DEVELOPMENT OF COMPOSITE USING COCONUT

COIR AND EPOXY RESIN

1
 ABSTRACT

When correctly combined with polymers, natural fibers like coconut,

banana, flax, and jute have good reinforcing capacity. These fibers are
reasonably priced, made from renewable resources, and have good specific
strength and specific modulus values. Thermoplastic polymers, despite issues
with high viscosities and poor fiber wetting, have a reduced cycle time and the
capacity to be reprocessed. The natural fiber-reinforced thermoplastic
composite materials that are produced have an appealing eco-friendliness due to
the renewability of natural fibers and the recyclability of thermoplastic
polymers.

The mechanical properties of the composite can be evaluated at different

volume fractions. Experimental results show that the tensile, static, and dynamic
properties of the composites are greatly influenced by increasing the percentage
of reinforcement. Chemical modification of the coir fiber can also lead to easier
permeating of the coir fiber and epoxy resin, which promotes effective
interfacial adhesion

2
OBJECTIVE OF THE PROJECT

Various filler loadings (10,20,30,40 & 50 weight%) of coir fiber/ epoxy

resin composites have been formulated for possible helmet shell fabrication.
The fiber length was 30mm and the ratio of epoxy resin, hardener was 1:0.8.

A total of 5 numbers of short beams of 4 mm х 19 mm х 300 mm were

produced and tested in flexure using universal testing machine. Impact test and
tensile test were also carried out. The impact strength, tensile strength and
tensile modulus were then calculated.

It was observed that the tensile strength of coir fiber/epoxy resin

composites was maximum at 30 wt% filler loading (23.68 N/mm2 ). The charpy
notch impact strength was also maximum at 30 wt.% (26.43KJ/m2 ). The value
however began to decrease as the filler loading increased.

Currently, industrial helmet shell is fabricated from Polycarbonate (PC)

and Acrylonitrile butadiene styrene (ABS). Their tensile strengths are PC; 60
N/mm2 and ABS; 46 N/mm2 while their charpy notch impact strengths are PC;
20.00-30.00 KJ/m2 and ABS; 10.00-29.00 KJ/m2 .

The values of coir/ epoxy resin composites fabricated are close to those
of PC and ABS. Again, the tensile modulus of coir/epoxy resin composites was
found to increase with an increase in filler loadings as follows: 10 wt.%.
(900.00N/mm2 ), 20 wt.% (977.80N/mm2 ), 30 wt.% (1000.00N/mm2 ), 40
wt.% (1066.67 N/mm2 ) and 50 wt.% (1733.3 N/mm2 ). On the other hand,
tensile modulus for ABS is 1,910 MPa.

Hence, coir/epoxy resin composite was used in industrial helmet

fabrication using hand lay- up technique to save cost.

3
 CHAPTER – 1

INTRODUCTION

4
 CHAPTER – 1

INTRODUCTION

Composites are formed by combining materials together to form an

overall structure that is better than the individual components. Composite
materials are materials made from two or more constituent materials with
significantly different physical or chemical properties, that when combined,
produce a material with characteristics different from the individual
components. The individual components remain separate and distinct within the
finished structure. The new material may be preferred for many reasons:
common examples include materials which are stronger, lighter or less
expensive when compared to traditional materials.

Fiber reinforced polymeric composites have been used for a variety of

structural applications because of their high specific strength and modulus
compared to metals. Initially developed for the aerospace industry, high-
performance or ‘advanced’ composites are now found in applications from
automotive parts to circuit boards, and from building materials to specialty
sporting goods. Most composites currently available on the market are designed
with long-term durability in mind and are made using non-degradable polymeric
resins, such as epoxies and polyurethane, and high-strength fibers, such as
graphite, aramids, and glass. Many of these polymers and fibers are derived
from petroleum, a non-replenish able commodity.

