STUDIES ON TRIBOLOGICAL PROPERTIES OF SIC AND FLY ASH REINFORCED GLASS FIBER EPOXY COMPOSITES BY TAGUCHI METHOD

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 6, November December 2016, pp , Article ID: IJMET_07_06_020 Available online at Journal Impact Factor (2016): (Calculated by GISI) ISSN Print: and ISSN Online: IAEME Publication STUDIES ON TRIBOLOGICAL PROPERTIES OF SIC AND FLY ASH REINFORCED GLASS FIBER EPOXY COMPOSITES BY TAGUCHI METHOD K.B.S.S. Rama Krishna P.G. Scholar, Department of Mechanical Engineering, ANITS College, Andhra Pradesh, India Dr. B Nagaraju Professor, Department of Mechanical Engineering, ANITS College, Andhra Pradesh, India M. Raja Roy Sr. Assistant Professor, Department of Mechanical Engineering, ANITS College, Andhra Pradesh, India B.B. Ashok Kumar Assistant Professor, Department of Mechanical Engineering, ANITS College, Andhra Pradesh, India ABSTRACT Glass Fiber Reinforced Epoxy composites are one of the most widely used composite materials due to its light weight and high impact resistance, used for aerospace, marine and other industrial applications. Glass Fiber used in industrial applications to make polymer matrix composite is having chemical inertness in nature. In this work, a method is proposed to add Fly Ash and Silicon Carbide (SiC) content to polymer matrix for improve the tribological properties of the composite. The testing was conducted on pin-on-disc machine under dry sliding condition as per ASTM G-99 standards. The controlling factors are Speed, Load, and Time. The responses such as Wear, Friction Force (FF), and coefficient of friction (COF) were analyzed. Signal-to- Noise(S/N) ratio and Analysis of Variance (ANOVA) were carried out to investigate the Tribological characteristics of polymer composites. The Experimental results shown that inclusion of fillers Fly ash, SiC in Glass fiber epoxy composites improves tribological behavior. Key words: Polymer Composites, Signal to Noise Ratio, Taguchi Method, ANOVA, Tribological properties

2 K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar Cite this Article: K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar, Studies On Tribological Properties of Sic and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method. International Journal of Mechanical Engineering and Technology, 7(6), 2016, pp INTRODUCTION A composite material is made by combining two or more materials are together to create a superior, unique material properties, minimizes their weakness and chemically distinct phases. A composite material is heterogeneous at a microscopic scale but statistically homogeneous at macroscopic scale. The composite materials have significantly different properties. The composites materials can be naturally or artificially made materials. There are many researches for new materials which will satisfy the specific requirements for various applications like aerospace, marine, industrial, structural, electrical, house-hold, etc.it is impossible of any material to fulfill all properties. Hence, newer materials are developed for more required properties. Composites are used in place of metals because they are equally strong but much lighter. In recent years most of the manufacturing units like aerospace, automotive, marine industries are using glass fiber reinforced composites as they offer a high strength and modulus strength compared to other metallic materials Literature Review Basavarajappa et al [1] have done their project using the optimization technique Taguchi and perform to acquire data in a controlled way. An orthogonal array and analysis of variance (ANOVA) was employed to investigate the influence of process parameters on the wear in composite materials. Based on Taguchi approach, the experimentation provides an orderly way to collect, analyzes, and interpret data. Incorporation of the silicon carbide particles in the polymer matrix as a secondary Reinforcement increases the wear resistance of composite material. B.Suresha et al [2] carried out experimentation to study the influence of two inorganic fillers of SiC particles and graphite on wear of the glass fabric reinforced epoxy composites. They reported that the increase of load and sliding velocity results higher wear loss. The coefficients of frictional values are increasing with increase of load and sliding velocities. V. Manikandan1 et al [3] Conducted experimentation to study the influence of fly ash fillers on mechanical and tribological properties of woven jute fiber reinforced polymer hybrid composite. Composites were prepared using hand layup method with weight percentage of fly ash as filler material. Bharat Admile et al [4] Performed experimentation on metal matrix composites which plays a vital role in tribological industries because of their inherent properties like high strength to weight ratio, low wear rate. Matrix material LM25 which is commercially available has advantage of lighter weight & major silicon content of alloy may helps to improve castability. ANOVA was used to determine the design parameters significantly influencing the wear rate. Sudeep Deshpande et al [5] investigated about sliding wear characteristics of epoxy composites. They reported that the addition of bone powder in hybrid fiber reinforced epoxy composites decreases the wear rate of composite. They are also studied about S/N ratio. From the literature survey, the authors have identified some of the gaps in the area of Tribological properties of SiC and Fly Ash reinforced epoxy composites. Hence they have made an attempt to investigate the inclusion of SiC and Fly Ash on Dry sliding wear, Frictional Force (FF), coefficient of friction (COF) on Epoxy reinforced composite materials. Fabrication of Epoxy Reinforced composite material by different weight percentages of SiC and Fly Ash are made by hand layup Technique. Wear, Frictional Force (FF) and coefficient of friction (COF) were analyzed by using pin-on-disc machine

