MODELING AND MECHANICAL PROPERTIES OF GLASS FIBER REINFORCED NYLON

Transcription

1 MODELING AND MECHANICAL PROPERTIES OF GLASS FIBER REINFORCED NYLON MUHAMMAD SYAFIQ BIN MOHD ZAMIL B. ENG. (HONS.) MANUFACTURING ENGINEERING UNIVERSITI MALAYSIA PAHANG

2 MODELING AND MECHANICAL PROPERTIES OF GLASS FIBER REINFORCED NYLON MUHAMMAD SYAFIQ BIN MOHD ZAMIL Report submitted in partial fulfilment of the requirements For the award of degree of Bachelor of Engineering in Manufacturing Engineering Faculty of Manufacturing Engineering UNIVERSITI MALAYSIA PAHANG June 2016

3 UNIVERSITI MALAYSIA PAHANG DECLARATION OF THESIS AND COPYRIGHT Author s Full Name : MUHAMMAD SYAFIQ BIN MOHD ZAMIL Identification Card No : Title : MODELING AND MECHANICAL PROPERTIES OF GLASS FIBER REINFORCED NYLON Academic Session : 2015/2016 I declare that this thesis is classified as: CONFIDENTIAL RESTRICTED OPEN ACCESS (Contains confidential information under the Official Secret Act 1972) (Contains restricted information as specified by the organization where research was done)* I agree that my thesis to be published as online open access (Full text) I acknowledge that Universiti Malaysia Pahang reserve the right as follows: 1. The Thesis is the Property of University Malaysia Pahang. 2. The Library of University Malaysia Pahang has the right to make copies for the purpose of research only. 3. The Library has the right to make copies of the thesis for academic exchange. Certified by: (Author s Signature) (Supervisor s Signature) MUHAMMAD SYAFIQ BIN MOHD ZAMIL Name of Author ASSOC. PROF. DR. DEWAN MUHAMMAD NURUZZAMAN Name of Supervisor Date: Date:

4 i SUPERVISOR S DECLARATION I hereby declare that I have checked this thesis and in my opinion, this thesis is adequate in terms of scope and quality for the award of the degree of Engineering Manufacturing or B.Eng (Hons.) Manufacturing Engineering. Signature :.. Name of Supervisor : DR. DEWAN MUHAMMAD NURUZZAMAN Position : ASSOC. PROF. Date : JUNE 2016

5 ii STUDENT S DECLARATION I hereby declare that the work in this thesis is my own except for quotation and summaries which have been duly acknowledged. The thesis has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature :. Name : MUHAMMAD SYAFIQ BIN MOHD ZAMIL ID Number : FA12009 Date : JUNE 2016

6 vii TABLE OF CONTENTS SUPERVISOR S DECLARATION STUDENT S DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES LIST OF ABBREVIATIONS Page i ii iii iv v vi vii xi xiv xv CHAPTER 1 INTRODUCTION 1.1 Introduction Problem Statement Objectives Processing Technique Scope of Project 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Polymers Thermoplastic Polymer Thermoset Polymer Polypropylene Nylon Fiber-Reinforced Plastic (FRP) Composites Glass Fiber-Reinforced Polymer (GFRP) 7

7 viii 2.9 Analysis Design Methods Software Autodesk Moldflow Processing Methods Injection Molding 9 CHAPTER 3 METHODOLOGY 3.1 Introduction Process Flow Chart Material Selection Nylon Glass Fibre Reinforcement Material Preparation % Nylon (PA6) + 5% Glassfibre % Nylon (PA6) + 10% Glassfibre % Nylon (PA6) + 15% Glassfibre % Nylon (PA6) + 20% Glassfibre Design and Moldflow Analysis Procedure of Design and Moldflow Analysis Injection Molding Part of Injection Molding Machine Procedure Injection Molding Machine Mechanical Test ( Tensile Test ) Software Setup ( Instron Bluehill ) Machine Setup Start Tensile Test End of Tensile Test Mechanical Test ( Impact Test Izod ) Microstructure Analysis 24

8 ix CHAPTER 4 RESULT AND DISCUSSION 4.1 Introduction Moldflow Analysis Gating Suitability Fill Time Temperature of Flow Front Time to Reach Ejection Temperature Air Traps Weld Lines Wrap Main Data of Injection Molding Tensile Test Result Analysis Introduction Pure Nylon %PA6 + 5%GF %PA6 + 10%GF %PA6 + 15%GF %PA6 + 20%GF Impact Test (IZOD) Result Analysis Introduction Pure Nylon %PA6 + 5%GF %PA6 + 10%GF %PA6 + 15%GF %PA6 + 20%GF Microstructure Analysis Introduction 66

9 x CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 Introduction Conclusion Recommendation 71 REFERENCES 72 APPENDICES A Gantt Chart FYP 73 B1 Edge Gate Moldflow Analysis Log 74 B2 Edge Gate Moldflow Analysis Result 77 C1 Centre Gate Moldflow Analysis Log 80 C2 Centre Gate Moldflow Analysis Result 83 D1 Pin Gate Moldflow Analysis Log 86 D2 Pin Gate Moldflow Analysis Result 89 E1 Tensile Test Result 3mm/min 92 E2 Tensile Test Result 5mm/min 98 E3 Tensile Test Result 10mm/min 103 F Impact Test Result 50 J 108 G Microstructure Analysis 113