With increasing numbers of applications and mass volume uses, in

particular, recording double-digit growth worldwide, disposal of composites
after their intended life is already becoming critical, as well as expensive.
Because composites are made using two dissimilar materials, they cannot be

5
easily recycled or reused. Most composites end up in landfills, while some are
incinerated after use, although there are some efforts to recycle and/or reuse
them. Both these disposal alternatives are expensive and wasteful, and may
contribute to pollution. In addition, landfills are decreasing in number, making
less space available to discard waste. Many applications, e.g. secondary and
tertiary structures and those used in consumer products for casing, packaging,
etc., do not require the high mechanical properties that advanced composites
possess. Since many of the fibers and resins are made using non-degradable,
mostly petroleum based materials, once discarded they do not degrade for
several decades under normal environmental conditions.

This exacerbates the existing ecological and environmental problems. In

recent years, the ever-growing worldwide litter problem has raised
environmental consciousness among consumers, manufacturers, and
governments. Further, it is estimated that we are currently consuming petroleum
at an ‘unsustainable’ rate, 100 000 times faster than nature can create it. To
alleviate these problems, governments in many countries have established laws
to encourage the use of recycled and/or bio-based ‘green’ products. Some
governments have enforced strict ‘take back’ laws requiring manufacturers to
take back packaging and products after their intended use. The growing global
environmental awareness and societal concern, high rate of depletion of
petroleum resources, concepts of sustainability, and new environmental
regulations have together triggered the search for new products and processes
that are compatible with the environment.

6
COCONUT COIR

Coconut is grown largely in many countries of tropical Asia. Indonesia

being its largest producer, the Philippines being second and India being third
collectively account for 73% of the world total coconut production. Brazil is the
fourth largest producer of coconut in the world. it is known to be used for
making wide variety of floor furnishing materials and mats, yarn, ropes etc.
since a very long time. But still a very small percentage of the produced fiber is
being utilized. Hence, several research works have been carried out to study the
utilization of coir as reinforcement in polymer composite.

Coir can be used as particulate reinforcement in three different forms: (a)

fine coconut dust form (b) Coarse coconut coir with high fiber content (c)
Coarse coconut coir with high chip content. In the present study coconut coir
was collected locally and was used in fine coir dust form as particulate
reinforcement in the fabricated composite. The chemical composition of coir is
given in table 1.

7
Table 1: Chemical composition of coir

Component Amount (in %)

Water Soluble 5.25

Pectin and related compounds 3.00

Hemicellulose 0.25

Lignin 45.84

Cellulose 43.44

Ash 2.22

Chemical Treatment

The collected fibers were first washed thoroughly with normal tap water to remove dirt and
other particles adhered to the fiber surface. Then the fibers were mercerized with 5% NaOH solution
for 4 hours at room temperature by maintaining liquor to fiber ratio of 15:1. The treated fibers were
then washed several times with distilled water to remove any NaOH sticking to the fiber surface until
a final pH of 7 was attained. To neutralize the alkali, dilute acetic acid may also be used. The fibers
were then dried at room temperature for 48 hours followed by oven drying at 100°C for 6 hours. The
mercerization of natural fiber occurs according to equation(1) .

𝐅𝐢𝐛𝐞𝐫 − 𝐎𝐇 + 𝐍𝐚𝐎𝐇 → 𝐅𝐢𝐛𝐞𝐫 − 𝐎 − − 𝐍𝐚+ + 𝐇𝟐𝐎 … . 𝐄𝐪𝐧. (𝟏)

8
 FLOW DIAGRAM OF THE PROJECT

Analyzation Of Review Papers

Selection Of Material (Epoxy polymer)

Selection Of Composites
( Coir fibre)

Specimen Preparation

Casting Process and Cutting Process

Testing Process

1. Tensile
2. Compression
3. Impact
4. Water
absorption

9
 CHAPTER – 2
LITERATURE SURVEY

10
 CHAPTER – 2

LITERATURE SURVEY

Coir has been tested as filler or reinforcement in different composite

material (Choudhury et al., 2007, Corradini et al., 2006, Geethamma, et al.,
1998, Owolabi et al., 1985 and karthikeyan et al.p, 2012).

