Professional Documents
Culture Documents
A PROJECT REPORT
Submitted By,
APINASH G (15AUR003)
GOKULPRASATH K (15AUR016)
KATHIRESWARAN P (15AUR025)
AUTOMOBILE ENGINEERING
DEPARTMENT OF AUTOMOBILE ENGINEERING
SCHOOL OF BUILDING AND MECHANICAL SCIENCES
i
DEPARTMENT OF AUTOMOBILE ENGINEERING
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI ERODE – 638060
BONAFIDE CERTIFICATE
Submitted for the end semester viva voce examination held on ___________
EXTERNAL DECLARATION:
ii
DEPARTMENT OF AUTOMOBILE ENGINEERING
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI ERODE – 638060
APRIL 2019
DECLARATION
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.
iii
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.
iv
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 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.
v
CONTENTS
vi
LIST OF FIGURES
vii
LIST OF TABLES
LIST OF GRAPHS
viii
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)
ix
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:
1
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.
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
2
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.
3
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.
4
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
5
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.
6
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
7
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.
8
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.
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
9
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
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
10
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.
11
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
12
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.
13
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
14
slag and calcium carbonate (CaCO3) brake pad composite shown better wear
properties than dolomite and comparable with the conventional asbestos based
brake pads.
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
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.
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.
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.
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.
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.
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)
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
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.
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)
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
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%
Table 4.4
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:
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))
The compressive test for jute and coir reinforced glass fiber with vinyl
ester and hardener was conducted.
Table 4.6
(Compressive test result)
From the table it is observed that when thickness increases compressive strength
also increases.
32
CHAPTER 5
CONCLUSIONS
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.
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:
35
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38