10 xi LIST OF FIGURES Figure No. Title Page 2.1 Example of fill time result Two plate mold ( Serope Kalpakjian, 2010 ) Three plate mold ( Serope Kalpakjian, 2010 ) Hot runner mold. ( Serope Kalpakjian, 2010 ) Operation in the injection molding. ( Serope Kalpakjian, 2010 ) Process Flow Chart ASTM D 638 Type I Injection Molding Machine Clamp section Universal Testing Machine (UTM) Instron Bluehill software Impact Test ( INSTRON CEAST 9050 ) Position of Specimen for Impact Test (IZOD) Pendulum Hammer (50J) Distance tighten of clamp Optical Microscope Machine Composition for microstructure analysis D Modeling of ASTM D638 specimen Three different gate location of ASTM D638 specimen Edge gate for ASTM D638 modeling Gating suitability Fill time Temperature at flow front Time to reach temperature Air traps Weld lines Wrap Successful ASTM D638 specimen Temperature used for Pure Nylon 42

11 xii 4.13 Temperature used for 95%PA6 + 5%GF Temperature used for 90%PA6 + 10%GF Temperature used for 85%PA6 + 15%GF Temperature used for 80%PA6 + 20%GF Fractured specimen (3mm/min) Fractured specimen (5mm/min) Fractured specimen (10mm/min) Stress-Strain Curve of Pure Nylon (3mm/min) Stress-Strain Curve of Pure Nylon (5mm/min) Stress-Strain Curve of Pure Nylon (10mm/min) Stress-Strain Curve of 95%PA6 + 5%GF (3mm/min) Stress-Strain Curve of 95%PA6 + 5%GF (5mm/min) Stress-Strain Curve of 95%PA6 + 5%GF (10mm/min) Stress-Strain Curve of 90%PA6 + 10%GF (3mm/min) Stress-Strain Curve of 90%PA6 + 10%GF (5mm/min) Stress-Strain Curve of 90%PA6 + 10%GF (10mm/min) Stress-Strain Curve of 85%PA6 + 15%GF (3mm/min) Stress-Strain Curve of 85%PA6 + 15%GF (5mm/min) Stress-Strain Curve of 85%PA6 + 15%GF (10mm/min) Stress-Strain Curve of 80%PA6 + 20%GF (3mm/min) Stress-Strain Curve of 80%PA6 + 20%GF (5mm/min) Stress-Strain Curve of 80%PA6 + 20%GF (10mm/min) Modulus (GPa), Rate 3mm/min Modulus (GPa), Rate 5mm/min Modulus (GPa), Rate 10mm/min Tensile Stress at Maximum Load (MPa), Rate 3mm/min Tensile Stress at Maximum Load (MPa), Rate 5mm/min Tensile Stress at Maximum Load (MPa), Rate 10mm/min Tensile Stress at Break (MPa), Rate 3mm/min Tensile Stress at Break (MPa), Rate 5mm/min Tensile Stress at Break (MPa), Rate 10mm/min Tensile Stress at Yield (MPa), Rate 3mm/min 60

12 xiii 4.45 Tensile Stress at Yield (MPa), Rate 5mm/min Tensile Stress at Yield (MPa), Rate 10mm/min Impact Test Pure Nylon Impact Test 95%PA6 + 5%GF Impact Test 90%PA6 + 10%GF Impact Test 85%PA6 + 15%GF Impact Test 80%PA6 + 20%GF Energy ( J ) Re (kj/m²) Absorb Energy (%) Structure of Pure nylon Structure of 95%PA6 + 5%GF Structure of 90%PA6 + 10%GF Structure of 85%PA6 + 15%GF Structure of 80%PA6 + 20%GF 69

13 xiv LIST OF TABLES Table No. Title Page 4.1 Tabulated Moldflow Analysis Temperature used for different composition of Glass fiber-reinforced Nylon Cooling time and Stroke material used for different composition of Glass fiber-reinforced Nylon Tensile Test (3mm/min) Tensile Test (5mm/min) Tensile Test (10mm/min) Impact Test Pure Nylon Impact Test 95%PA6 + 5%GF Impact Test 90%PA6 + 10%GF Impact Test 85%PA6 + 15%GF Impact Test 80%PA6 + 20%GF 64

14 xv LIST OF ABBREVIATIONS ASTM American Society for Testing Materials CAD Computer Aided Design CATIA Computer Aided Three-dimensional Interactive Application GF Glass Fibre GFRP Glass Fibre-Reinforced Polymer FKP Fakulti Kejuruteraan Pembuatan FRP Fibre-Reinforced Plastic OM Optical Microscope PA6 Nylon 6 PMC Polymer Matrix Composites PP Polypropylene UTM Universal Testing Machine