STUDY ON THE PROPERTIES OF POLYMER MATRIX

COMPOSITE USING USED PLASTICS AND VERGIN

PLASTICS AND ITS REINFROCEMENT EFFECTS

A PROJECT REPORT

A THESIS

Submitted by

M.SUDHERSAN.
(730421410012)

in the partial fulfillment for the award of degree

of

MASTER OF ENGINEERING

in

MANUFACTURING ENGINEERING

ERODE SENGUNTHAR ENGINEERING COLLEGE

(AUTONOMOUS)

PERUNDURAI, ERODE - 638 057

APRIL 2023
 ERODE SENGUNTHAR ENGINEERING COLLEGE
(AUTONOMOUS) PERUNDURAI, ERODE – 638057

BONAFIDE CERTIFICATE

Certified that this project report “EXPERIMENTAL STUDY ON THE

PROPERTIES OF POLYMER MATRIX COMPOSITE USING USED
PLASTICS AND VERGIN PLASTICS AND ITS REINFROCEMENT
EFFECTS” M.SUDHERSAN (730421410012) is the Bonafide work of who
carried out the project work under my supervision. Certified further that to the best of
my knowledge the work reported herein does not form part of any other thesis or
dissertation on the basis of which a degree or award was conferred on an earlier
occasion on this or any other candidate

SIGNATURE SIGNATURE
Mr. N.S. MOHAN, M.E., (Ph.D.) Dr. N. SARAVANAN, ME., Ph.D.
SUPERVISOR HEAD OF THE DEPARTMENT
Assistant Professor Professor & Head
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
Erode Sengunthar Engineering Erode Sengunthar Engineering
College, Erode – 638057. College, Erode – 638057.

Submitted for End Semester project viva voce Examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We wish to convey our heartfelt thanks to our esteemed and respected Founder,
UDYOG RATTAN THIRU J. SUDHANANDHEN who always blessed us to give the
best.

We heartily express our profound gratitude to our respected President&

Correspondent, Thiru. G. KAMALAMURUGAN for his constant support. We heartily
express our profound gratitude to our respected Secretary Thiru. S. N. THANGARAJU
B.E, M.B.A for his constant support.

We would like to express our sincere thanks to our Principal,

Dr.V.VENKATACHALAM, M.S., M.Tech., Ph.D., for forwarding us to do our project
and offering adequate duration in completing our project.

We are grateful to Dr. N.SARAVANAN, M.E., Ph.D., Professor and Head of the
Department of Mechanical Engineering and for his anchoring support in doing this project.

We express our sincere thanks to our beloved Project Coordinators

Dr.R.SASIKUMAR, M.E., Ph.D., Assistant Professor, Department of Mechanical
Engineering who is always with us to carry out this project successfully.

We express our sincere thanks to our beloved project supervisor

Mr.N.S.MOHAN, M.E.,(Ph.D.)., Assistant professor, Department of Mechanical
Engineering who is always monitor our project sincerely and be helpful for our project
success.

We express our sincere thanks to other teaching and non-teaching faculty members
of Mechanical Engineering Department, Electronics and Instrumentation Engineering
Department of Erode Sengunthar Engineering College for their valuable support and co-
operation while working for this project. i
 DECLARATION

I affirm that the project work titled “STUDY ON THE PROPERTIES OF

POLYMER MATRIX COMPOSITE USING USED PLASTICS AND VERGIN
PLASTICS AND ITS REINFROCEMENT EFFECTS” being submitted in partial
fulfillment for the award of MASTER OF ENGINEERING is the original work carried
out by me. It has not formed the part of any other project work submitted for award of any
degree or diploma, either in this or any other University.

SUDHERSAN M
(730421410012)

I certify that the declaration made above by the candidate is true.

Signature of the Supervisor,

Mr.N.S.MOHAN, M.E.,(Ph.D.).,
Assistant professor,
Department of Mechanical Engineering
Erode Sengunthar Engineering College
Perundurai, Erode - 638 057

ii
 ABSTRACT

The development of biodegradable plastics has reduced the use of

non-biodegradable plastics, but there is still no adequate remedy for the
hazardous plastics that we have been using for so long. Eliminating the
dumping of discarded plastics is the motivation behind this endeavor. Non-
biodegradable plastics are discarded without being reused, becoming landfill
waste. This idea offers a suitable solution to convert discarded plastic
materials into functional furniture utilizing pulverization technique, as
opposed to having them end up in a landfill and maybe destroying our
ecosystem.

The danger of pollution resulting from the heating of plastic material

is eliminated by using the pulverization technology to handle the waste
plastics. Waste plastic is thrown into the pulverizing device, which grinds it
into granules or powder. These powders are then combined with epoxy glue
and a hardener to form a fluid that can be injected into the necessary cavities
to give the polymers their desired shape. This method allows for the
conversion of large amounts of non-biodegradable plastic into practical home
and workplace furnishings and appliances.

Keywords: PET, Low Density Polyethylene, High Density Polyethylene,

Mechanical testing.

