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1 UNIVERSITI MALAYA UNIVERSITY OF MALAYA PEPERIKSAAN IJAZAH SARJANA MUDA SAINS EXAMINATION FOR THE DEGREE OF BACHELOR OF SCIENCES SESI AKADEMIK 2011/2012 : SEMESTER 1 ACADEMIC SESSION 2011/2012 : SEMESTER 1 SCES3354 : Bahan Komposit SCES3354 : Composite Materials Januari 2012 January 2012 Masa : 2 jam Time : 2 hours ARAHAN KEPADA CALON: INSTRUCTIONS TO CANDIDATES: Jawapan bagi soalan baru hendaklah dimulakan pada halaman baru. Answer for new question should start on a new page. Tandakan nombor soalan di muka hadapan buku jawapan mengikut urutan yang sama seperti jawapan di dalam buku. Indicate question number on the front page of answer book in the same order as answer in the book(s). Jawapan boleh diberikan sama ada dalam Bahasa Malaysia atau Bahasa Inggeris. Answer can be written either in Malay or English. (Kertas ini mengandungi 4 soalan dalam 5 halaman yang dicetak) (This question paper consists of 4 questions on 5 printed pages)
2 SCES3354/02 Jawab SEMUA soalan. Answer ALL questions. 1. Beri komen tentang kenyataan berikut. Give comment on following statements. Idea dan penggunaan pengisi dan / atau tetulang dalam penyediaan produk siap adalah tidak baru. The idea and application of filler and/or reinforcement in the preparation of finished products are not new. Bagi kegunaan penjimatan tenaga dalam industri pembuatan kenderaan / pengangkutan, kekuatan dan modulus spesifik yang tinggi pada bahan komposit polimer adalah kelebihan tambahan. For energy saving application in vehicle / transport industries, high specific strength and modulus of polymer composite materials are added advantages. (e) (f) (g) Pembasahan adalah satu faktor yang sangat penting dalam komposit matriks polimer yang diperkuat dengan gentian. Wetting is a very important factor in fibre reinforced polymer matrix composites. Pemutusan gentian semasa ujian spesimen komposit bukan sentiasa merupakan mekanisma yang menjadi pilihan. Fibre breakage during testing of composite specimens is not always the preferred mechanism. Mesin pengacuan suntikan boleh digunakan untuk memproses bahanbahan thermoset, tetapi dengan pemerhatian khusus. Injection moulding machine can be used to process thermoset materials with special care. Salah satu faktor utama yang perlu dipertimbangkan dalam memilih mesin pemprosesan yang digunakan adalah jenis polimer (termoplastik atau termoset). One of the main factors needed to be considered in selecting the processing machinery to be used is the type of polymers (thermoplastics or thermosets). Dari darjah penghabluran, ianya boleh dijangka secara kasar sama ada polimer tertentu mudah atau sukar untuk di proses. From the degree of crystallinity, it can be guessed roughly whether certain polymers are easy or difficult to process. (Nota: 3 markah setiap satu, maksimum 20 markah) (Note: 3 marks each, maximum 20 marks)
3 SCES3354/03 2. Berikan keterangan ringkas untuk yang berikut:- Give short explanations for the following:- Kekuatan tegangan komposit polimer diperkuat dengan gentian tak selanjar boleh diramalkan dengan menggunakan persamaan berikut. Semua simbol-simbol mempunyai makna yang sama seperti yang ' diberikan dalam nota kuliah. Apakah m dan bagaimana ia menyumbang kepada kekuatan komposit? Tensile strength of discontinuous fibre reinforced polymer composites can be predicted using the following simplified equation. All symbols have the ' same meaning as given in the lecture notes. What is m and how does it contribute to the composite strength? uc = l o uf Vf + m (1- V f ) Bahan-bahan komposit polimer yang digunakan untuk kegunaan sebagai kerangka untuk kereta lumba dan sayap kapalterbang kecil diperkuat dengan gentian kaca dan gentian karbon masing-masingnya. Polymer composite materials used for the application as chassis for racing cars and small aircraft wing are reinforced with glass and carbon fibres respectively. Dalam ujian hentaman and tegangan, mekanisma sumbangan gentian ke arah peningkatan sifat-sifat komposit adalah berbeza. In impact and tensile tests, the mechanisms of fibre contribution towards the improvement of composite properties is different. Dalam analisis teori taburan panjang gentian, apabila membandingkan gentian dengan diameter yang berbeza, nisbah aspek gentian kritikal adalah lebih sesuai untuk diambil sebagai rujukan dan bukannya panjang gentian kritikal. In theoretical analyses of fibre length distribution, when comparing fibres with different diameters, the critical fibre aspect ratio is more appropriate to be taken as reference point instead of critical fibre length. (Nota: 5 markah setiap satu, maksimum 20 markah) (Note: 5 marks each, maximum 20 marks)
