Faculty of Engineering ANALYSIS OF WOOD WASTE COMPOSITE Omar Qaiyum Bin Sulaiman Bachelor of Engineering with Honours (Mechanical and Manufacturing Engineering) 2008
UNIVERSITI MALAYSIA SARAWAK BORANG PENGESAHAN STATUS TESIS UNIVERSI TI MALAYSIA SARAWAK JUDUL: ANALYSIS OF WOOD WASTE COMPOSITE SESI PENGAJIAN: 2007/2008 Saya OMAR QAIYUM BIN SULAIMAN mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut: APPROVAL SHEET 1. Tesis adalah hakmilik Universiti Malaysia Sarawak. 2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Membuat pendigitan untuk membangunkan pangkalan Data Kandungan Tempatan. 4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 5. **Sila tandakan ( )di kotak yang berkenaan: This project report attached here to, entitle INVESTIGATION OF GLASS FIBER REINFORCED POLYMER (GFRP) COMPOSITE FLEXURAL STRENGTH WITH DIFFERENT TYPES OF JOINING METHOD prepared and presented by SULIT NOR HANIFAWATI BT INAI (8924) as a partial fulfillment of the requirement for TERHAD degree of Bachelor of Engineering with Honours in Mechanical and Manufacturing Engineering is hereby read TIDAK and TERHAD approve by: (Mengandungi maklumat yang berdarjah keselamatan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: 163-A, Jalan Baru, Pak Sabah, 23000 Dungun, Terengganu Mdm. Marini Bt Sawawi (Nama Penyelia) Tarikh: Tarikh: Catatan: * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
APPROVAL SHEET This project report attached here to, entitle ANALYSIS OF WOOD WASTE COMPOSITE prepared and presented by OMAR QAIYUM BIN SULAIMAN (12743) as a partial fulfillment of the requirement for degree of Bachelor of Engineering with Honours in Mechanical and Manufacturing Engineering is hereby read and approve by: Date: (Mdm. Marini Bt Sawawi) Project Supervisor Faculty of Engineering University Malaysia Sarawak
ANALYSIS OF WOOD WASTE COMPOSITE OMAR QAIYUM BIN SULAIMAN This report is submitted in partial fulfillment of the requirements for the degree of Bachelor of Engineering with Honours (Mechanical and Manufacturing Engineering) Faculty of Engineering UNIVERSITI MALAYSIA SARAWAK 2008
Dedicated to my beloved family and friends
ACKNOWLEDGEMENT I would like to acknowledge my supervisor, Madam Marini bt Sawawi for her valuable effort, advise and comment. She provides helpful suggestion and guidance in preceding my final year project successfully. Special thanks go to Madam Mahsuri bt Yusof for her helpful feedback and support. Then, I would like to convey my sincere thanks to all technicians especially Mr. Masri and Mr. Sabariman for their help on technical aspect of this project. I would also like to thank to my fellow friends for their contribution of ideas and encouragement. My appreciation finally goes to the most important persons in my life; family and love ones who always stand by me. They give me full supports mentally and financially, an encouragement throughout the completion of the project. i
TABLE OF CONTENTS CONTENT ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES NOMENCLATURE Page i ii iii iv vii x xii CHAPTER 1: INTRODUCTION 1.1 Introduction 1 1.2 Wood-Based Industry 2 1.3 Wood Waste 3 1.4 Composite 6 1.5 Scope And Objective 7 CHAPTER 2: LITERATURE REVIEW 2.1 Introduction 8 2.2 Wood 9 2.2.1 Wood Composites 10 iv
2.3 Composite 21 2.3.1 Matrix 22 2.3.2 Reinforcements 23 2.3.2.1 Particulate 24 2.3.2.2 Flake 25 2.3.2.3 Fiber 25 2.3.2.4 Fillers 26 2.4 Mechanical Properties 27 2.4.1 Tensile testing 27 CHAPTER 3: METHODOLOGY 3.1 Introduction 30 3.2 Fabrication of Test Specimen 31 3.2.1 Filtering Process of Wood Particles 32 3.2.2 Particle Volume Fractions 33 3.2.3 Cold Press Moulding 34 3.3 Specimen Preparation 36 3.3.1 Tensile Test Specimen 38 3.3.2 Tabs 39 3.3.3 Total Number of Test Specimens 40 3.4 Tensile Properties of Polymer Matrix 41 Composite Materials (ASTM D 3039) v
CHAPTER 4: RESULTS AND DISCUSSIONS 4.1 Introduction 44 4.2 Data Analysis of Sample A 45 4.3 Data Analysis of Sample B 46 4.4 Modulus of Elasticity 47 4.5 Tensile Strength 51 4.6 Surface Fracture Analysis 52 4.7 Discussion 54 CHAPTER 5: CONCLUSIONS AND RECOMMENDATIONS 5.1 Conclusion 56 5.2 Recommendations 58 REFERENCES 60 APPENDIX A 63 APPENDIX B 69 vi