iii
 சுருக்கம்

மக்கும் பிளாஸ்டிக்கின் பரிணாமம் மக்காத பிளாஸ்டிக்கின்

பயன்பாட்டைக் குறைத்துவிட்டது, ஆனால் இத்தனை
நாட்களாக நாம் பயன்படுத்தி வரும் நச்சுப்
பிளாஸ்டிக்குகளுக்கு இன்னும் சரியான தீர்வு
வழங்கப்படவில்லை. இப்பணியை மேற்கொள்வதன்
பின்னணியில் பிளாஸ்டிக் கழிவுகள் கொட்டப்படுவதை
ஒழிக்க வேண்டும். மக்காத பிளாஸ்டிக்குகள்
மறுபயன்பாட்டின்றி கைவிடப்பட்டு, குப்பை கிடங்காக
மாறுகிறது. இந்தத் திட்டம், பயன்படுத்தப்பட்ட பிளாஸ்டிக்
பொருள்களை, தூளாக்கும் நுட்பத்தைப் பயன்படுத்தி
பயனுள்ள மரச்சாமான்களாக மாற்றுவதற்கு ஒரு
பொருத்தமான வழியை வழங்குகிறது, இல்லையெனில் அது
நமது சுற்றுச்சூழல் அமைப்பைப் பேரழிவிற்கு உட்படுத்தும்
திறன் கொண்ட நிலப்பரப்பாக மாறும்.பிளாஸ்டிக் கழிவுகளை
பதப்படுத்துவதற்கு தூள்மயமாக்கல் முறையைப்
பயன்படுத்துவது பிளாஸ்டிக் பொருட்களை சூடாக்குவதால்
ஏற்படும் மாசுபாட்டை நீக்குகிறது. பிளாஸ்டிக் செதில்களை
துகள்களாக அல்லது பொடிகளாக மாற்றும் பொடி செய்யும்
இயந்திரத்தில் கழிவு பிளாஸ்டிக்கை விடப்படுகிறது. பின்னர்
இந்த பொடிகள் எபோக்சி பிசின் மற்றும் கடினப்படுத்தியுடன்

iv
கலக்கப்படுகின்றன, இதனால் பிளாஸ்டிக்குகளுக்கு
வடிவத்தை வழங்க தேவையான குழிக்குள் அதை
ஊற்றலாம். இந்த அணுகுமுறையின் மூலம், மக்கும்
அல்லாத பிளாஸ்டிக் பொருட்களை உபயோகமான வட்டு
ீ
உபயோகப் பொருட்கள் மற்றும் வடு/அலுவலக
ீ
மரச்சாமான்களாக மாற்றலாம்.

v
 TABLE OF CONTENT

CHAPTER PAGE
TITLE NO
NO
ABRSTRACT ii
LIST OF TABLEES v
LIST OF FIGURES vi
LIST OF CHARTS viii
LIST OF ABBREVATION ix
TEST REPORT x
1 INTRODUCTION 1
1.1 Composite Material 1
1.1.1 Ceramic Matrix Composites 2
1.1.2 Polymer Matrix Composites 3
1.1.3 Metal Matrix Composites 3
1.2 Polymer 5
1.3 Categories of
Composites Manufacturing 5
Techniques
1.3.1 Open Mould Process 5
1.3.2 Closed Mould Process 6
2 LIERATURE REVIEW 8
3 OBJECTIVES AND METHODOLOGY 11
3.1 Objectives 11
3.2 Methodology 11
3.2.1 Materials Used 12
3.2.1.1 Plastic Powder 12
3.2.1.2 Epoxy Resin (Ly-556) 14

vi
 TABLE OF CONTENT

CHAPTER PAGE
TITLE NO
NO
3.2.1.3 Hardener (Hy-951) 15

3.2.1.4 Die 16

3.2.2 Hand Lay-Up Method 16

4 FABRICATION OF PLATE 17

4.1 Fabrication Process 19

5 TESTING AND RESULT 22

5.1 Tensile Test 22

5.2 Flexural Strength Test 24

5.3 Impact Test 26

6 ADVANTAGES AND DISAVANTAGES 28

6.1 Advantages 28

6.2 Disadvantages 29

7 APPLICATION OF COMPOSITES 30
MATERIAL AND
COST ESTIMATION
7.2 Cost Estimation 30

8 RESULT AND DISCUSSION 31

9 CONCLUSION 32

10 REFERENCES 37

vii
 LIST OF TABLES

TABLE PAGE
TITLE
NO. NO.

5.1 Tested values of tensile strength on 23

different specimens
5.2 Tested values of Flexural strength on 25
different specimens
5.3 Tested values of Izod Impact Strength on 27
different specimens
7.1 Cost spend for purchased items 30

viii
 LIST OF FIGURES

FIGURES
NO.
PAGE
TITLE
NO.

1.1 Ceramic Matrix Composites 2

1.2 Polymer Matrix Composites 3

1.3 Metal Matrix Composites 4

1.4 Open mould process 5

1.5 Spray lay-up process 6

1.6 Closed mould process 6

3.1 Plastic Powder 13

3.2 Epoxy resin (LY-556) 14

3.3 Hardener (HY-951) 15

3.4 Die 16

3.5 Hand lay-up method 16

4.1 Mixture of Resin, hardener, and plastic powder 17

4.2 Moist hand layup method 18

4.3 Virgin and single use plastic powder mould 19

ix
 LIST OF FIGURES

FIGURES PAGE
TITLE
NO. NO.

4.4 Specimens for Tensile, Flexural and Impact 20

Test
4.5
Specimens for Tensile, Flexural and
21
Impact Test

5.1 Universal Testing Machine (Tensile Testing 22

Setup)

5.2.1 Tensile Sample specimen before testing 23

5.2.2 Tensile Sample specimen after testing 23

5.3 Universal Testing Machine 24

(Flexural Strength testing Setup)

5.4.1 Bending Test Sample specimen before testing 25

5.4.2 Bending Test Sample specimen after testing 25

5.5 Impact Testing Machine 26

5.6.1 Impact test Sample specimen before testing 27

5.6.2 Impact test Sample specimen after testing 27

x
 LIST OF CHARTS

CHART PAGE
TITLE
NO NO
5.1 Comparison of Tensile strength on different samples 23
5.2 Comparison of Flexural strength on different samples 25
Comparison of Izod Impact strength on different
5.3 27
samples

xi
 LIST OF ABBREVATIONS

CMC Ceramic Matrix Composite

MMC Metal Matrix Composite

PMC Polymer Matrix Composite

ASTM American Society for Testing and Materials

UTM Universal Testing Machine

UTS Ultimate Tensile Strength

CS Area Cross Sectional Area

MPa Megapascal (Pressure Unit)

GPa Gigapascal (Pressure Unit)

xii
 LIST OF TABLES

TABLE PAGE
TITLE
NO. NO.