3 Studies On Tribological Properties of Sic and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method Taguchi Technique has been employed to conduct the experiments and ANOVA method is used to obtain the contribution factors. 2. MATERIALS USED FOR FABRICATION In order to fabricate the SiC and Fly Ash reinforced glass fiber epoxy composites, the following materials are used Glass fiber (woven roving mat) Glass fibers are the most common of all reinforcing fibers for Polymeric Matrix Composites (PMC). The principle advantages of glass fibers are low cost, high tensile strength, high chemical resistance, and excellent insulating properties. The glass fibers come in variety of forms based on silica which is combined with other elements to create specialty glass. Woven roving mat is used as glass fiber as shown in Fig Epoxy resin Epoxy resins are polymeric or semi-polymeric materials, and as such rarely exist as pure substances, since variable chain length results from the polymerization reaction used to produce them. Epoxy resins are formed from a long chain molecular structure similar to vinyl ester with reactive fiber at either end [6]. In this work, Araldite Ly 556 is used as epoxy resin in the present work for the fabrication of composites. Figure 1 Woven roving mat 3. FABRICATION OF COMPOSITES Figure 2 Fabrication by Hand lay-up method 3.1. Hand lay-up technique Hand lay-up technique is the simplest and oldest open molding method of composite fabrication process. In this work, Silicon carbide, fly ash powder of different weight percentages (0%, 2.5%, 5%) are mixed with epoxy-hardener mixture and fiber reinforcements and filler materials of epoxy mixture are placed manually against the mold surface as shown in Fig2. The thickness is controlled by layers placed against the mould. After the preparation of specimens, the work pieces are cured for 24 to 48 hrs so that work pieces will get hard. After this, the specimens were cut according to ASTM G99 standards using cutting machine and finished the composite material with Emory paper. The designations of work pieces are shown in Table

4 K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar Material code Glass Fiber (wt%) Table 1 Designation of work pieces Matrix(wt%) SiC Filler (wt%) FlyAsh filler (wt%) Base S S The Glass fiber reinforced composite specimens were prepared as per ASTM G99 standards and are reported in Fig 3, 4 and 5. Fig 3 Specimens of bear composite material Fig 4 Specimens of S1 composite material Fig 5 Specimens of S2 composite material 4. EXPERIMENTAL WORK Fig 6 Pin-on-disc machine set up 4.1. Wear test- Pin-on-disc set up: Wear samples are prepared with in the form of square pin (30mm 5mm 5mm) as per ASTM G99 standards. Contact surfaces were prepared by grinding against 600-grit silicon carbide paper and cleaning with acetone. Experiments have been conducted in the Pin-on-disc type Friction and Wear monitor as shown in Fig 6.(WIN DUCOM; TL-20) with data acquisition system which was used to evaluate the wear behavior of the Composite against hardened ground steel disc (En-32) having hardness 65 HRC and surface roughness (Ra) 0.5μm.[7] It is versatile equipment designed to study wear under dry sliding condition. Sliding generally occurs between a stationary Pin and a rotating disc. The disc rotates with the help of a D.C. motor having speed range rpm, track diameter 70mm, load 0 to 100 N. Load is to be applied on pin (specimen) by dead weight through pulley string arrangement Plan of Experiment Taguchi L9 Orthogonal Array The experiment specifies control factors wear testing conditions include sliding speed, applied load, and Time. The experiments were carried out to analyze the influence of above 202