Yao et al., 2013. Studied about Coconut coir which is the most
interesting product as it has the lowest thermal conductivity and bulk density.
The mechanical properties of coir toughened unsaturated polyester with
different reinforced body forms, namely; coir non- woven needle mat, coir mesh
and coir rope.

Yuhazri et al., 2007 - From the study, the tensile strength of coir
nonwoven is the highest among the three with a value of 24.97 MPa at 20 wt.%
coir content. The effect of fiber orientation on the mechanical properties of
helmet made from coir/ epoxy resin with 10 wt.% coir and 90 wt.% epoxy
only.. The work reported improved mechanical performance of the helmet. It
also reccomended that the percentage of coconut fiber in the matrix must be
more than 10 wt.% for better results.

Misra et al., 2007, investigated fire retardant coir epoxy micro-

composites. The coir fiber was treated with saturated bromine water for
increasing the electrical properties and then mixed with stannous chloride
solution for improving the fire retardant properties, it was observed that only
5% of fire retardant filler reduced the smoke density by 25% and the LOI value
increased to 24%. The mechanical properties of the composites were not

11
affected much after the incorporation of fillers and their flexural strength and
flexural modulus increased tremendously.

Almeida et al., 2008, investigated the structural characteristics and

mechanical properties of coir fiber/ polyester composites. The as-received coir
fiber was characterised by scanning electron microscopy and X-ray dispersion
analysis. Composites were prepared with two moulding pressures and they
noted that with 50 wt.% fiber, rigid composites were obtained and with higher
content the composites performed more like flexible agglomerates.

Bensely et al., 2009, investigated and evaluated the mechanical

properties of coir fiber composites using scanning electron micrographs
obtained from fractured surfaces to evaluate the interfacial properties of
coir/epoxy and compared with glass fiber epoxy. The results indicate that coir
fiber can be used as a potential reinforcing material for making low load bearing
plastic composites.

Junior et al., 2010, studied the tensile properties of post-cured polyester

matrix composites incorporated with the thinnest coir fibers. Tensile specimens
with up to 40 vol.% of long and aligned coir fibers were tested and their fracture
surfaces analysed by scanning electron microscopy. A relative improvement
was found in the tensile properties.

Zuradia et al., 2011, investigated the effect of fiber length on

mechanical properties of coir fiber reinforced cement- album composites. They
noted that by increasing the length of fiber, the flexural strength increased. But
incorporation of long fiber into cement paste reduced the workability of the
paste and thus introduced voids that resulted in the increase in water absorbtion.

12
 Verma et al., 2010, reviewed the use of coir fiber, a natural fiber
abundantly available in India and Africa and explored the potentials of the coir
fiber polymer composites and its mechanical properties as well as being a
reinforcement in polymer matrix. They noted its wide application especially in
packaging and furniture. Studies have shown that fiber modification improves
resistance to moisture induced degradation of interface and composite
properties (Josep et al., 2000).

Ruhul Khan et al., 2012, studied the mechanical properties of coir fiber
ethylene glycol dimethacrylate base composites. Tensile strength (TS), Young’s
modulus (YM) and elongation at break (Eb%) of virgin coir fibers were found
to be 152 MPa, 5.3 GPa and 36% respectively. Coir fibers were treated with
ultraviolet (UV) radiation and were found to improve the mechanical properties
significantly.

Coir fiber-reinforced ethylene glycol dimethacrylate (EGDM)-based

composite was prepared and characterized. The surface of the coir fibers was
modified with monomer EGDMA under UV radiation. Soaking time, monomer
(EGDMA) concentration and radia intensities were optimized over mechanical
properties. The highest values of TS, YM, Eb and polymer loading (PL) were
found for 50 wt.% EGDMA at 125th pass of UV radiation for 7 minutes
soaking time. Pre-treatment with UV radiation on the coir fiber was found to be
more effective for the increment of its mechanical properties.

