MODELING AND MECHANICAL PROPERTIES OF GLASS FIBER REINFORCED NYLON MUHAMMAD SYAFIQ BIN MOHD ZAMIL B. ENG. (HONS.) MANUFACTURING ENGINEERING UNIVERSITI MALAYSIA PAHANG
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
UNIVERSITI MALAYSIA PAHANG DECLARATION OF THESIS AND COPYRIGHT Author s Full Name : MUHAMMAD SYAFIQ BIN MOHD ZAMIL Identification Card No : 90030710-10-5047 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:
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
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
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 1 1.2 Problem Statement 2 1.3 Objectives 2 1.4 Processing Technique 2 1.5 Scope of Project 3 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 5 2.2 Polymers 5 2.3 Thermoplastic Polymer 5 2.4 Thermoset Polymer 6 2.5 Polypropylene 6 2.6 Nylon 6 2.7 Fiber-Reinforced Plastic (FRP) Composites 7 2.8 Glass Fiber-Reinforced Polymer (GFRP) 7
viii 2.9 Analysis Design Methods 8 2.9.1 Software Autodesk Moldflow 8 2.10 Processing Methods 8 2.10.1 Injection Molding 9 CHAPTER 3 METHODOLOGY 3.1 Introduction 11 3.2 Process Flow Chart 12 3.3 Material Selection 13 3.3.1 Nylon 6 13 3.3.2 Glass Fibre Reinforcement 13 3.4 Material Preparation 13 3.4.1 95% Nylon (PA6) + 5% Glassfibre 14 3.4.2 90% Nylon (PA6) + 10% Glassfibre 14 3.4.3 85% Nylon (PA6) + 15% Glassfibre 14 3.4.4 80% Nylon (PA6) + 20% Glassfibre 15 3.5 Design and Moldflow Analysis 15 3.5.1 Procedure of Design and Moldflow Analysis 16 3.6 Injection Molding 17 3.6.1 Part of Injection Molding Machine 17 3.6.2 Procedure Injection Molding Machine 18 3.7 Mechanical Test ( Tensile Test ) 19 3.7.1 Software Setup ( Instron Bluehill ) 19 3.7.2 Machine Setup 19 3.7.3 Start Tensile Test 20 3.7.4 End of Tensile Test 20 3.8 Mechanical Test ( Impact Test Izod ) 23 3.9 Microstructure Analysis 24
ix CHAPTER 4 RESULT AND DISCUSSION 4.1 Introduction 26 4.2 Moldflow Analysis 30 4.2.1 Gating Suitability 33 4.2.2 Fill Time 34 4.2.3 Temperature of Flow Front 35 4.2.4 Time to Reach Ejection Temperature 36 4.2.5 Air Traps 37 4.2.6 Weld Lines 38 4.2.7 Wrap 39 4.3 Main Data of Injection Molding 40 4.4 Tensile Test Result Analysis 44 4.4.1 Introduction 44 4.4.2 Pure Nylon 48 4.4.3 95%PA6 + 5%GF 50 4.4.4 90%PA6 + 10%GF 51 4.4.5 85%PA6 + 15%GF 53 4.4.6 80%PA6 + 20%GF 54 4.5 Impact Test (IZOD) Result Analysis 62 4.5.1 Introduction 62 4.5.2 Pure Nylon 62 4.5.3 95%PA6 + 5%GF 63 4.5.4 90%PA6 + 10%GF 63 4.5.5 85%PA6 + 15%GF 64 4.5.6 80%PA6 + 20%GF 64 4.6 Microstructure Analysis 66 4.6.1 Introduction 66
x CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 Introduction 70 5.2 Conclusion 70 5.3 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
xi LIST OF FIGURES Figure No. Title Page 2.1 Example of fill time result 8 2.2 Two plate mold ( Serope Kalpakjian, 2010 ) 9 2.3 Three plate mold ( Serope Kalpakjian, 2010 ) 9 2.4 Hot runner mold. ( Serope Kalpakjian, 2010 ) 10 2.5 Operation in the injection molding. ( Serope Kalpakjian, 2010 ) 10 3.1 Process Flow Chart 12 3.2 ASTM D 638 Type I 15 3.3 Injection Molding Machine 17 3.4 Clamp section 21 3.5 Universal Testing Machine (UTM) 22 3.6 Instron Bluehill software 22 3.7 Impact Test ( INSTRON CEAST 9050 ) 23 3.8 Position of Specimen for Impact