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Materials Today: Proceedings 5 (2018) 5908–5917 www.materialstoday.com/proceedings

ICMPC 2017

Raw natural fiber reinforced polystyrene composites: Effect of

fiber size and loading
Mohd Farhan Zafara*, M.Arif Siddiquia*
a
Department of Mechanical Engineering, Z.H.C.E.T., A.M.U., Aligarh, India

Abstract

In this study in-situ polymerization technique is used to prepare styrene monomer and natural fibres like rice husk (RH), wheat
husk (WH), mustard husk (MH) reinforced composites. Three different sizes i.e. 250-355 micron, 355-500 micron, 500-710
micron and three different loading i.e. 5%, 10% and 15 % were used to study the mechanical behaviour of these composites. The
synthesized polymer is injected to prepare the specimen for different mechanical tests like tensile test, flexural strength test etc.
The morphology of the fractured specimen is studied using the SEM micrographs. The results have shown an improvement in
the tensile strength and flexural strength as compared to unfilled polystyrene.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.

Keywords:Polystyrene; Rice Husk; Wheat Husk; Mustard Husk; In-situ polymerization; Mechanical Properties.

1. Introduction

Composites are materials composed of two or more different materials with the properties of the resultant
material being superior to the properties of the individual material that makes up the composites. Due to increased
use of polymer composites and rising environmental awareness throughout the world, greater attention is being paid
to the incorporation of biopolymer based materials as filler in polymer matrices instead of petrochemical based
materials [1-3]. Different natural fibres like sisal, flax, kenaf, wheat, rice, jute, coir etc., due to their renewable
nature offer a number of advantages over other synthetic fibres such as glass fibres, aramid fibres and carbon fibres
[4-5]. In addition to this it is also reported that natural fibres have several advantages like low density, competitive
mechanical properties, specific strength and stiffness properties, good vibration absorption and high resistance to
fracture while reducing energy consumption. [6-9]

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.
 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917 5909

Different methods are used for the fabrication and processing of these natural fibre composites are compression
molding, extrusion, injection molding, long fibre thermoplastic direct (LFT-D) method, pultrusion, resin transfer
molding, etc. The researchers have utilised these methods to prepare a variety of composites to study the physical,
mechanical and morphological properties of the composites. In the present research a very unique approach has
utilized for the synthesis of the polymer composite i.e. in-situ polymerization followed by injection molding for
preparation of different samples. Mechanical properties were then tested to characterize these samples.

2. Materials and Methods

2.1. Materials
Matrix: Styrene monomer, is utilized for preparing the polymer composite, purchased from Otto Company in 500
ml bottles.
Reagents: Methanol was purchased from CDH Pvt. Ltd in500ml bottles
Acetone was purchased from CDH Pvt. Ltd in 500ml bottles
Benzoyl peroxide (BPO) was purchased from LobaChemie Pvt. Ltd in 500g bottles
Glassware for smooth completion of experiments glassware and equipment were used.
Fillers: Natural fillers: Rice Husk (RH), Wheat Husk (WH) and Mustard Husk (MH). These fillers were collected
from different agricultural farms, cleaned for any dirt and stones, dried properly in sun and ground finely. The
grounded fillers are then categorized using different filler sizes i.e., 250-355 µ, 355-500 µ, 500-710 µ. These fillers
are then added to make polymer composites.
2.2. Synthesis of Polystyrene Composites
Washing of Styrene: Styrene monomer (500 ml) is taken into the separating funnel and an equal amount of 10%
NaOH is added for washing the styrene to get the inhibitors removed from the monomer. The separating funnel is
shaken vigorously so that all of the monomer is washed properly and proper polymerization can take place. The
mixture of NaOH and inhibitor is collected in the beaker by the stop cock and the washed styrene is left in the
funnel.
In-situ Polymerization: The washed monomer collected is placed on the hot water bath and is heated upto 90-110oC.
For initiation of the polymerization reaction, initiator (Benzoyl Peroxide) is added so that polymerization may start.
After the polymerization reaction is started and the monomer start to become more viscous (around 30-40 minutes
duration), the measured amount of filler particles (5%, 10% or 15%) is added for proper mixing. During the whole
course of polymerization a mechanical stirrer is placed to continually stir the monomer so that no lumps may
produce and also a more homogenous polymer is synthesized.
This synthesized polymer composites when polymerizes to form a paste like composite is shifted from beaker to a
plastic plate that have been lined with some oil for lubricating purpose. The polymer on the plate is kept in the oven
for 3-4 hrs at 100-120o C. The composite thus placed in oven is then completely polymerized and is converted into a
solid polymer.
Preparation of specimen: The solid polymer composite thus prepared is collected and break into smaller pieces and
then fed into injection moulding machine to prepare samples for different tests.