LIST OF TABLES Table Page 1.1 Production of Logs From Natural Forests, 2 Plantation Forests, and Rubber Plantation (Wood-Based Industry) 1.2 Production of Selected Wood-Based Product 3 (Wood-Based Industry) 2.1 Mechanical properties of wood fibers, 14 Nylon and PP materials (McHenry, E. and Stachurski, Z.H. 2002) 3.1 Tensile Specimen Geometry Requirements 36 (ASTM International, 2006) 3.2 Tensile Specimen Geometry Recommendations 37 (ASTM International, 2006) x
3.3 Number of test specimens in tensile test 41 (ASTM International, 2006) 4.1 Young s modulus and tensile strength 48 of Sample A 4.2 Young s modulus and tensile strength 49 of Sample B xi
LIST OF FIGURES Figure Page 1.1 Flow of wood as it is converted to 4 new products (Environmental Statistics team. 2006) 2.1 Comparison of tensile strength and 11 modulus of composites of virgin HDPE and recycled HDPE with wood fiber (Selke, S.E. and Wichman, I. 2004) 2.2 Effect of matrix type and weight fraction 14 of wood fiber on tensile strength (McHenry, E. and Stachurski, Z.H. 2002) 2.3 Effect of matrix type and weight fraction 15 of wood fiber on tensile modulus (McHenry, E. and Stachurski, Z.H. 2002) vii
2.4 SEM micrograph of Nylon-wood fiber 16 composite fracture surface showing partially melted Nylon fiber. (McHenry, E. and Stachurski, Z.H. 2002) 2.5 Types of composites based on reinforcement 24 shape (Kaw, A.K. 2006) 3.1 General Procedure of the Project 30 3.2 Wood waste 31 3.3 Polyester resin 31 3.4 Filter A 32 3.5 Filter B 32 3.6 Cold Press Moulding (a) press open loading resin; 35 (b) press closed pressure applied 3.7 Tension Test Specimen Drawing (SI) 38 (ASTM International. 2006) viii
3.8 Testometric machine 42 4.1 Stress versus strain for sample A 45 (10%, 20% and 30% volume fraction of fiber, V p ) 4.2 Stress versus strain for sample B 46 (10%, 20% and 30% volume fraction of fiber, V p ) 4.3 Comparison of Young s modulus of Sample A 50 and Sample B (10%, 20% and 30% volume fraction of particulate, V p ) 4.4 Comparison of tensile strength of Sample A 51 and Sample B (10%, 20% and 30% volume fraction of particulate, V p ) 4.5 SEM of sample A surface showing the flaws 52 (10% V p ) 4.6 SEM of sample A fracture surface showing 53 the surface of particle (10% V p ) ix
ABSTRACT Wood waste can be economically utilized to generate energy, produce new product or will be disposed. Another alternative is utilizing the wood waste as reinforcement materials to produce a wood waste composite with promising potential. This project investigated the potential of wood waste to produce a composite material by determining the mechanical properties of the composite. Polyester resin and particle of wood waste were used to produce wood waste composite. The specimen preparation and tensile test have been carried out according to ASTM D 3039, the standard method for determination of tensile properties of polymer matrix composite. The result from this project shows that, the wood waste has a potential to produce a composite materials with high tensile strength and high Young s modulus. The highest tensile strength is achieved with sample A with particle size of 0.0064 mm 2 or less at 30% particle volume fraction which is 22.013 MPa while the Young Modulus is 553.003 MPa. The strength of the wood waste composite is also influenced by the size of particle of wood waste. The smaller the size of particles, the inherent flaws will be reduces and tensile strength will increase. The tensile strength of sample A (smaller particle size) is proportional to the increase in volume fraction of particle. Whereby, for tensile strength of sample B is inversely proportional to the increase in volume fraction of particle. ii
