of three separate fillers. The result showed that palm slag
has significant potential to use as filler material in brake pad composite. The
wear rate of palm slag composite was comparable with the conventional
asbestos based brake pad. The result also supported by SEM micrograph. Palm

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slag and calcium carbonate (CaCO3) brake pad composite shown better wear
properties than dolomite and comparable with the conventional asbestos based
brake pads.

M.A.Maleque et-al [9] used natural fibre reinforced aluminium composite,


coconut fibres as filler or fibre along with aluminium composite with phenolic
resin as binder. Composite is made using powder metallurgy technique. The
better properties in terms of higher density, lower porosity and higher
compressive strength were obtained from 5% and 10% coconut fibre
composites. The compressive strength showed the 10% coconut fibre exhibited
higher strength to withstand the load application and higher ability to hold the
compressive force. From the morphological study of the materials, it was found
that the coconut fibre well distributed to the matrix and acts as filler in the
friction materials.

Zhezhenfu et-al [10] developed Eco-friendly brake friction composites which


are composed of plant flax fibre, mineral basalt fibre, and as reinforcements,
natural graphite as solid lubricant, zircon as abrasive, vermiculite and baryte as
functional and space fillers, and cardanol based benzoxazine toughened
phenolic resin as binder. Vermiculite acts as noise reduction agent. The friction
sample without flax fibres shows slightly higher friction coefficient than the
samples containing flax fibres at lower temperature. Also, the effect of
temperature on friction coefficient indicates that the fade phenomenon appears
at higher temperature and higher content of flax fibres. Therefore, the optimal
amount of flax fibres led to the stable and suitable friction coefficient. It is
evident that at higher temperature, the wear resistance of friction samples
containing flax fibres was enhanced significantly due to ductile fracture and
char formation of the natural fibres at elevated temperature.

15
T. Singh et al [11] designed, fabricated and characterized the hybrid phenolic
friction composites based on lapinus– aramid combination. Even though aramid
pulp has peculiar characteristics like better fibrillation with most of the
ingredients; ease processing aids by imparting better pre-form green strength it
loses its strength at elevated temperatures. Lapinus/volcanic rock fibre
inherently comprises of metallic-silicates (viz. mixture ofSiO2,CaO +
MgO,Fe2O3,Al2O3 ). It possesses good dispersion property, reduces sensitivity to
cracking and blistering during molding/post-curing, possess heat resistant up to
1000˚C. It uses phenolic resins of NOVLAC type as binder, barites and graphite
as other compositions. The results also shown that the increased lapinus content
with corresponding decrease in aramid content were observed to be effective to
enhance the friction -performance, fade performance and stability coefficient of
the friction composites, however wear performance, recovery performance,
friction fluctuations and variability in friction coefficient get deteriorates.

Kunal singha [12] reviewed on basalt fibre as it is now being a popular choice
for the material scientist for the replacement of steel and carbon fibre. Industrial
production of basal fibres on basis of their new technologies made its cost equal
or even less than the glass fibre. Basalt originates from volcanic magma and
flood volcanoes, a very hot fluid or semi fluid material under the earth's crust,
solidified in the open air. Chemical composition of basalt rock contains oxides
of Si, Mg, Al, Fe, Na, K, Ti, Mn, Cr etc. Due to its high temperature resistance
it can be used as substitute for asbestos in brake pads. If acidity modulus Ms
>1.5 then it is called rock wool fibre. Basalt fibre possesses low weight to
strength ratio, better

Arnab Ganguly et al [13] prepared new composite material consists of


phenolic resin along with epoxy resin as toughness to overcome the brittle

16
nature which is caused by phenolic resin. Graphite and silica flour are added to
act as anti-wear additives and the addition of silicone resins acts as a fire
retardant. The cashew nut resin is added to improve the temperature resistance
of the composite. The composite synthesized was characterized using SEM
(scanning electron microscopy) technique. The samples were subjected to
several tests including a wear test, ‘thermo gravimetric analyses’. It was also
found to exhibit exemplary friction and anti-wear characteristics along with
providing high temperature stability. The constituents used in the composite are
extremely economical and are hence appropriate for industrial applications.

P.V. Gurunath et al [14] used newly developed resin in brake pad materials
due to phenolics suffer from serious drawbacks and limitations such as
evolution of noxious volatiles (viz. NH3(ammonia), HCHO(formaldehyde), etc.)
during ambient temperature curing very short shelf life. Results are compared
with the resin that is capable of heat induced ring opening polymerization is
made in the laboratory with the traditional Novel phenol resin., it was concluded
that the composites based on newly developed resin showed superior
performance to the composite based on traditional phenolic resin. These
features, however, reflect the performance of materials in severe operating
conditions where surface temperature of pads may exceed 400oC. It indicated
large potential to replace the commercially used phenolic resins. The laboratory
scale preparation studies also indicated the cost of synthesis of the new resin is
comparatively lower than the phenolics. During the experiment they noted that
there is no correlation between strength properties of resins, composites and
their wear behaviour.