3. Mechanical Test

3.1. Tensile Test: Tensile test was performed on UTM G-410B (Fig. 2) having maximum load of 5 kN. The test was
carried out at speed of 2 mm/min at atmospheric condition (25o C). The size of the specimen was prepared according
to ASTM D 638 “Type I”. An average of readings for two specimen was taken for each combination to get the final
results.
Tensile Strength: It is calculated by dividing the maximum load in Newton by the original cross-sectional area of the
specimen (mm2). [10];
3.2. Flexural Test:
Flexural strength is the ability of the material to withstand bending forces applied perpendicular to its longitudinal
axis. Test sample for flexural test was127.0 mm x 12.7 mm x3.2 mm in size. Three point loading system was used
5910 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917

to get the result. A bar of rectangular cross section was put on two supports and was loaded by means of a loading
nose midway between the supports. The test was initiated by applying the load to the specimen at the specified
crosshead rate. The load was measured at which the fracture takes place. A total of two specimens are taken and
readings are averaged for the final results.
PL
S=
Where S= stress (MPa); P=load (N); L=length of span (mm); b= width of specimen (mm); d=thickness of the
specimen (mm).The length, width and thickness of specimens were measured accurately by Vernier calliper. Span
between two supports was adjusted equal to 16 times the thickness of the specimen.

4. Results and Discussion

4.1. Tensile Test

Tensile Test showed the tensile strength for in-situ polymerized virgin polystyrene is found to be 8.15N/mm2.

Rice husk filled polystyrene composite.

Table 1 Tensile Strength of rice husk filled polystyrene composite
S.No Tensile Strength(kN/mm2) Average Tensile Strength (N/mm2)
Filler Size(µ) Filler Loading (%)
T1 T2 T3
1 250-355 5 0.010 0.006 0.025 13.714
2 355-500 5 0.023 0.020 0.026 23.010
3 500-710 5 0.007 0.006 0.001 4.659
4 250-355 10 0.019 0.017 0.013 16.086
5 355-500 10 0.015 0.009 0.009 10.971
6 500-710 10 0.008 0.007 0.005 6.682
7 250-355 15 0.005 0.011 0.008 7.983
8 355-500 15 0.025 0.014 0.020 19.717
9 500-710 15 0.018 0.016 0.023 19.116

RH 250-355 micron RH 355-500 micron RH 500-710 micron

25
Tensile Strength (N/mm2)

20

15

10

0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler composition

Fig.1. Effect of particle loading on tensile strength (TS) at different filler sizes
 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917 5911

Wheat husk filled polystyrene composite

Table 2 Tensile Strength of wheat husk filled polystyrene composite

Average Tensile
Tensile Strength(kN/mm2)
S.No. Filler Size(µ) Filler Composition Strength (N/mm2)
T1 T2 T3
1 250-355 5% 0.016 0.010 0.016 14.080
2 355-500 5% 0.006 0.016 0.008 10.254
3 500-710 5% 0.007 0.015 0.014 11.787
4 250-355 10% 0.028 0.022 0.027 25.675
5 355-500 10% 0.007 0.017 0.009 11.286
6 500-710 10% 0.000 0.009 0.008 5.722
7 250-355 15% 0.033 0.019 0.032 27.985
8 355-500 15% 0.020 0.011 0.010 13.387
9 500-710 15% 0.016 0.007 0.011 11.139