4 SCES3354/04 3. Komposit termoplastik diperkuat dengan gentian disediakan dengan proses pultrusi dan acuan suntikan dengan pecahan isipadu gentian sebanyak 18%. Dalam ujian regangan, didapati tegangan matriks pada pemanjangan 1.55%, tegasan ricih matriks dan pemanjangan pemutusan komposit adalah 36.5 MPa, 47.8 MPa dan 1.57% masing-masingnya. Dari maklumat produk pengeluar gentian, dilaporkan bahawa garis pusat, pemanjangan pemutusan, kekuatan tegangan dan modulus Young gentian adalah 7 μm, 1.55%, 3,750 MPa dan 235 GPa masing-masingnya. Dari analisis taburan panjang gentian, didapati bahawa bilangan gentian yang lebih pendek dan lebih panjang daripada panjang gentian kritikal dalam komposit acuan suntikan adalah 356 dan 193 dengan panjang purata 0.22 mm dan 0.53 mm masing-masingnya. Tegasan ricih matrix diambil sebagai kekuatan ricih antara muka komposit. Jawab yang berikut: - Fibre reinforced thermoplastic composites were prepared by pultrusion and injection moulding processes with fibre volume fraction of 18%. In tensile tests, it was found that stress in matrix at 1.55% elongation, matrix shear stress and fracture strain of composites are 36.5 MPa, 47.8 MPa and 1.57% respectively. From the fibre manufacturer literature, it was reported that the diameter, fracture strain, tensile strength and Young's modulus of fibre are 7 μm, 1.55%, 3750 MPa and 235 GPa respectively. From the fibre length distribution analysis it was also found that number of fibres shorter and longer than the critical fibre length in injection moulded composites are 356 and 193 with their average length as 0.22 mm and 0.53 mm respectively. Matrix shear stress is taken as composites interfacial shear strength. Answer the following:- Seperti yang dibincangkan semasa kuliah, kompaun yang disediakan dengan proses pultrusi dan spesimen acuan suntikan boleh dikelaskan dalam kategori apa? As discussed during the lecture, pultruded compound and injection moulded specimen can be classified under which category? (4 markah/marks) Kirakan panjang gentian kritikal komposit semasa putus dan pada pemanjangan yang biasanya digunakan untuk mengira modulus Young. Calculate the critical fibre length of composites at fracture and at strain that is normally used to compute Young s modulus. (4 markah/marks) Kirakan sumbangan daripada gentian sub-kritikal, gentian super-kritikal dan matriks kepada kekuatan regangan komposit. Calculate contributions from the sub-critical fibres, super-critical fibres and matrix to the composites strength. (12 markah/marks) Kirakan kekuatan regangan komposit. Calculate tensile strength of the composites. (2 markah/marks)
5 SCES3354/05 (e) Kekuatan regangan komposit yang didapati secara percubaan adalah 157 MPa. Berikan komen tentang perbezaan nilai ini berbanding dengan nilai yang diramalkan dalam di atas. Tensile strength of composite determined by experiment was 157 MPa. Give explanation on the difference in this value compared to the predicted value in above. 4. Dengan merujuk kepada pemprosesan polimer dan bahan komposit, jawab perkara-perkara berikut:- With reference to polymer and composite materials processing, answer the following:- Dalam fabrikasi bumper untuk kereta penumpang, sebelum pengacuan suntikan menjadi produk siap, bahan-bahan seperti matriks polimer, gentian, bahan tambahan, dan lain-lain pada mulanya dikompaun menggunakan extruder. Mengapa proses ini (ekstrusi) perlu? In the fabrication of bumper for passenger car, before injection moulding to the finished product, materials such as polymer matrix, fibre, additives, etc were first compounded using extruder. Why is this process (extrusion) necessary? Bezakan diantara teknik-teknik pemprosesan secara satu demi dan secara berterusan. Jelaskan jawapan anda dengan contoh dan bantuan gambarajah. Differentiate between batch and continuous processing techniques. Explain your answer with example and aid of diagram(s). Bezakan diantara pemprosesan acuan terbuka dan acuan tertutup. Differentiate between open mould and closed mould processing. Berikan gambar rajah rekabentuk mesin asas / pembinaan bagi sama ada mesin pengacuan suntikan, mesin pengacuan mampatan atau ekstruder. Labelkan bahagian-bahagian atau komponen yang penting dan terangkan fungsi mereka. Give the diagram of the basic machine construction / design for either an injection moulding machine, a compression moulding machine or an extruder. Label the important parts or components and explain their function. (12 markah/marks) **************************
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