Priyadarshini Tapas et al [16] studied the physical and mechanical properties


of Al2O3 filled jute fiber reinforced epoxy composites. The experiment was
carried out to identify the effect of filler properties of composites. Jute and

17
Al2O3 taken as reinforcement and epoxy as matrix, they have observed that
filler makes significant changes on different properties of composites. They
have also observed that hardness, strength and tensile modulus increased with
increase in the fiber and filler and inter laminar shear strength increased only by
increasing fiber and decreased in addition of filler on composite

M. Ramesh et al. [17] observed the mechanical properties of jute, sisal and
glass fiber reinforced composites. In addition to that they observed maximum
tensile strength of glass fiber into jute fiber composite. They have also noticed
that sisal and jute mixture composites sample is capable of having maximum
flexural strength and maximum impact strength. The variation of tensile
strength and compressive strength of epoxy based sisal-glass hybrid composites
was also studied.

Gopinath et al [18] studied experimentally the mechanical properties of jute


fiber in polyester and epoxy matrices and their results showed that jute-
polyester processing time is far minor as compared to jute-epoxy laminate.

K.Devendra, T.Rangaswamy [19] experimental results indicated that SiC


filled composites having high impact strength when compared with other filled
composites this due to that good bonding strength between filler, matrix and
fiber and flexibility of the interface molecular chain resulting in absorbs and
disperses the more energy, and prevents the crack initiator effectively. The
flexural strength results indicated that composites filled by SiC exhibited
maximum flexural strength when compared with other filled composites but
lower than the unfilled composites this is due to the good compatibility between
filler and matrix.

18
Xue Li (2007) [20] studied the increased use of natural fibers as replacement to
man-made fiber in fiber-reinforced composites and opened up further industrial
possibilities. Natural fibers have the advantages of low density, low cost and
biodegradability. However, the main disadvantages of natural fibers in
composites are the poor compatibility between fiber and matrix and the relative
high moisture absorption. Therefore, chemical treatments are considered in
modifying the fiber surface properties. The different chemical modifications on
natural fibers for use in natural fiber-reinforced composites are reviewed.
Chemical treatments including alkali, silane, acetylation, benzoylation,
acrylation, maleated coupling agents, isocyanates, permanganate and others are
discussed. The chemical treatment of fiber aimed at improving adhesion
between the fiber surface and the polymer matrix may not only modify the fiber
surface but also increases the fiber strength. Water absorption of composites is
reduced and their mechanical properties are improved.

Yafeilu et al in (2013) [21] investigated the “Jute fibers and powdered hazelnut
shells as natural fillers in non-asbestos organic non-metallic friction
composites'" about Engineering materials based on eco-friendliness imposes a
major concern in recent decades. The eco-friendliness also plays a major role in
friction composite industry. Wear particles with varying chemistries which are
toxic to the environment are released when brakes are applied. Asbestos, which
causes adverse effects on human health, was banned as friction composite in
1980. Similarly, aramide fibres, which is hardly an eco-friendly material is a
synthetic fibre is prepared by means of chemical synthesis.

Se Young Kim, In Sub Han, Sang Kuk Woo [22] the addition of filler
consisting of a combination of silicon and carbon black powders decrease the
negligible amount residual free silicon but increased the amount of internal

19
reaction bonded SIC and filler reduced the flexural strength indicating damage
to the fiber but it drastically improved the wear resistance characteristics of the
composites.

S.A.R. Hashmi et al [23] investigated the “Graphite modified cotton fiber


reinforced polyester composites under sliding wear conditions” about Natural
fiber reinforced polymer composite takes the advantage over synthetic fiber
reinforced polymer composite due to the following reasons (i) low density
(ii).wide range of mechanical properties (iii) bio degradability (iv) eco-friendly.
Cotton is one of the most popular natural fiber which is used in varied
applications from fabrics to composites.

CHAPTER 3

METHODOLOGY

20
3.1 ALKALI TREATMENT:
The collected jute and coir fibre were suspended in a solution of caustic
soda (NaOH) for one day to remove the remnant dust. The fibres are then
watered to remove the caustic soda and are exposed to sun light for one week.
The dehydrated fibres were ground into powder form of grain size of <100 mm
using a hammer mill.