ABSTRAK Hampas kayu boleh digunakan secara ekonomis untuk menjana tenaga, menghasilkan produk baru atau dibuang. Alternatif lain adalah menggunakan hampas kayu sebagai bahan penguat untuk menghasilkan komposit hampas kayu yang berpotensi. Projek ini menyelidik tentang potensi hampas kayu untuk menghasilkan bahan komposit dengan menentukan sifat-sifat mekanikal bagi komposit. Resin polyester dan partikel hampas kayu digunakan untuk menghasilkan komposit hampas kayu. Penyediaan spesimen dan ujian regangan dijalankan berpandukan ASTM D 3039. kaedah piawai bagi sifat regangan untuk matrik polimer komposit. Keputusan daripada projek ini menunjukkan bahawa hampas kayu mempunyai potensi untuk menghasilkan bahan komposit yang mempunyai kekuatan regangan dan Young s Modulus yang tinggi. Kekuatan regangan yang paling tinggi dicapai dengan sampel A dengan saiz partikel 0.0064mm 2 atau kurang bagi 30% pecahan isipadu partikel iaitu 22.013 MPa manakala Young s Modulus ialah 553.003 MPa. Kekuatan komposit hampas kayu dipengaruhi oleh saiz hampas kayu. Semakin kecil saiz partikel hampas kayu, kewujudan kecacatan akan berkurang dan kekuatan regangan akan bertambah. Kekuatan regangan bagi sampel A (partikel yang bersaiz lebih kecil) adalah berkadar terus dengan penambahan pecahan isipadu partikel. Manakala, kekuatan regangan bagi sampel B adalah berkadar songsang dengan penambahan pecahan isipadu partikel. iii
NOMENCLATURE w p W p W m W c υ p V p V m V c ρ m ρ p Weight fraction Weight of particles Weight of matrix Weight of composite Volume fraction Volume of particles Volume of matrix Volume of composite Density of matrix Density of particles xii
CHAPTER 1 INTRODUCTION 1.1 Introduction Production of wood waste from the logging activities and wood-based processing mill such as plywood mills is not only causing environmental problems but also can create wastetage if it not being utilized properly. One aspect that should be looking at is by utilizing the waste as a reinforcement materials to produce composite. The combination of wood waste and matrix will offer interesting mechanical properties that cannot be achieved by coventional materials. Apart from that, utilizing wood waste as reinforcement materials will not only impose great saving but also for producing a wood waste composite with promising potential. 1
1.2 Wood-Based Industry The production and supply logs in Peninsular Malaysia are subjected to the National Forest Policy, which determines the annual allowable cut, in line with Malaysia s commitment towards sustainable forest management. The State Government of Sarawak has introduced Forest (Planted Forests) Rules 1997, which provide for the orderly development of forest plantations in the State. Main source of logs are from Sarawak, followed by Sabah, with supplies from natural forest, plantation forest and rubber plantation declined from 30.4 million cubic meters in 1996 to 26.9 million cubic meters in 2005 is shown in Table 1.1 (Wood-Based Industry). Table 1.1: Production of Logs From Natural Forests, Plantation Forests, and Rubber Plantation (Wood-Based Industry) Year Peninsular Malaysia Sarawak Sabah Total ( 000 cubic meters) 1996 8,419 16,080 5,931 30,430 2000 5,074 14,270 4,151 23,495 2005 8,585 12,040 6,280 26,905 Sources: Forestry Department, Peninsular Malaysia, Forestry Department, Sarawak and Forestry Department, Sabah 2
1.3 Wood Waste Wood waste can be obtained from wood-based processing mill such as plywood mills, sawmills, and integrated pulp and paper mills. In 2005, the production of selected intermediate wood-based product amounted to 11.3 million cubic meters is shown in Table 1.2. Major products were plywood, at 5.1 million cubic meters or 45.4 percent of total production and sawn timber product, at 5.1 million cubic meters or 45.1 percent of total production (Wood-Based Industry). Table 1.2: Production of Selected Wood-Based Product (Wood-Based Industry) 1997 2000 2005 ( 000 cubic metres) Total 13,532 11,857 11,284 Plywood 4,448 4,435 5,126 Sawn timber 7,176 5,590 5,087 Mouldings 743 716 375 Veneer 1,165 1,116 696 Pulp and Paper 681 1,078 1,372 Source: Ministry of Plantation Industries and Commodities 3