5 Studies On Tribological Properties of Sic and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method factors on dry sliding wear of Glass fiber reinforced composite material Control factors and their levels are shown in Table 2. If the full factorial design was used, it would have 3 3 = 27 runs. The L9 (27) (3 3) array requires only 9 runs, a fraction of the full factorial design. The standard Taguchi experimental plan with notation L9 Orthogonal array was used in the present work as shown in Table-3. Table 2 Controlling parameters and their levels Factors Level 1 Level 2 Level 3 Speed(rpm) Load (kg) Time (min) Table 3 Orthogonal array L9 (3 ) Ex no Speed (rpm) Load (Kg) Time (Min) RESULTS AND DISCUSSION S/N Ratio and ANOVA Analysis: By using pin on disc testing machine tribological behavior of B, S1, and S2 composite materials. The influence of control parameters sliding speed, load, and time on wear, friction force, coefficient of friction (COF) has been evaluated using S/N ratio response analysis. The wear rate was considered as the quality characteristic with the concept of "the smaller-the-better" and calculated by using following equation. Table 4, 5, and 6 shows experimental values of wear, frictional force, coefficient of friction (COF), and S/N ratio by Taguchi analysis. Mini Tab17 software was used to obtain Mean Plots. S/N ratio = -10 Log 10 [ y ]. Table 4 L9 (3 ) Orthogonal Array for Base Material Ex no Wear S/N Friction S/N S/N CF (µm) Ratio force Ratio Ratio

6 K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar Table 5 L9 (3 ) Orthogonal Array for S1 Material Ex no Wear S/N Friction S/N S/N CF (µm) Ratio force Ratio Ratio Table 6 L9 (3 ) Orthogonal Array for S2 Material Ex no Wear S/N Friction S/N S/N CF (µm) Ratio force Ratio Ratio Main Effects Plot (data means) for SN ratios Main Effects Plot (data means) for SN ratios SPEED(RPM) LOAD(KG) SPPED(RPM) LOAD(KG) Mean of SN ratios TIME(MIN) Mean of SN ratios TIME(MIN) Signal-to-noise: Smaller is better Signal-to-noise: Smaller is better Fig 6 Wear Main Effects of S/N ratio Fig 7 Frictional force Main Effects For Base Material of S/N ratio for Base Material Fig 6 shows the wear main effective plots of S/N wear ratio for base material. It is observed that if speed increases the S/N ratio of wear decreases, similarly observed that if load increases the S/N ratio of wear increases initially up to 4kg there after decreases. Correspondingly recognized that time increases the S/N ratio of wear decreases initially up to 10min thereafter increases. Similarly frictional force and coefficient of friction graphs generated these are shown Fig 7 and Fig 8 respectively