3.2 HAND LAY-UP TECHNIQUE:


Hand lay-up technique is the simplest method of composite processing.
The infrastructural requirement for this method is also minimal. The processing
steps are quite simple. First of all, a release gel is sprayed on the mould surface
to avoid the sticking of polymer to the surface. Thin plastic sheets are used at
the top and bottom of the mould plate to get good surface finish of the product.
Reinforcement in the form of woven mats or chopped strand mats is cut as per
the mould size and placed at the surface of mould after plastic sheet. Then
thermosetting polymer in liquid form is mixed thoroughly in suitable proportion
with as prescribed hardener (curing agent) and poured onto the surface of mat
already placed in the mould. The polymer is uniformly spread with the help of
brush. Second layer of mat is then placed on the polymer surface and a roller is
moved with a mild pressure on the mat-polymer layer to remove any air trapped
as well as the excess polymer present. The process is repeated for each layer of
polymer and mat, till the required layers are stacked. After placing the Plastic
sheet, release gel is sprayed on the inner surface of the top mould plate which is
then kept on the stacked layers and the pressure is applied. After curing either at
room temperature or at some specific temperature, mould is opened, and the
developed composite part is taken out and further processed. The time of curing
depends on type of polymer used for composite processing. For example, for
epoxy-based system, normal curing time at room temperature is 24-48 hours.
This method is mainly suitable for thermosetting polymer-based composites.

21
Capital and infrastructural requirement is less as compared to other methods.
Production rate is less, and high-volume fraction of reinforcement is difficult to
achieve in the processed composites.

3.3 FIBRE MATERIAL PREPARATION:


Raw material Jute and coir are cleaned with water and dried for
sometimes. After various treatments its outer surface is removed using knife and
it is slice into necessary dimension.

3.3.1 Brake pad composition:


1. Jute mat, glass fiber and vinyl ester resin
2. Coir mat, glass fiber and vinyl ester resin

3.3.2 Mechanical Testing:


a) Tensile Test:
A tensile test, also known as a tension test, is one of the most
fundamental and common types of mechanical testing. A tensile
test applies tensile (pulling) force to a material and measures the specimen's
response to the stress.
The composite specimen was sized to the necessary dimension
using a cutter. The test is carried out at room temperature conditions (30˚C)
with a load cell of 250 KN and at a speed of 2mm/min. The specimen test rivets
application of tension in the work piece until it cracks. The tensile stress was
recorded according to tension. The test conducted for it blender ratio. The tests
are frequent as a minimum 3-5 times and the average values are noted.

b) Compression Test:
Compression testing is a very common testing method that is used
to establish the compressive force or crush resistance of a material and the

22
ability of the material to recover after a specified compressive force is applied
and even held over a defined period of timeCompression tests are carried out on
vinyl ester resin and composite specimens to determine modulus of elasticity,
compressive strength and Poisson’s ratio. The specimens are loaded, leaving an
unsupported length as the test section.

c) Wear Test:
Pin-on-disc wear testing is a method of characterized the
coefficient of friction, frictional force and rate of wear between two
materials. During this tribology test, a stationary disc articulates against a
rotating pin while under an applied load.

Fig 3.1
(Pin on Disc - Friction and wear tester)

Pin-on-disc wear testing can simulate multiple wear including


unidirectional, bidirectional, Omni directional and quasi-rotational. Wear test
have been conducted in the Pin-on-disc type Friction and Wear monitor with
data acquisition system which was used to evaluate the wear behavior of the

23
composites. It is versatile equipment designed to study wear under sliding
condition only. Sliding generally occurs between a stationary specimen Pin and
a rotating disc against hardened ground steel disc (En-32) surface roughness (R
a) 0.5 µm. The disc rotates with the help of a D.C. motor; having speed range 0-
2000 rev/min with wear track diameter of 100 mm. Load is to be applied on pin
(specimen) by dead weight through pulley string arrangement.

CHAPTER 4

RESULTS AND DISCUSSIONS

4.1 WEAR TEST:

24
The table 4.1, 4.2 shows the coefficient of friction of composite between
the rotating disc and the stationary specimen in the case of jute and coir
reinforced glass fiber with vinyl ester resin at different loads and at 50cm/sec
sliding velocity. From the graph it is observed that with the increase in load the
coefficient of friction decreases. It is also observed that the addition of glass
fiber increases the coefficient of friction up to 12.5%. Further addition of glass
fiber i.e. at 15%, coefficient of friction decreases. The coefficient of friction
decreases with increase in load and increases with addition of glass fiber at 75
cm/sec & 100cm/sec sliding velocities.