WH 250-355 micron WH 355-500 micron WH 500-710 micron

30

25
Tensile Strength (N/mm2)

20

15

10

0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler Composition

Fig.2. Effect of particle loading on tensile strength (TS) at different filler sizes
5912 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917

Mustard husk filled polystyrene composite

Table 3 Tensile Strength of mustard husk filled polystyrene composite

Average Tensile
Tensile Strength(kN/mm2)
S.No Filler Size(µ) Filler Composition Strength (N/mm2)
T1 T2 T3
1 250-355 5% 0.022 0.003 0.024 15.981
2 355-500 5% 0.002 0.007 0.006 5.120
3 500-710 5% 0.018 0.017 0.008 14.373
4 250-355 10% 0.023 0.019 0.017 19.767
5 355-500 10% 0.007 0.003 0.008 5.874
6 500-710 10% 0.010 0.016 0.008 11.348
7 250-355 15% 0.009 0.018 0.015 14.083
8 355-500 15% 0.007 0.003 0.008 5.898
9 500-710 15% 0.010 0.016 0.008 11.479

MH 250-355 micron MH 355-500 micron MH 500-710 micron

25

20
Tensile Strength (N/mm2)

15

10

0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler Composition

Fig.3. Effect of particle loading on tensile strength (TS) at different filler sizes

The results shows that at lower sizes of filler the tensile strength increases to some extent and then decreases in
case of rice husk and mustard husk while in case of wheat husk it increases as the filler percentage is increased. This
may be because of better dispersion of filler particles in case of wheat husk particles. It is also evident from the
graph that for filler having particle sizes 355-500 µ, the tensile strength increases as we increase the filler loading.
This can very well be attributed to the fact that at larger size the homogenization and flow of filler particles is
smoother.
For larger filler size, i.e. 500-710 µ, the tensile strength increases as the filler loading increases in case of rice husk
composites while in case of wheat and mustard husk composites it increases at lower level of loading but decreases
 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917 5913

as the loading is decreased. In all as we increase the particle size for filler the tensile strength increases to certain
level but does not appreciate much after certain level.

4.2. Flexural Strength Test

The length of the specimen for calculating the flexural strength was taken 16 times the thickness of the specimen i.e.
3.5 X 16 = 56mm. The flexural strength of the unfilled polystyrene composite is found to be 25.598 N/mm2.

Rice husk filled polystyrene composite

Table 4 Flexural Strength of rice husk filled polystyrene composite
Flexural Strength (N/mm2) Average Flexural
S.No Filler Size (µ) Filler Loading (%)
S1 S2 Strength (N/mm2)
1 250-355 5 36.7901 35.8424 36.3162
2 355-500 5 34.5915 38.9144 36.7530
3 500-710 5 18.7013 18.1818 18.4416
4 250-355 10 33.7331 34.7092 34.2212
5 355-500 10 21.8746 21.9112 21.8929
6 500-710 10 19.6603 23.1940 21.4271
7 250-355 15 22.4999 20.6482 21.5741
8 355-500 15 45.9677 40.0480 43.0079
9 500-710 15 35.8446 42.5350 39.1898

RH 250-355 micron RH 355-500 micron RH 500-710 micron

50
45
40
Flexural Strength( N/mm2)

35
30
25
20
15
10
5
0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler Composition

Fig.4. Effect of particle loading on flexural strength at different filler sizes

5914 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917

Wheat husk filled polystyrene composite

Table 5 Flexural Strength of wheat husk filled polystyrene composite

Flexural Strength (N/mm2) Average Flexural
S.No Filler Size (µ) Filler Loading (%)
S1 S2 Strength (N/mm2)
1 250-355 5 26.3262 22.6854 24.5058
2 355-500 5 21.5477 25.7536 23.6507
3 500-710 5 39.1195 37.8353 38.4774
4 250-355 10 40.6533 36.6986 38.6759
5 355-500 10 39.0035 34.5777 36.7906
6 500-710 10 22.9636 22.6756 22.8196
7 250-355 15 44.6157 47.0770 45.8463
8 355-500 15 34.2460 33.3105 33.7783
9 500-710 15 29.1204 25.4921 27.3063