5.4 Tested values of tensile strength on 23

different specimens
5.5 Tested values of Flexural strength on 25
different specimens
5.6 Tested values of Izod Impact Strength on 27
different specimens
7.1 Cost spend for purchased items 30

xiii
 LIST OF FIGURES

FIGURES
NO.
PAGE
TITLE
NO.

1.7 Ceramic Matrix Composites 2

1.8 Polymer Matrix Composites 3

1.9 Metal Matrix Composites 4

1.10 Open mould process 5

1.11 Spray lay-up process 6

1.12 Closed mould process 6

3.6 Plastic Powder 13

3.7 Epoxy resin (LY-556) 14

3.8 Hardener (HY-951) 15

3.9 Die 16

3.10 Hand lay-up method 16

4.4 Mixture of Resin, hardener, and plastic powder 17

4.5 Moist hand layup method 18

4.6 Virgin and single use plastic powder mould 19

xiv
 LIST OF FIGURES

FIGURES PAGE
TITLE
NO. NO.

4.4 Specimens for Tensile, Flexural and Impact 20

Test
4.5
Specimens for Tensile, Flexural and
21
Impact Test

5.1 Universal Testing Machine (Tensile Testing 22

Setup)

5.2.1 Tensile Sample specimen before testing 23

5.2.2 Tensile Sample specimen after testing 23

5.3 Universal Testing Machine 24

(Flexural Strength testing Setup)

5.4.1 Bending Test Sample specimen before testing 25

5.4.2 Bending Test Sample specimen after testing 25

5.5 Impact Testing Machine 26

5.6.1 Impact test Sample specimen before testing 27

5.6.2 Impact test Sample specimen after testing 27

xv
 LIST OF CHARTS

CHART PAGE
TITLE
NO NO
5.1 Comparison of Tensile strength on different samples 23
5.2 Comparison of Flexural strength on different samples 25
Comparison of Izod Impact strength on different
5.3 27
samples

xvi
 LIST OF ABBREVATIONS

CMC Ceramic Matrix Composite

MMC Metal Matrix Composite

PMC Polymer Matrix Composite

ASTM American Society for Testing and Materials

UTM Universal Testing Machine

UTS Ultimate Tensile Strength

CS Area Cross Sectional Area

MPa Megapascal (Pressure Unit)

GPa Gigapascal (Pressure Unit)

xvii
 CHAPTER 1
INTRODUCTION

A composite material is a material that is made up of two or more different

materials, often with different physical and chemical properties, that are combined
to create a new material with improved or unique properties. Examples of
composite materials include fiberglass, carbon fiber, and reinforced concrete.
These materials are often stronger, lighter, and more durable than their individual
components, making them useful in a variety of applications such as construction,
aerospace, and automotive industries. Despite the fact that they can't replace
composite materials, there are currently a wide variety of solutions that can replace
the heavy materials. A crucial aspect of our everyday lives is played by composite
materials. Composites are a way of creating new types of materials by fusing two
or more components in various proportions using various matrices.

Basically, three different forms of composites are available: metal matrix,

ceramic matrix and fiber (polymer) matrix. are made in various ways. B. Hand
layup method, compression molding, spray layup method, etc. 

Recently, researchers have mainly focused on the production of bio

composites. Bio composites are derived from readily available sources
(availability) and are highly effective in reducing hazards due to the presence of
natural ingredients

CLASSIFICATION OF COMPOSITES
A composite material is a material made from two or more constituent
materials with significantly different physical or chemical properties that, when
combined, produce a material with different characteristics.

1
 Chart No. 1.1 Classification of composite material

Composite materials
(based on matrix)

Ceramic matrix Polymer matrix Metal matrix

composites composites composites

Thermoplastic matrix Thermoset matrix

composites composites

CERAMIC MATRIX COMPOSITES

Ceramic matrix composites (CMCs) are a type of composite material made by

combining ceramic fibers or particles with a ceramic matrix. The resulting material
has improved mechanical properties, such as higher strength and stiffness, compared
to traditional ceramics. CMCs are used in high-temperature applications, such as
aerospace components, gas turbine engines, and nuclear reactors, due to their ability
to withstand extreme thermal and mechanical stresses. They are also being developed
for other applications, such as automotive components, biomedical implants, and
sporting goods.

Fig. 1.1 Ceramic Matrix Composites

2
 POLYMER MATRIX COMPOSITES

Polymer matrix composites (PMCs) are a type of composite material made by

combining a polymer resin (such as epoxy or polyester) with reinforcing fibers (such
as carbon, glass, or aramid). The resulting material has improved mechanical
properties, such as higher strength and stiffness, compared to traditional polymers.
PMCs are widely used in various industries, including aerospace, automotive,
construction, and sports equipment, due to their lightweight, corrosion resistance, and
design flexibility. They are used in applications such as aircraft and spacecraft
components, automotive body parts, wind turbine blades, and sporting goods.
Fig. 1.2 Polymer Matrix Composites

METAL MATRIX COMPOSITES

Metal matrix composites (MMCs) are a type of material that combines two or
more materials to create a new material with improved properties. In MMCs, a metal
matrix is reinforced with a second material, such as ceramic, carbon, or other metals,
to enhance its strength, stiffness, wear resistance, thermal conductivity, and other
properties. The reinforcement materials are dispersed throughout the matrix in the
form of particles, fibers, or whiskers, which help to distribute loads and prevent
cracks from propagating. MMCs have a wide range of applications in aerospace,
automotive, electronics, defense, and other industries, where high-performance
materials are required.
3
 Fig. 1.3 Metal Matrix Composites

POLYMER

A Resin is a solid or highly viscous substance of plant or synthetic origin that is

typically convertible into polymers after curing.