The surface of the fiber was also mercerized (alkali treatment) using
aqueous NaOH solutions (5-50%) at varied time and temperature. It was found
that TS of the mercerized composites increased with the increase in NaOH
solutions (up to 10%) and then decreased. The composites made using
mercerized fibers treated with EGDMA showed further increase in TS. Pre-
13
treatment with mercerization + UV treatment of coir fiber showed significant
improvement in the mechanical properties of coir fiber- based composites.
Helmet shell is currently fabricated from Acrylonitrile Butadiene Styrene
copolymer (ABS) or Polycarbonate (PC) by injection moulding process.
However, ABS and PC are expensive and are uncommon with very high tooling
cost. Some countries have their standard for helmet specification.

For example,

Europe: ECE 22.05, Japan: JIST 8133: 2000 and USA: SNELL M2000.
Natural fiber polymer composite have recently had a great resurgence of interest
for several reasons, among which are cost advantage and environmental
preservation. Hand lay- up process which does not require expensive tooling
can be adopted as an alternative to the injection moulding method using suitable
polymers for this method, like epoxy resin and unsaturated polyester with very
cheap, available and renewable natural fibers.

In Nigeria, coir fiber is harvested from coconut palm and is an abundant

waste material. Large quantities of this waste are left in the field as under
utilized. Information based on utilization of coir fiber for helmet production are
limited. Hence, in this research, efforts have been made to treat the coir fiber
before incorporating into epoxy ( bisphenol A diglycidyl ether) polymer matrix.
Test materials have been prepared and series of filled epoxy composites with
coir fiber loading (10- 50 wt.%), was used to study the effect of the filler
content. The aim of this work is to study the mechanical properties of epoxy
filled modified coir fiber composite for helmet shell production.

14
 CHAPTER - 3

METHODOLOGY

15
 CHAPTER - 3

METHODOLOGY

INTRODUCTION

A composite material can be defined as a combination of two or more

materials that results in better properties than those of the individual components
used alone. In contrast to metallic alloys, each material retains its separate
chemical, physical and mechanical properties. The reinforcing phase of the
composites provides the strength and stiffness, to make them harder, stronger and
stiffer than the matrix. The reinforcement is usually in the form of a fibre or a
particulate.

The length-to-diameter ratio is known as the aspect ratio, and can vary
greatly for fibres because the length of the fibre is much greater than its diameter.
Continuous fibres have high aspect ratios, while discontinuous fibres have low
aspect ratios, and the orientation of continuous fibre composites normally is
perfect, while discontinuous fibres generally have a random orientation.
Continuous fibre composites are often made into laminates by stacking single
sheets of fibres in different orientations to obtain the desired strength and stiffness
properties with fibre volume as high as 60 to 70%.

In general, the smaller the diameter of the fibre, the higher its strength, but
the cost increases when the diameter becomes smaller. In addition, smaller
diameter fibres have greater flexibility, and are more amenable to fabrication
processes such as weaving or forming, across the radius. The continuous phase is
the matrix, which is a polymer, metal or ceramic. Polymers have low strength and
stiffness, metals have intermediate strength and stiffness but high ductility, and

16
ceramics have high strength and stiffness but are brittle. Discontinuous fibre
composites are normally random in alignment which drastically reduces their
strength and modulus. However, these composites are generally much less costlier
than continuous fibre composites. Therefore, continuous fibre composites are used
where higher strength and stiffness are required even at a higher cost, and
discontinuous fibre composites are used where cost is the main driver and strength
and stiffness are less important.

II. TYPES OF COMPOSITES

Broadly the composite materials in use in the industry today are classified
into the three main categories as

a) Metal Matrix Composites (MMCs)

b) Ceramic Matrix Composites (CMCs)

c) Polymer Matrix Composites (PMCs)

III. POLYMER MATRIX COMPOSITES

In general, the mechanical properties of polymers are inadequate for many

structural applications, and their strength and stiffness are low when compared to
metals and ceramics. These problems are rectified by Composites Metal matrix
composites (MMCs) Ceramic matrix composites (CMCs) Polymer matrix
composites (PMCs) reinforcing different materials with polymers. The processing
of polymer matrix composites need not involve high pressure and high
temperature.