Plywood and sawn timber has recorded the highest production of selected woodbased product. That means the large quantity of wood waste has been produced by plywood mills and sawmills. Sawdust is the best example of wood waste which can be used to produce wood waste composites. Usually, the wood waste will be disposed or can be economically utilized for co-production of energy. The productions of wood waste composites provide an additional market for wood waste, thereby helping to reduce waste disposal burdens. The flow of wood as it is converted to new products is shows in Figure 1.1 Harvested trees Trunk and larger branches removed from forest Saw logs Small logs Sawn timber Wood chips (Chipped logs) Poles, posts, and firewood Wood chip residuals Particleboard Fiberboard Figure 1.1: Flow of wood as it is converted to new products (Environmental Statistics team. 2006) 4
Harvested tree from logging activity is converted into trunk and larger branches. The trunk and branches will pass through the saw logs which produce sawn timber. The trunk and branches also pass through the small logs which produce wood chips, poles, post and, firewood. The wood chips or wood waste from saw logs and small logs can be use to produce a new product (Environmental Statistics Team. 2006). Wood chips can be produced by grinding small logs and pulp logs into small pieces. Chipping process is important to make pulp, paper and a final export product. However, there is an increasing use of wood chips as an energy source, for example burning them for space and water heating. The particular wood chips are useful to produce new products. The forestry industry has become very adept at making use of residual products or wood waste from the manufacture of other products. For example, the residual chips and sawdust from saw mills can be use to produce composite and panels such as fiberboard, chipboards, particleboard and wood cement boards. Fiberboard is a wood product reconstituted from wood fibers and regularly made from lower quality logs and some wood waste. The most common use for fiberboard is on joinery and furniture manufacturing due to its even density and smooth surface. Particleboard is a composite product made from wood particles. The development of particleboard manufacturing arose from the desire to utilize waste (Environmental Statistics Team. 2006). 5
1.4 Composite The development and usage of natural composites is starting with composite wall made of straw and mud in a long time ago. Then, the utilization of natural composites has been extended into modern applications such as automotive industries. The usage of natural fibers is domestically grown and available in a large quantity which can reduce cost. The production of natural composites is concentrate to increase the usage of waste materials from wood, coconut, sago palm and many more (Peter, C.F.K. 2006). The development of natural composites is one of the factors that leading to this project, Analysis of Wood Waste Composite. The combinations of wood fibers and thermoplastic polymers will produce composite materials that are lightweight, and offer high strength to weight ratios. The combination of wood fibers and thermoplastic polymers also presents a number of problems. The problems are incompatibility and inferior interface between the fiber and matrix that does not adequately transfer stress to the load bearing fiber. Therefore the mechanical properties of wood waste composite are dependent on the characteristics of the wood fiber and thermoplastic polymers interface (McHenry, E. and Stachurski, Z.H. 2002). 6
Composites are becoming an essential part of materials in modern technologies. Composites have unique and unusual properties that cannot be met by conventional materials such as metal alloys, ceramics, and polymers. Composite materials offer advantages such as less weight, lower cost and more strength (Matthews F.L. and Rawlings R.D. 1994). 1.5 Scope And Objective The objective of studying and implementing this project are listed below; 1. To investigate the potential of wood waste to form a composite material. 2. To analyze and evaluate the mechanical properties of wood waste composite. 7