Chart No. 1.3 Types of polymers

4
CATEGORIES OF COMPOSITE MANUFACTURING TECHNIQUES
 Open mould process
 Closed mould process

OPEN MOULD PROCESS:

The open mold process is a method of manufacturing composite materials
such as fiberglass reinforced plastic (FRP) using a reusable mold that is open on
one side. In this process, the mold is first coated with a release agent to prevent the
composite material from sticking to it. The reinforcement material, which is
usually fiberglass or carbon fiber, is then placed in the mold, followed by the resin.
The mold is then closed and the resin is allowed to cure. Once cured, the mold is
opened and the finished product is removed. This process is commonly used in the
production of boat hulls, automotive components, and other large parts.
TYPES
a. Hand lay-up process
b. Spray lay-up process
c. Vacuum bag autoclave process
d. Filament winding process

Fig. 1.4 Open Mould Process

5
 Fig. 1.5 Spray lay-up process

CLOSED MOULD PROCESS:

Closed mould process is a manufacturing technique used to create
composite parts in a mold that is closed during the entire production process. Unlike
the open mould process, which leaves the composite material exposed to the
environment during curing, the closed mould process keeps the composite material
enclosed in the mold until it has fully cured.

There are several types of closed mould processes, including:

1. Compression Molding: In this process, the composite material is placed in the

mold, and then the mold is closed under high pressure. The pressure helps to evenly
distribute the resin and reinforcement fibers, resulting in a strong and uniform part.

2. Injection Molding: In this process, the composite material is injected into a closed
mold under high pressure. The material is then allowed to cure before the mold is
opened, and the finished part is removed.

Fig. 1.6 Compression Mould Process & Injection Mould Process

6
 CHAPTER 2
LITERATURE REVIEW

Anshu Anjali Singh, Priyanka and Kishor Biswas et al [1], Structure,

Mechanical and Thermal properties of coconut fiber reinforced polypropylene
composites with 2% MAPP as a compatibilizer (2015), In their work coconut fiber
reinforced polypropylene (CNF/PP) composite with 2% MAPP-moleic anhydride
Gratted polypropylene as a compatibilizer, before compounding, coconut fiber are
chopped of length 4.5mm were dried in an over at 60˚c overnight to remove the
moisture CNF, MAPP and the PP(polypropylene) are mixed manually. Tensile
strength for 5% of CNF and 95% of PP has 22.91 MPa and 10% of CNF and 90%
of PP has 24.59 MPa. Also shown SEM images of 5/95 and 40/90 CNF/PP
composites.

K. Praveen Kumar, M.Mazoor Hussain, Sirdhara Reddy et al [2], An

overview of Thermal and Mechanical properties of natural fiber Reinforced
Hybrid composites [2018]. In their work coconut coir, Jute fiber, Epoxy resin is
used as binder silicon carbide (SiC) is used as filer material. Tensile, compressive,
Hardness Test are carried out and thermal properties investigation are carried in
their work and concluded that increasing filler material tends to increase the
modules and hardness but decrease tensile strength of the composite.

D.Verma, P.C.Gope, A.Shandilya, A.Gupta, M.K.Maheswari et al [3] Coir

Fiber Reinforced and application in polymer composites. A review [2016]. In their
work we know some properties of fibers like Banana, Coir, Sisal, Pineapple,
Talipot, jute. We understand the classification of the composites and chemical
composition of coir.
Xue Yang, Liqian Huang, Longdi Cheng et al [4].Studies of Moisture
Absorption and Release Behaviour of Akund fiber (2012). In their work, Akund
fiber is obtained from Calotropis procera, the fiber's moisture absorption and
10
releasing are investigated. Akund fiber's moisture absorption and releasing are
compared with Kapok and cotton. From that, Akund fiber has a quick moisture
release and slow moisture absorption performance. The initial rate of moisture
release of akund fiber is much higher than that of cotton, and similar to kapok. But
its initial speed of moisture absorption is the slowest, and closest to cotton. From
their work, we understand the moisture absorption and releasing behavior.

Debasmita Pani, punyapriya Mishra et al [5]. Analysis of mechanical properties

of coir composites with varied compositions [2019]. In their work, composites
were fabrication using hand lay-up technique with Epoxy resin (LY556) and
Hardener (HY951) in the ratio of 10:1. The coconut coir are mixed in different
weight proportions, before this it have been treated with NaOH and fabricated.
The mechanical properties are examined and shown. The scanning electron
microscopic image of different composition are shown. The result of their work is
increased gluing between fiber and matrix and 53% increased in tensile strength
compared to composites with raw fibers.

Paulo Pecas, Hugo Carvalho, Hatiz Salman et al [6], Natural Fiber Composites
and their Application: A Review [2018], they had done review study in natural
fiber application. The fibers are Abaca, Bamboo, Coir, Cotton, Eucalyptus, Flax,
Hemp, Jute, Kenaf, Pineapple, Ramie, Sisal- their properties are also listed. The
properties listed are tensile strength, young’s modulus, elongation at break,
moisture content and also stated the chemical treatment effect on functional
properties of natural fiber. The application of natural fiber in European automotive
industry in 2012 is stated.
Mohammed Affan Usmani et al [7], A Review study of Natural fiber reinforced
composite material: Types and Properties (2018). In their study review properties
of natural fibers and its chemical properties are stated. The description about fibers
are stated in their study review.

Malla Surya Teja, et al [8], made the Experimental Investigation of Mechanical

11
and Thermal properties of sisal fiber reinforced composites and effect of Sic filler
material,(2016). In this they exhibited that the tensile strength of composite with
10%SiC 2.53 times greater than that of composite without Sic. Thermal properties
includes thermal conductivity, specific heat capacity, and thermal diffusivity.

Braga R. A, et al [9], The author Compare the analysis of the mechanical and
thermal properties of polyester hybrid composites by jute and glass fiber. To
improve mechanical properties jute was hybridized with glass fiber(2015). The
different tests are Flexural, thermal, impact, density and water absorption using
hybrid composites samples. The thermal properties of the composites without
glass fiber it lost more mass where temperature is a function, more percentage of
glass fiber with composite lost less weight with increasing temperature. So that the
composite with more percentage of glass fiber absorbs more water when
composite with more jute fiber.