7 Studies On Tribological Properties of Sic and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method Main Effects Plot (data means) for SN ratios SPEED(RPM) LOAD(KG) Mean of SN ratios TIME(MIN) Fig 8 Coefficient of friction Main Effects of S/N ratio for Base Material 5.1. Main effect plot results for S1 material It is observed that if speed increases the S/N ratio of wear increases, similarly observed that if load increases the S/N ratio of wear decreases. Correspondingly recognized that time increases the S/N ratio of wear decreases initially up to 10min thereafter increases. It is observed that if speed increases the S/N ratio of frictional force decreases, similarly observed that if load increases the S/N ratio of Frictional force increases. Correspondingly recognized that time increases the S/N ratio of frictional force decreases initially up to 10min thereafter increases. It is observed that if speed increases the S/N ratio of coefficient of friction increases, similarly observed that if load increases the S/N ratio of coefficient of friction increases initially up to 4kg thereafter decreases. Correspondingly recognized that time increases the S/N ratio of coefficient of friction increases initially up to 10min there after decreases Main effect plot results for S2 material It is observed that if speed increases the S/N ratio of wear decreases, similarly observed that if load increases the S/N ratio of wear increases initially up to 4kg thereafter decreases. Correspondingly recognized that time increases the S/N ratio of wear increases. It is observed that if speed increases the S/N ratio of frictional force increases, similarly observed that if load increases the S/N ratio of Frictional force decreases. Correspondingly recognized that time increases the S/N ratio of frictional force decreases initially up to 10min thereafter increases. It is observed that if speed increases the S/N ratio of coefficient of friction increases, similarly observed that if load increases the S/N ratio of coefficient of friction increases. Correspondingly recognized that time increases the S/N ratio of coefficient of friction decreases Analysis of variance (ANOVA) ANOVA was used to determine the design parameters significantly influencing the response. Table 7 shows the results of ANOVA for wear. This analysis was evaluated for a confidence level of 95%, that parameter on the response, indicating the degree of influence on the result. Total sum of squares = sum of squares groups + sum of squares with in group Mean squares (MS) = F-test is a statistical test in which the test static has an F-distribution under null hypothesis. Exact F-test mainly a rise when the models have been squares, F statistic like regression try to find the connection between the two P values of equal or smaller than F= 5 10 Signal-to-noise: Smaller is better

8 K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar P is probability obtaining a result at least as extreme as the one that was actually observed, given that the null hypothesis is true. Delta is the difference between the maximum and minimum average S/N ratio for factors. Rank is the rank of each delta and the largest delta. It can be observed from the results obtained that speed was the most significant parameter having the highest statistical influence (40.53%) on the dry sliding wear of composites followed by load (31.51%) and time (12.15%).When the P-value for this model was less than 0.05, then the parameter or interaction can be considered as statistically significant. This is desirable as it demonstrates that the parameter or interaction in the model has a significant effect on the response. From an analysis of the results obtained in Table 7, it is observed that the interaction effect of load & speed is significant influencing wear rate of base composites. Similarly, From an analysis of the results obtained in Table 8 it is observed that the interaction effect of speed & load is significant influencing frictional force rate of base composites. From an analysis of the results obtained in Table 9 it is observed that the interaction effect of Load & speed is significant influencing coefficient of friction of base composites. Table 7 Delta, Ranks and ANOVA analysis of Base wear Level Delta Rank DF F P % Speed Load Time Error 2 Total Table 8 Delta, Ranks and ANOVA analysis of Base friction Level Delta Rank DF F P % Speed Load Time Error 2 Total Table 9 Delta, Ranks and ANOVA analysis of Base coefficient of friction Level Delta Rank DF F P % Speed Load Time Error 2 Total Delta, Ranks and ANOVA analysis of S1 material It can be observed from the results obtained that Time was the most significant parameter having the highest statistical influence (45.81%) on the dry sliding wear of composites followed by load (23.59%) and speed (9.49%). When the P-value for this model was less than 0.05, then the parameter or interaction can be considered as statistically significant. This is desirable as it demonstrates that the parameter or interaction in the model has a significant effect on the response. From an analysis it is observed that the interaction effect of load & time is significant influencing wear rate of S1 composites. Similarly From an 206