Test (IZOD) 23 3.9 Pendulum Hammer (50J) 24 3.10 Distance tighten of clamp 24 3.11 Optical Microscope Machine 25 3.12 Composition for microstructure analysis 25 4.1 3D Modeling of ASTM D638 specimen 27 4.2 Three different gate location of ASTM D638 specimen 28 4.3 Edge gate for ASTM D638 modeling 29 4.4 Gating suitability 33 4.5 Fill time 34 4.6 Temperature at flow front 35 4.7 Time to reach temperature 36 4.8 Air traps 37 4.9 Weld lines 38 4.10 Wrap 39 4.11 Successful ASTM D638 specimen 41 4.12 Temperature used for Pure Nylon 42
xii 4.13 Temperature used for 95%PA6 + 5%GF 42 4.14 Temperature used for 90%PA6 + 10%GF 43 4.15 Temperature used for 85%PA6 + 15%GF 43 4.16 Temperature used for 80%PA6 + 20%GF 44 4.17 Fractured specimen (3mm/min) 45 4.18 Fractured specimen (5mm/min) 45 4.19 Fractured specimen (10mm/min) 46 4.20 Stress-Strain Curve of Pure Nylon (3mm/min) 48 4.21 Stress-Strain Curve of Pure Nylon (5mm/min) 49 4.22 Stress-Strain Curve of Pure Nylon (10mm/min) 49 4.23 Stress-Strain Curve of 95%PA6 + 5%GF (3mm/min) 50 4.24 Stress-Strain Curve of 95%PA6 + 5%GF (5mm/min) 50 4.25 Stress-Strain Curve of 95%PA6 + 5%GF (10mm/min) 51 4.26 Stress-Strain Curve of 90%PA6 + 10%GF (3mm/min) 51 4.27 Stress-Strain Curve of 90%PA6 + 10%GF (5mm/min) 52 4.28 Stress-Strain Curve of 90%PA6 + 10%GF (10mm/min) 52 4.29 Stress-Strain Curve of 85%PA6 + 15%GF (3mm/min) 53 4.30 Stress-Strain Curve of 85%PA6 + 15%GF (5mm/min) 53 4.31 Stress-Strain Curve of 85%PA6 + 15%GF (10mm/min) 54 4.32 Stress-Strain Curve of 80%PA6 + 20%GF (3mm/min) 54 4.33 Stress-Strain Curve of 80%PA6 + 20%GF (5mm/min) 55 4.34 Stress-Strain Curve of 80%PA6 + 20%GF (10mm/min) 55 4.35 Modulus (GPa), Rate 3mm/min 56 4.36 Modulus (GPa), Rate 5mm/min 56 4.37 Modulus (GPa), Rate 10mm/min 57 4.38 Tensile Stress at Maximum Load (MPa), Rate 3mm/min 57 4.39 Tensile Stress at Maximum Load (MPa), Rate 5mm/min 58 4.40 Tensile Stress at Maximum Load (MPa), Rate 10mm/min 58 4.41 Tensile Stress at Break (MPa), Rate 3mm/min 59 4.42 Tensile Stress at Break (MPa), Rate 5mm/min 59 4.43 Tensile Stress at Break (MPa), Rate 10mm/min 60 4.44 Tensile Stress at Yield (MPa), Rate 3mm/min 60
xiii 4.45 Tensile Stress at Yield (MPa), Rate 5mm/min 61 4.46 Tensile Stress at Yield (MPa), Rate 10mm/min 61 4.47 Impact Test Pure Nylon 62 4.48 Impact Test 95%PA6 + 5%GF 63 4.49 Impact Test 90%PA6 + 10%GF 63 4.50 Impact Test 85%PA6 + 15%GF 64 4.51 Impact Test 80%PA6 + 20%GF 64 4.52 Energy ( J ) 65 4.53 Re (kj/m²) 65 4.54 Absorb Energy (%) 66 4.55 Structure of Pure nylon 67 4.56 Structure of 95%PA6 + 5%GF 67 4.57 Structure of 90%PA6 + 10%GF 68 4.58 Structure of 85%PA6 + 15%GF 68 4.59 Structure of 80%PA6 + 20%GF 69
xiv LIST OF TABLES Table No. Title Page 4.1 Tabulated Moldflow Analysis 30 4.2 Temperature used for different composition of Glass fiber-reinforced Nylon 45 4.3 Cooling time and Stroke material used for different composition of Glass fiber-reinforced Nylon 40 4.4 Tensile Test (3mm/min) 47 4.5 Tensile Test (5mm/min) 47 4.6 Tensile Test (10mm/min) 48 4.7 Impact Test Pure Nylon 62 4.8 Impact Test 95%PA6 + 5%GF 63 4.9 Impact Test 90%PA6 + 10%GF 63 4.10 Impact Test 85%PA6 + 15%GF 64 4.11 Impact Test 80%PA6 + 20%GF 64
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