Madhusudhan T, et al [10], Mechanical Characterization of Jute and Rubber

Particles Reinforced Epoxy Polymer Composites(2016). In this tensile and flexural
properties are influenced by the fiber composition than the rubber particulate. The
combination of these materials in composites can be used as alternative in any
synthetic fiber filled polymer composites.

12
 CHAPTER 3

OBJECTIVES AND METHODOLOGY

OBJECTIVES

 To convert waste plastic into useful appliances/furniture without

polluting the environment.
 To avoid piling-up of landfills by transforming lumps of used
plastic into useful products.
 To enhance rural employment.
 To promote entrepreneurship among the young engineers.

METHODOLOGY
To achieve the objective of this research the following tasks have to be
executed

 Conducting literature review to the related subject of the research.

 Collecting materials such as Non-Biodegradable Plastic.
 Preparing mould to produce a plate as per ASTM standard.
 Preparing and manufacturing the composite specimen.
 Test the composite plate for analyzing the mechanical properties.
 Discuss the result, recommendation to improve the strength
of composite of this research.

13
 METHODOLOGY

MATERIALS USED:

Materials used are

1. Pulverized Plastic Powder

2. Epoxy resin (LY-556) and

3. Hardener (HY-951)

14
 Pulverized Plastic Powder:

Powdered plastic processes help reduce material costs, recover value and improve
product quality so you can stay focused on your business. Our high-purity recycling
expertise and experience in handling high-value materials coordinate a series of
customized processes to ensure efficient, complete and economical processing
solutions for high-value and specialty polymers such as powdered plastics.

Fig. 3.1

Advantages of Pulverized Plastic Powder:

Comparing to standard reinforcing polymer matrix has the
subsequent advantages.
 High toughness
 Low cost
 Free from Hazard
 Sensible thermal properties

15
EPOXY RESIN (LY-566):

The starting materials for epoxy matrices are low molecular weight organic liquid
resins containing various epoxy groups, which are three-membered rings composed
of oxygen and carbon atoms. Epoxy resins are highly reliable and have excellent
mechanical properties. Epoxy resins contribute to the strength, durability, and
chemical resistance of composites. Epoxies come in liquid, solid, and semisolid
forms and are typically cured by reaction with amines or anhydrides.  
Fig. 3.3 Epoxy Resin (LY-556)

Properties of LY556:

Excellent chemical resistance especially to acids at temperature up to80˚c.

HARDENER (HY-951):

The HY-951 (Tri-ethylane-Teyramie) hardener could be a activity agent to

be properly and completely mixed with Epoxy resin to gain a good mechanical
properties.

16
 Fig. 3.4 Epoxy Hardener (HY-951)

Epoxy resin (or) polyester requires hardener to initiate curing, its conjointly
known as catalyst, the substance that hardness the adhesive once mixed with
organic compound.
DIE:

To fabricate the natural fiber reinforced composite plate die is required which
follows the ASTM- standard. The dimension of the die is ( l*b*t =25cm *25cm *
1cm ).

17
 Fig. 3.5 Die

3.2.2. HAND LAY-UP METHOD

Resins are impregnated by hand into fibers which are in the form of woven,
knitted, stitched or bonded fabrics. This is accomplished by rollers or brushes for
forcing the resin into the fabrics by means of rotating rollers and bath of resin. The
laminates are allowed to cure under standard atmospheric conditions.

Fig. 3.6 Hand lay-up method

18
 CHAPTER 4
FABRICATION OF PLATEFABRICATION

PROCESS

Step 1: Choice of matrix material

Epoxy Resin (LY-556) has been taken because of excellent adhesion to wide variety
of fibers andother substrates. Hardener (HY-951) is used to curing process.

Step 2: Selection of Reinforcement

Non-Biodegradable Plastic is converted into Pulverized Plastic Powder

Step 3: Mixture of Pulverized Plastic Powder, Epoxy Resin, Hardener

Hardener and Epoxy Resin are mixed in the ratio of 1:8(i.e. 1ml
hardener and 8m epoxy resin) then the pulverized plastic powder mixed for 5-8
minutes

Fig. 4.1

19
Step 4: Moist Hand lay-up method

Hand layup technique is the simplest approach of composite processing. The

infrastructural requirement for this method is also minimal. The processing steps
are simple. To start with, a release gel is applied on the mould floor to avoid
sticking of polymer to surface. Skinny Plastic sheets are used at the top and
bottom of the mildew plate to get right surface end of the product.
Reinforcement inside the shape of woven mats or chopped strand mats are reduce
as consistent with mildew size and positioned on the surface of mould after
19perspex sheet.
Then thermosetting polymer is mixed with hardener in appropriate share. The
resin and hardener mix are well mixed with 30g of pulverized plastic powder,
The air formation between the fiber is removed by giving pressure with help of a
wooden piece. The mix will be spread evenly between the pulverized plastic
powder, By placing the weight over the composite in the die, to produce well
finished composite plate

Fig. 4.2

20
Fig. 4.3 Virgin and single use plastic powder mould

21
Step 6: Preparing the specimen for testing
Cutting the specimen as per ASTM size for different testing and
imageof the specimen for testing is shown below.

Cutting the Specimens in dimensions as per the ASTM Standards are

 Tensile Test ASTM D3039

Length = 170mm, Wide = 20mm, Thickness = 1cm
 Flexural Strength Test ASTM D7264
Length = 140mm, Wide = 12mm, Thickness = 1cm
 Impact Test ASTM D6110
Length = 125mm, Wide = 13mm, Thickness = 1cm

Fig. 4.5 Specimens for Tensile, Flexural, and Impact Test.

22
Fig. 4.5 Specimens for Tensile, Flexural, and Impact Test.

23
 CHAPTER 5
TESTING AND RESULT

5.1 TENSILE TEST

Tensile strength is the ability of a material to withstand a pulling (tensile) force.