9 Studies On Tribological Properties of Sic and Fly Ash Reinforced Glass Fiber Epoxy Composites by Taguchi Method analysis of the results obtained it is observed that the interaction effect of speed, load & time is significant influencing frictional force rate of S1composites and from an analysis of the results obtained in Table 12 it is observed that the interaction effect of speed, load & Time is significant influencing frictional force rate of composites Delta, Ranks and ANOVA analysis of S2 material It can be observed from the results obtained that Load was the most significant parameter having the highest statistical influence (71.07%) on the dry sliding wear of composites followed by speed (21.41%) and Time (6.12%). When the P-value for this model was less than 0.05, then the parameter or interaction can be considered as statistically significant. This is desirable as it demonstrates that the parameter or interaction in the model has a significant effect on the response. From an analysis of the results obtained it is observed that the interaction effect of speed, load & time is significant influencing wear rate of S2 composites. Similarly From an analysis of the results obtained it is observed that the interaction effect of speed & load is significant influencing frictional force rate of S2 composites and From an analysis of the results obtained it is observed that the interaction effect of speed, load & Time is significant influencing coefficient of friction rate of S2 composites. 6. CONCLUSIONS Experimental investigation on Tribological properties of Flyash and silicon carbide reinforced Glass fiber epoxy composites with different weight(0%,2.5%,5%) percentages using pin-on-disc machine and analysis of tribological characterstics in ANOVA are done in this work.the results concluded that In base material wear was influenced by factors speed followed by load and time. In base material frictional force (FF) was influenced by factors load followed by speed and time. In base material coefficient of friction (COF) was influenced by factors speed followed by load and time. In S1 material wear was influenced by factors time followed by load and speed. In S1 material frictional force (FF) was influenced by factors Load followed by time and speed. In S1 material coefficient of friction (COF) was influenced by factors load followed by speed and time. In S2 material wear was influenced by factors load followed by speed and time. In S2 material frictional force (FF) was influenced by factors Load followed by speed and time. In S2 material coefficient of friction (COF) was influenced by factors speed followed by load and time. It is observed that coefficient of friction decreses when wear increases for base material, S1 material and S2 material. It is observed that frictional force increses when wear increases for base material, S1 material and S2 material. REFERENCES [1] S. Basavarajappa, K.V. Arun, J. Paulo Davim (2009), Effect of Filler Materials on Dry Sliding Wear Behavior of Polymer Matrix Composites A Taguchi Approach, Journal of Minerals & Materials Characterization & Engineering, 8(5), pp , [2] B.Suresha,G.Chandramohan,J.N.Prakash,,V.Balusamy, K.Sankaranarayanasamy(2006).The Role of Fillers on Friction and Slide Wear Characteristics in Glass-Epoxy Composite Systems, Journal of Minerals & Materials Characterization & Engineering, 5(1), pp , [3] V. Manikandan1, S. Richard, M. Chithambara Thanu, Effect of Fly Ash As Filler On Mechanical & Frictional Properties of Jute Fiber Reinforced Composite, International Research Journal of Engineering and Technology (IRJET) 02 (07)

10 K.B.S.S. Rama Krishna, Dr. B Nagaraju, M. Raja Roy and B.B. Ashok Kumar [4] Bharat Admile G.Kulkarni S.A. Sonawane, Application of Taguchi Method for Optimization of Process Parameters for Wear loss of LM25/Flyash Composite. International Journal of Innovations in Engineering and Technology (IJIET) Volume 4 Issue Dec [5] Sudeep Deshpande T. Rangaswamy(2016), Sliding Wear Characteristics of Bone Powder Filled Hybrid Fiber Reinforced Epoxy Composites, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) Volume 13, Issue 1 Ver. I (Jan. - Feb. 2016). [6] R. Hemanth M. Sekar B. Suresha(2014).Effects of Fibers and Fillers on Mechanical Properties of Thermoplastic Composites, Indian Journal of Advances in Chemical Science 2 (2014) [7] Ramkrishna Parihar and Sanjay Jathar. Application of Taguchi Method To Optimize Tensile Shear Strength between Stainless Steel Aisi304 and Mild Steel, International Journal of Mechanical Engineering and Technology, 6(10), 2015, pp [8] Chandra Shekar, N B D Pattar and Y Vijaya Kumar, Design and Study of the Effect of Multiple Machining Parameters in Turning of AL6063T6 Using Taguchi Method. International Journal of Design and Manufacturing Technology 7(3), 2016, pp [9] R. Manjunatha, T.M Chandrashekaraiah, Girish Kumar and N. Jagannatha, Optimization of Machining Parameters on Al SI (LM 6) Alloy Using Taguchi Method and Utility Concept. International Journal of Mechanical Engineering and Technology, 7(4), 2016, pp [10] N.Mohan C.R.Mahesha, R. Raja (2014). Tribo-mechanical behavior of Sic filled glass-epoxy composites at elevated temperatures, International Journal of Engineering, sciences and Technology 6(5), 2014, pp