Composition of glass fiber %


Load(kg)
0% 5% 7.5% 10% 12.5% 15%
4kg

0.37521 0.35121 0.39882 0.42121 0.44126 0.43121


6kg

0.35121 0.33254 0.36425 0.37525 0.40121 0.39128


8kg

0.33254 0.37521 0.36554 0.35231 0.39785 0.38216


Table 4.1
(Wear test result at 50cm/sec)

25
1.4

1.2

0.8
8
6
0.6 4

0.4

0.2

0
0% 5% 8% 10% 13% 15%

Graph 4.1
(Coefficient of friction at different loads at 50cm/sec sliding velocity)

Composition of glass fibre %


Load%
0% 5% 7.5% 10% 12.5% 15%
4kg 0.39740 0.42101 0.43154 0.46656 0.47145 0.48254

6kg 0.38454 0.38462 0.38512 0.38545 0.42325 0.47154

8kg 0.36514 0.37944 0.37451 0.37523 0.42129 0.44451

Table 4.2
(Wear test result at 100cm/sec sliding velocity)

26
1.6

1.4

1.2

1
8kg
0.8
6kg
4kg
0.6

0.4

0.2

0
0% 5% 8% 10% 13% 15%

Graph 4.2
(Coefficient of friction at different loads at 100 cm/sec sliding velocity)

The table 4.3, 4.4 shows the weight loss of composite between the
rotating disc and the stationary specimen in the case of jute and coir reinforced
glass fiber with vinyl ester resin at different loads at 50cm/sec sliding velocity.
The weight loss of composite at 50 cm/sec sliding velocity shown in the graph
which was plotted against the percentage of composition and weight loss in
grams. As the load increases weight loss decreases with the addition of glass
fiber material the weight loss increases gradually.

27
Composition of glass fiber %
Load(kg) 0% 5% 7.5% 10% 12.5% 15%
4kg 0.02 0.003 0.003 0.004 0.004 0.005

6kg 0.001 0.002 0.002 0.003 0.003 0.004

8kg 0.001 0.001 0.001 0.002 0.002 0.003

Table 4.3
(Weight loss result at 50cm/sec sliding velocity)

0.03

0.02

0.02
8kg
6kg
0.01 4kg

0.01

0
0% 5% 8% 10% 13% 15%

Graph 4.3
(Weight losses at different loads and at 50cm/sec sliding velocity)

28
Composition of glass fiber %
Load(kg) 0% 5% 7.5% 10% 12.5% 15%

4kg 0.004 0.005 0.006 0.006 0.006 0.007

6kg 0.004 0.003 0.004 0.004 0.005 0.006

8kg 0.002 0.002 0.003 0.004 0.004 0.005

Table 4.4

(Weight loss result at 100cm/sec sliding velocity)

0.02

0.02

0.02

0.01

0.01
8kg
0.01
6kg
4kg
0.01

0.01

0
0% 5% 8% 10% 13% 15%

Graph 4.4
(Weight loss at different loads and at 100cm/sec sliding velocity)

29
4.2 TENSILE TEST:

Load Displacemen Time


(kg) t (mm) (Sec)
0 0 0
0 0 0
0 0.00 0
0 0 0
2.5 0.05 0.4
4.2 0.1 1
4.2 0.15 1.5
4 0.21 2
4 0.26 2.5
3.6 0.31 3
3.6 0.37 3.5
3.4 0.42 4
3.2 0.47 4.6
3.2 0.52 5.1
3 0.58 5.6
3 0.63 6.1
2.8 0.68 6.6
2.8 0.74 7.1
3 0.79 7.6
2.8 0.84 8.1
2.8 0.89 8.6
3.8 0.95 9.1
6.9 1 9.6
9.4 1.05 10.2
11.7 1.11 10.7
15 1.16 11.2
18.1 1.21 11.7
22.7 1.27 12.2
29.9 1.32 12.7
37.2 1.37 13.2
42.4 1.42 13.7
50.1 1.48 14.2
58.2 1.53 14.7
63.8 1.58 15.3
72.3 1.69 15.8
80.6 1.74 16.3
85.8 1.79 16.8