Tensile test is used to determine the tensile strength of the specimen,
% elongation of length and % reduction of area. Tensile test is usually carried out
in universal testing machine.

Fig. 5.1 Universal Testing Machine (Tensile Testing Setup)

Sample Specimens:

Sample 1 => Single use PET Plastic

Powder Sample 2 => Virgin Plastic Powder

24
Fig. 5.2.1 Tensile sample specimen Fig. 5.2.2 Tensile Sample
Specimen before testing after testing
The below table shows the tested value of Tensile strength on three
different sample specimens for two set of specimens from each sample plate. The
test report from the lab is shown next to the reference page.
Table 5.1 Tested values of tensile strength on three different specimens

Sample CS Peak %
UTS
No. Area Load Elongation
(N/𝑚𝑚2)
(𝑚𝑚2) (N)
1 180.00 1132.927 4.110 6.298

2 180.00 1035.190 4.540 5.749

Chart No. 5.1 Comparison of Tensile strength on two different samples

Chart Title
6.4
6.3
6.2
6.1
6
5.9
5.8
5.7
5.6
5.5
5.4
Ultimate Tensile Strength
Single use PET Plastic powder Virgin plastic powder

25
5.1 FLEXURAL STRENGTH TEST

Bending test methods measure the behavior of materials subjected to simple beam
loads. Also called crossbar test for some materials. Maximum fiber stress and
maximum strain are calculated for incremental loads. The results are plotted on a
stress-strain diagram. Flexural strength is defined as the maximum stress of the
outermost fibers. Flexural strength tests are performed on a universal testing
machine (UTM) on three different specimens from two sets of heats on three
different composite panels. Tested to ASTM Standard D7264 = 140mm long,
13mm wide and 5mm thick 

Fig. 5.3 Universal Testing Machine (Flexural Strength testing Set

Sample Specimens :

Sample 1 => Single use PET Plastic

Powder Sample 2 => Virgin Plastic Powder

26
Fig. 5.4.1 Bending Test sample specimen Fig. 5.4.2 Bending Test Sample
Specimen before testing after testing
The below table shows the tested values of Flexural strength on three
different sample specimens for two set of specimens from each sample plate.
The test report from the lab is shown after the reference page.

Table 5.2 Tested values of flexural strength on three different composition specimens

Sample CS Area Peak Load Flexural Flexural

No. (𝑚𝑚2) Strength Modulus
(N) (MPa) (GPa)
1 117.000 73.899 6.632 212.436

2 117.000 357.378 32.072 1201.021

Chart No. 5.2 Comparison of flexural strength on three different composition

samples for two batch

Chart Title

16
14

12

27
10
8

0
Single use PET Plastic powder Virgin plastic
powder
Flexural Strength

28
5.1 IMPACT TEST
Impact testing determines the amount of energy a material absorbs upon rupture. This
absorbed energy is a measure of the toughness of a particular material and serves as a
tool to study the temperature-dependent brittle-ductile transition. The purpose is to
determine if a material is brittle or ductile in nature.  

Fig. 5.5 Impact Testing Machine

The Izod impact strength test is an ASTM standard method of determining

the impact resistance of materials. A pivoting arm is raised to a specific height
(constant potential energy) and then released. The arm swings down hitting a
notched sample, breaking the specimen.
The impact test is carried for three different composition sample specimens
for two set of batches.

Sample Specimens:

Sample 1 => Single use PET Plastic

Powder Sample 2 => Virgin Plastic Powder

29
 Fig. 5.6.1 Impact test sample specimen Fig. 5.6.2 Impact
test Sample Specimen before testing after testing

The below table shows the tested values of Izod Impact strength on three
different sample specimens for two set of specimens from each sample plate. The
test report from the lab is shown after reference page.

Table 5.3 Tested values of Izod Impact Strength on three different

composition specimens.

Sample Izod Impact Value in

No. Joule for given
thickness
1 0.25
2 0.15

Chart No. 5.3 Comparison of Izod Impact strength on three different

composition samples for two batch.

Chart Title
0.3

0.25

0.2

0.15

0.1

0.05

0
Izod Impact Value in Joule

Single use PET Plastic Powder Virgin plastic powder

30
 CHAPTER 6
ADVANTAGES AND DISADVANTAGES

ADVANTAGES
They may be eco-friendly, bio-degradable, to be had in massive quantities,
renewable reasonably priced and feature low density in comparison to synthetic
fibers together with glass, aramid, carbon, and steel fibers.

 Low cost and high overall performance of NFRPC’s contented the financial
component of the industry.

 The disposal of NFRPC’s is straightforward in comparison to SFRPC.

 The abrasive plastic is a whole lot lower which leads to benefits regarding technical
process and recycling system of the composite substances.

 Polymer Matrix composites are used in location of glass often in non-structural

programs. Automotive additives including doorways, bonnets, and many others.
Crafted from glass fiber bolstered components are now being replaced with the aid
of NFRPC.

Good relative mechanical properties such as tensile modulus and flexural modulus
and improved surface finish of molded parts composites over the Synthetic Fiber
Reinforced Polymer Composites (SFRPC).

31
DISADVANTAGES

 High moisture absorbing property is the fundamental downside of the

natural fibers. This phenomenon reduces the interfacial bonding between the
polymer matrix and fiber and causes destructive effects on the mechanical
properties.
 These have bad wettability, incompatibility with some polymeric
matrices.
 Plant fibers cannot be used at once in its herbal shape. It requires chemical
modification to take away the waxy layer to enhance the interfacial adhesion
between fibers and polymer matrix.

32
 CHAPTER 7
APPLICATION OF COMPOSITE MATERIAL

APPLICATION OF COMPOSITES IN VARIOUS FIELDS

There are several industries such as automotive, construction, energy, and aerospace.
In European countries, recyclability is 95% in 2015, so they are using Polymer
Matrix composites in automotive industries. In India there will be scope for
composite materials in future, if concerned about environment and other aspects
Polymer Matrix composites provides solution for the recyclability.

