LAB MANUAL

AIM:
To prepare fiber reinforced composites by using vacuum bagging system.

EQUIPMENT:
Apparatus of Vacuum Bagging system consists of three major parts.

1) Fabrics, Mold And Reinforcements

a) Release fabric
b) Perforated Film
c) Breather material
d) Mastic Sealant
e) Vacuum Bagging film
f) Fiber Glass reinforcement

2) Chemicals
a) Gel coat
b) Accelerator
c) Resin MATRIX
d) Catalyst
e) Releasing Agent

3) Other Accessories
a) Scissors

b) Brushes

c) Gloves
SCHEMATIC DIAGRAM FOR VACUUM BAGGING SYSTEM
THEORY:

COMPOSITE
Composite material consists of at least two materials which are combined to improve
combined mechanical properties that would be different to properties if materials were
used as the single entity. Mainly composite materials consist of Resin Matrix and a
reinforcement .added to improve the strength and stiffness of matrix, While the
reinforcement is usually in fiber forms
Composite are divided into three main types
1) Polymers matrix composites also known as FRP or fiber reinforced composite panels
2) Ceramic matrix composites
3) Metal matrix composites

VACUUM BAGGING METHOD

Vacuum Bagging System is a process which uses a two side mould to produce the Fiber
reinforced composite panels. Lower side mold is rigid mainly made up of Wood while
vacuum bag forms the upper to complete the mold. After completing the mold set
vacuum pressure is applied on the system for improving consolidation of the composite
and removing air bubbles of the Cured laminate of Fiberglass reinforced plastic. Process
is mostly performed on ambient temperatures depending on the resin system used with
the vacuum pressure acting on the system. Vacuum Pump or air compressor is used to
extract air bubbles from the Vacuum bagging system.

PHASES DURING THE CURING OF POLYESTER RESIN

Gel Time: Time required between the addition of curing agent and giving time for
setting the resin to become a soft gel. On this stage liquid resin has lost its ability to flow
viscous.
Hardening Time: It’s the time when resin is hard enough and can be easily removed
from the mould.
Maturing Time: The time required for composite laminate to acquire its desired
hardness and stability, This time can vary from few hours to weeks and it is solely
dependent on Resin Matrix and the curing system used.
PROCEDURE
1) Cut the fabrics (Release, Breather) and films (Vacuum Bag and perforated film)
according to requirement.
2) Apply the gel coat to the mold.
3) After 45 minutes apply releasing agent to the mold.
4) Add accelerator with un-catalyzed-polyester resin and mix it. After mixing add the
catalyst to accelerated polyester resin.
5) Place layers of Fiberglass Reinforcement (Woven Or CSM) in the mold and apply Resin
Matrix to it.
6) Place layers of release fabric, breather fabric and vacuum bag over the mould.
7) Connect Vacuum port with the vacuum bag by puncturing a small hole in it.
8) Turn the vacuum Pump on, to start the evacuation of air from the bag.
9) After curing the composite for about 45 minutes, turn off the vacuum pump and
remove the films and fabrics.
10) Remove the flat panel of fiber reinforced composite carefully from the mould.

PRECAUTIONS

1) Adequate ventilation should be there in the lab.

2) Wear protective clothing.
3) Avoid bare hand contact with chemicals and fiber reinforcements.
4) Keep chemicals away from flame in order to avoid fire explosion.
5) Avoid empty containers.
6) Never use solvents that can damage the Vacuum pump.
7) Make sure that Switches and electric cords are defect free.