30
93.9 1.85 17.3
99.3 1.9 17.8
107.4 1.95 18.3
115.1 2.01 18.8
120.5 2.06 19.3
44.3 2.11 19.8
1.9 2.16 20.3
1.3 2.22 20.8
1.1 2.27 21.3
1.1 2.32 21.8
1.1 2.38 22.3
1.1 2.43 22.8
0.9 2.48 23.3
0.9 2.54 23.8
1.1 2.59 24.3
0.7 2.64 24.8
1.1 2.69 25.4
0.9 2.75 25.9
0.9 2.8 26.4
0.9 2.85 26.9
0.9 2.91 27.4
0.9 2.96 27.9
1.1 3.01 28.4
0.9 3.06 28.9
0.9 3.12 29.4
0.9 3.17 29.9
0.9 3.22 30.4
0.7 3.28 30.9
0.5 3.33 31.4
0.5 3.33 31.9
0.5 3.33 32.4
Table 4.5
(Tensile test result)

31
15-05-6 15-10-6 15-15-6

1400

1200
Bearing load(N)

1000

800

600

400

200

0
0 0.5 1 1.5 2 2.5 3

Displacement(mm)

Graph 4.5
(Tensile test observed between Displacement (mm) and Bearing Load (N))

4.3 COMPRESSIVE TEST:

The compressive test for jute and coir reinforced glass fiber with vinyl
ester and hardener was conducted.

SI.NO DIMENSIONS (l*b*t) LOAD


1 150mm*150mm*50mm 4.18 kN
2 150mm*150mm*75mm 5.87 kN

Table 4.6
(Compressive test result)

From the table it is observed that when thickness increases compressive strength
also increases.

32
CHAPTER 5

CONCLUSIONS

Natural fibre reinforced polymer composites are attractive and demanding


materials to replace conventional materials in order to solve critical
environmental problems. As demands for utilization of bio-degradable materials
increase due to environmental concerns and government regulations, several
industries attempt to replace the conventional materials in automobiles with
biodegradable materials where friction and wear are important. This paper
reviews the tribological behaviour of key natural fibre reinforced polymer
composites, such as jute, kenaf, sisal, coir, rice husk, date and oil palm,
sugarcane, and bio-waste products. The study on the physical, mechanical and
wear behavior of jute fiber and coir fiber composites led to the following
conclusions:
 Fabrication of woven, jute fiber and coir fiber reinforced vinyl
composites has been done successfully.
 Wear loss and coefficient of friction of jute reinforced composites
decreases with increase in normal loads.
 The coefficient of friction is increased up to 12.5% and then decreased
with the addition of filler at sliding velocity of 50Cm/Sec.
 The coefficient of friction is increased with the addition of filler at sliding
velocity of 75Cm/Sec & 100 Cm/Sec.
 The study on physical and mechanical properties of jute and coir fiber
reinforced vinyl composites revealed that these properties are affected by
fiber type, fiber content and void content.
 Wear study depicted an improvement in the wear resistance and frictional
behavior of the vinyl with the addition of jute and coir fiber.
 The weight loss is decreased with increase in sliding velocity and
increased with increase in addition of glass fiber.

33
 The jute and coir fiber reinforced vinyl composites fabricated and
experimented upon in investigation are found to have adequate potential
for a wide range of applications particularly in hostile environment.
From this investigation we conclude that the jute and coir fibre are very
appropriate material for manufacturing the braking pads for being having good
wear. And to avoid fragile featured by them, they are supported with glass fibre.
The reinforcing material contributes to the wear resistance of the material
according to the requirements of the braking pads by controlling its weight
ratios.

5.1 SCOPE FOR FUTURE RESEARCH:

The present study on jute and coir fiber reinforced vinyl composites
leaves a wide scope for future researchers to find many other aspects of these
composites. Few recommendations for the future investigation comprise:
 The present study has been carried out using simple hand lay-up
technique. However, the research work can be extended further by
considering other methods of composite fabrication and the effect of
manufacturing techniques on the performance of composites can similarly
be analyzed.
 Besides many advantages of natural fibers, the main disadvantages of
natural fibers in composites are the poor compatibility between fiber and
matrix and the relative high moisture absorption due to their hydrophilic
nature. The limited compatibility between the constituents of a composite
usually results in a decrease in the mechanical and wear properties.
Therefore, the study can be extended further by considering the chemical
treatments in modifying the fiber surface properties to improve the
adhesion between fiber and matrix materials and the study can be
analyzed similarly.

34
 The present study can be extended further by the development of hybrid

composites using hard particulate fillers along with jute fibre and the
study can similarly be analysed.

5.2 APPLICATIONS:
The applications of the newly developed composite materials can be used
to replace the asbestos materials as well as the metallic and semi metallic
materials. They are having good mechanical properties and can be used in the
following applications:

 Structures that resist wear with temperature.


 Avoiding frictional material deformation.
 Automobile parts like brake pads, brake liner and clutch plates, etc.
 Cost effective material for building and construction industry.

35
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