WH 250-355 micron WH 355-500 micron WH 500-710 micron

50

45

40
Flexural Strength (N/mm2)

35

30

25

20

15

10

0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler Composition

Fig.5. Effect of particle loading on flexural strength at different filler sizes

 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917 5915

Mustard husk filled polystyrene composite

Table 6 Flexural Strength of mustard husk filled polystyrene composite

Flexural Strength (N/mm2)
S.No Filler Size (µ) Filler Loading (%) Average Flexural Strength (N/mm2)
S1 S2
1 250-355 5 45.5737 43.6730 44.6234
2 355-500 5 12.7456 13.0340 12.8898
3 500-710 5 19.6065 0.0818 9.8441
4 250-355 10 25.9881 29.0348 27.5115
5 355-500 10 19.7764 17.4462 18.6113
6 500-710 10 21.9738 26.2574 24.1156
7 250-355 15 25.5401 26.1521 25.8461
8 355-500 15 32.2838 28.9440 30.6139
9 500-710 15 21.2831 21.2043 21.2437

MH 250-355 micron MH 355-500 micron MH 500-710 micron

50

45

40
Flexural Strength (N/mm2)

35

30

25

20

15

10

0
0% 2% 4% 6% 8% 10% 12% 14% 16%
Filler Composition
Fig.6. Effect of particle loading on flexural strength at different filler sizes
Above analysis represents the flexural strength for different variety of husks at different loading for different
sizes. Flexural Strength for the in-situ polymerized virgin polystyrene came out to be 25.598 N/mm2.
The graphs indicates that at lower sizes of filler , the flexural strength increases as the filler loading is increased
but this increase in flexural strength is not as prominent as in case of filler size of 355-500 µ. Except in case of
wheat husk where the increase in flexural strength is more at lower size of filler particle, better flexural strength is
observed in case of filler particle having size 355-500 µ.
When the filler size is increased further i.e. 500-710 µ, the change in flexural strength is not so appreciable at
higher percentages of loading. Although in case of rice husk this change is quite prominent.
5916 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917

4.3. Micrographic Examination

Following figures shows the SEM images of the fractured specimen at the point of fracture. These micrographs clearly show the
agglomerates that are being formed in the polymerization process. These husk agglomerates forms the stress raisers and the specimen
fails at this point. The micrographs also show the layered structure of the polymers. It is quite clear from the micrographs that the rice
husk filled composites gives a better morphology as compared to the wheat and mustard husk composites.

a) MH5_500-710 micron

b) MH10_250-355 micron c) MH10_355-500 micron

d) RH5_355-500 micron e)RH10_250-355 micron

 Mohd Farhan Zafar et al. / Materials Today: Proceedings 5 (2018) 5908–5917 5917

f) RH15_500-710 micron g) WH5_500-710 micron

h) WH15_250-355 micron i) WH15_355-500 micron

Fig.7 SEM micrographs of fractured specimen
5. Conclusions
From the results it may be concluded that the properties of the polymer composites are better than the properties of virgin
polymer in most of the cases. To conclude it is very well established from this work that composites having filler size of 250-355 µ
give the best tensile properties in case of wheat husk and mustard husk at 10% loading while for rice husk the maximum tensile
strength is achieved at 5% loading for size 355-500 µ. Also for flexural strength the best properties were observed at 15 %
loading at sizes 355-500 µ. The micrographs give a clear insight of the synthesized polymer composite, its microstructure and the
formation of agglomerates. The micrographs reveal that the composites prepared by rice husk filled polymer are the best in terms
of the dispersion of filler particle.
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