 Mattresses, doormats, car door interior works done from the Polymer
Matrix composites.

 In the interior door linings and panels, door panels, center console
are fabricated from the Polymer Matrix composites.

 In Mercedes Benz C, S, E & A class truck using Polymer Matrix

composites in roof cover, Insulations, Glove box.

In Aerospace, Bombardier has used Polymer Matrix composites Hand luggage

cabin doors to meet European standard.

7.1 COST ESTIMATION

Table 7.1 Cost spend for purchased items.

S. No. ITEMS COST

1. Plastic Powder, Epoxy Resin and
Hardener 2300
2. Composite plate Cutting and Testing
2000
3. Miscellaneous
1600

33
 CHAPTER 8
RESULT AND DISCUSSION

RESULT AND DISCUSSIONS

 Nowadays a lot of attention is paid to environmental-friendly substances.

This led to developing interest in natural Lignocellulos’s substances and composites.

 Lignocelluloses composites has extra safety all through hearth (floor of

fireplace) than the man-made polymers because of loss of dangerous melting and less
poisonous gases and smoke manufacturing.

 Concerning about environment, polymers (Plastics commonly known) have

high strength. It has been observed that mechanical properties of composites together
with tensile, flexural strength, impact strength shows significantly resin and hardener -
75% and pulverized plastic powder -25% composition which has better strength than
other compositions.

34
 CHAPTER 9
CONCLUSION

 The mechanical residences of epoxy resin composites reinforced with

Polymer Matrix composites had been studied.

 The combination of pulverized plastic powder, Epoxy resin and hardener

gives more strength for the material, the pulverized plastic powder are spread
uniformly, this will bloom the adhesive ability of the pulverized plastic
powder with the matrix inside the fabricated composite resulting in true
tensile strength.

 The Epoxy resin and hardener 75% and pulverized plastic powder 25%
improves the tensile strength of the reinforced composite.

 The combination of pulverized plastic powder, Epoxy resin and hardener

makes the composite material as versatile material and stronger.

It is concluded that composite material fabricated pulverized plastic powder,

(Epoxy resin and hardener) in the composition of 25% and 75% respectively,
epoxy resin has better mechanical strength compared

35
 CHAPTER 10

REFERENCES

[1] Anshu Anjoli Singh, Priyanka and Kishor Biswas, “Structure,

Mechanical and Thermal properties of Coconut Fiber Reinforced
Polypropylene Composites with 2%MAPP as a Compatibilizer”.
Applied Polymer Composites, Volume-2, Issue-2, 2015.

[2] K. Praveen kumar, M. Manzoor Hussain, Sridhara Reddy, “An

overview of Thermal and Mechanical properties of Natural Fiber
Reinforced Hybrid Composites ”. International Journal of Current
Engineering and Scientific Research, Volume-5, Issue-1, 2018.

[3] D. Verma, P.C. Hope, A. Shandilya, A.Gupta, “ Coir fiber

Reinforcement and Application in polymer composites". Journal for
Material and Environmental Science, Volume-4, Issue-2, 2016.

[4] Xue Yang, Liqian Huang, Longdi Cheng, “Studies of Moisture

Absorption and Releasing Behaviour of Akund fiber”. Advances in
Mechanical Engineering, Volume 2012.

[5] Debasmita Pani, Punyapriya Mishra, “Analysis of Mechanical

Properties of coir composites with varied compositions”. International
Journal of Material Sciences and Technology, ISSN 2249-3077, Volume-9,
Issue-1, 2019.

[6] Paulo Pecas, Hugo Carvalho, Hafiz Salman, “Natural Fiber Composites
and Their Applications: A Review”, Journal of Composites Science,
Volume-2, Issue-66, 2018.

[7] Mohammed Affan Usmani, “A Review Study of Natural Fiber

Reinforced Composite Material: Types and Properties”, International
Journal of Advance Research, Ideas and Innovations in Technology,
36
Volume-4, Issue-5, 2018.
[8] Malla Surya Teja, M V Ramana, D Sriramulu and C J Rao.
“Experimental Investigation of Mechanical and Thermal properties of sisal
fiber reinforced composites and effect of Sic filler material”. IOP Conf.
Series: Materials Science and Engineering 149 (2016) 012095
doi:10.1088/1757- 899X/149/1/012095.

[9] Braga R. A, Silva R. S Magalhaes Jr, P. A, “A Comparative the

analysis of the mechanical and thermal properties of polyester hybrid
composites by jute and glass fiber”. Journal of Engineering Research and
Applications, ISSN: 2248-9622, Vol. - 5, Issue-5, Part -2, May 2015.

[10] Madhusudhan T, SenthiL Kumar M, “ Mechanical Characterization of

Jute and Rubber Particles Reinforced Epoxy Polymer Composites”. IOSR
Journal Of Pharmacy, (e)- ISSN: 2250-3013, (p)-ISSN: 2319-4219,
Volume 6, Issue 12 Version. 1 (Dec 2016), PP. 23-27.

[11] G. L. Easwara Prasad, R. Velmurugan, “A Study on Impact strength

characteristics of coir polyester composites”. Journal of Advanced
Materials Science, Volume-6, Issue-1, 2015.

[12] S. Manoj Kumar, D. Surendran, Experimental and Investigation of

Leaf Spring by using Bamboo and Coconut Fiber with Epoxy Composite.
IRJET, ISSN: 2278-0181, issue- 2018.

[13] Madhusudhan. S. V, Kiran Kumar. N, Chethana. K. V, “Experimental

study on fatigue behavior of Glass/Vinyl ester Composite”. International
Journal of Innovative Research in Advanced Engineering, Volume-4,
Issue- 04, ISSN: 2349- 2163, 2017.

37
[14] G R, Sanjay M R, L. Laxman Naik. Arpitha G R Mechanical
properties of Epoxy Based Hybrid Composites Reinforced with
Sisal/SIC/Glass Fibers. International Journal of Engineering Research and
General Science, Volume 2, Issue 5, August-September 2014 ISSN 2091-
2730.
[15] R.Sakthivel, D.Rajendran. Experimental Investigation and Analysis
a Mechanical properties of Hybrid Polymer Composite Plates.
International Journal of Engineering Trends and Technology (IJETT) –
Volume 9 Number 8 -
Mar 2014.

[16] A.Gowthami, K.Ramanaiah, A.V.Ratna Prasad, K.Mohana Rao , G.

Sridhar Babu. “Experiment on Effect of Silica on Thermal and
Mechanical Properties of Sisal Fiber Reinforced Polyester Composites”. J.
Mater. Environ. Sci. 4 (2) (2013) 199-204 ISSN: 2028-2508.

38
 CHAPTER 10
FUTURE SCOPE

Further our project can be developed by the scholars based on thefollowing

criteria’s

 Now we prepared by the hand lay-up method, in future by using the

other techniques like spraying method, compression method and
injection method can be used for improving the strength

 In near future we have also planned to enhance our research by

incorporating Metal matrix composite with polymer matrix in- order to
obtain a hybrid product in which improvised results may be obtained.

 Our product can be pigmented as per requirement and can be

recycled n-number of times and it can also be used in the field of
furniture making, automobile, cookery products and as for decoration
purpose.

39
 REFERENCES

[1] Anshu Anjoli Singh, Priyanka and Kishor Biswas, “Structure, Mechanical
and Thermal properties of Coconut Fiber Reinforced Polypropylene
Composites with 2%MAPP as a Compatibilizer”. AppliedPolymer
Composites, Volume-2, Issue-2, 2015.

[2] K. Praveen kumar, M. Manzoor Hussain, Sridhara Reddy, “An overviewof

Thermal and Mechanical properties of Natural Fiber Reinforced Hybrid
Composites ”. International Journal of Current Engineering and Scientific
Research, Volume-5, Issue-1, 2018.

[3] D. Verma, P.C. Hope, A. Shandilya, A.Gupta, “ Coir fiber Reinforcement

and Application in polymer composites". Journal for Material and
Environmental Science, Volume-4, Issue-2, 2016.

[4] Xue Yang, Liqian Huang, Longdi Cheng, “Studies of Moisture Absorption
and Releasing Behaviour of Akund fiber”. Advances in Mechanical
Engineering, Volume 2012.

[5] Debasmita Pani, Punyapriya Mishra, “Analysis of Mechanical Properties

of coir composites with varied compositions”. International Journal of
Material Sciences and Technology, ISSN 2249-3077, Volume-9, Issue-1,
2019.

[6] Paulo Pecas, Hugo Carvalho, Hafiz Salman, “Natural Fiber Composites
and Their Applications: A Review”, Journal of Composites Science, Volume-
2, Issue-66, 2018.

[7] Mohammed Affan Usmani, “A Review Study of Natural Fiber Reinforced

Composite Material: Types and Properties”, International Journal of Advance
Research, Ideas and Innovations in Technology, Volume-4, Issue-5, 2018.

37
[8] Malla Surya Teja, M V Ramana, D Sriramulu and C J Rao. “Experimental
Investigation of Mechanical and Thermal properties of sisal fiber reinforced
composites and effect of Sic filler material”. IOP Conf. Series: Materials
Science and Engineering 149 (2016) 012095 doi:10.1088/1757-
899X/149/1/012095.

[9] Braga R. A, Silva R. S Magalhaes Jr, P. A, “A Comparative the analysis of

the mechanical and thermal properties of polyester hybrid composites by jute
and glass fiber”. Journal of Engineering Research and Applications, ISSN:
2248-9622, Vol. - 5, Issue-5, Part -2, May 2015.

[10] Madhusudhan T, SenthiL Kumar M, “ Mechanical Characterization of

Jute and Rubber Particles Reinforced Epoxy Polymer Composites”. IOSR
Journal Of Pharmacy, (e)- ISSN: 2250-3013, (p)-ISSN: 2319-4219, Volume 6,
Issue 12 Version. 1 (Dec 2016), PP. 23-27.

[11] G. L. Easwara Prasad, R. Velmurugan, “A Study on Impact strength

characteristics of coir polyester composites”. Journal of Advanced Materials
Science, Volume-6, Issue-1, 2015.

[12] S. Manoj Kumar, D. Surendran, Experimental and Investigation of Leaf

Spring by using Bamboo and Coconut Fiber with Epoxy Composite. IRJET,
ISSN: 2278-0181, issue- 2018.

[13] Madhusudhan. S. V, Kiran Kumar. N, Chethana. K. V, “Experimental

study on fatigue behavior of Glass/Vinyl ester Composite”. International
Journal of Innovative Research in Advanced Engineering, Volume-4, Issue-
04, ISSN: 2349- 2163, 2017.
[14] G R, Sanjay M R, L. Laxman Naik. Arpitha G R Mechanical properties
of Epoxy Based Hybrid Composites Reinforced with Sisal/SIC/Glass Fibers.
International Journal of Engineering Research and General Science, Volume 2,
Issue 5, August-September 2014 ISSN 2091-2730.
38
[15] R.Sakthivel, D.Rajendran. Experimental Investigation and Analysis a
Mechanical properties of Hybrid Polymer Composite Plates. International
Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number
8-
Mar 2014.

[16] A.Gowthami, K.Ramanaiah, A.V.Ratna Prasad, K.Mohana Rao , G.

Sridhar Babu. “Experiment on Effect of Silica on Thermal and Mechanical
Properties of Sisal Fiber Reinforced Polyester Composites”. J. Mater. Environ.
Sci. 4 (2) (2013) 199-204 ISSN: 2028-2508.

39