17
 Due to this reason, the usage of polymer matrix composites has grown
rapidly, and become popular for structural materials. Two types of polymer
composites are:

 Fibre reinforced polymer (FRP)

 Particle reinforced polymer (PRP)

Natural fibres are a class of hair-like material that is continuous filaments,

similar to pieces of thread which can be converted into filaments.

Natural fibres are grouped into different categories, based on their origin,
derivations of plant, animal and mineral types the detailed classification is shown
in Figure-1.

18
 These sustainable and eco-efficient fibres have been applied as substitutions
for glass and other synthetic fibres in diverse engineering applications. With the
consideration of environmental consciousness, natural fibres are biodegradable and
hence, they can alleviate the problem of massive solid wastes, and relieve the
pressure of landfills, if they are used for replacing other non-degradable materials
for product development. Besides, according to their inherent properties, natural
fibres are flexible for processing, due to their being less susceptible to machine
tool damage and health hazards during manufacture.

19
 CHAPTER – 4
COMPONENTS DETAILS

20
 CHAPTER – 4
COMPONENTS DETAILS

MATERIALS REQUIRED

POLYMER COMPONENT : E-Poxy polymer

NATURAL COMPONENT : COIR FIBRE
FOR COMPRESSION MOLDING : 290 X 290 mm MOLD

Materials: Before treatment

COIR FIBRE

EPOXY POLYMER

Purchased from:
GL metals & chemical enterprises, CBE-2.
Abirami enterprises, Trichy-1.

21
PROPERTIES OF EPOXY RESIN (LY556)

Epoxy resins are defined as “a family of monomeric or oligomeric materials

that can be further reacted to form thermoset polymers possessing a high degree of
chemical and solvent resistance, outstanding adhesion to a broad range of
substrates, a low order of shrinkage on cure, impact resistance, flexibility, and
good electrical properties.” When selecting an epoxy resin, the resin, modifiers,
and cross-linking agent can be custom-selected to create specific characteristics for
a particular application. This allows epoxy resins to be used in a wide variety of
applications.

Epoxy Resin Characteristics

Epoxy resins are known for high performance. They are the building blocks
for adhesives, coatings, reinforced plastics, and composite materials such as
fiberglass and carbon fiber, which remain intact under intense conditions. When
properly cured, epoxy resins offer a number of desirable characteristics, including:
 Resistance to chemicals, particularly alkaline environments
 Heat resistance
 Adhesion to a variety of substrates
 High tensile, compression, and bend strengths
 Low shrinkage during curing
 High electrical insulation and retention properties
 Corrosion resistance
 Cures under a wide range of temperatures
 Resistance to fatigue

22
Epoxy Resin Applications
Typically when the terms “structural adhesive” or “engineering adhesive”
are used, they are referencing epoxies. Epoxy resins stick to wood, concrete, metal,
glass, stone, and most plastics; making them incredibly versatile. Just a few of the
many useful epoxy resin applications include:
 Construction: Laminated wood, walls, roofs, flooring, and more.
 Paints and coatings: Outdoor coatings, sealers, heavy-duty protective
coatings, industrial and automotive paints, primers, and sealers.
 Industrial tooling and composites: Molds, master models, laminates,
castings, fixtures, and other industrial production aids, as well as carbon-fiber-
reinforced and composite parts.
 Turbine technology: Wind turbine blades.
 Electrical systems and electronics: Motors, generators, transformers, gear
switches, bushings, insulators, printed wiring boards (PWBs), potting, and
semiconductor encapsulants.
 Consumer and marine: You can pick up epoxies in most hardware and
marine stores in packs that facilitate the mixing of resin and hardener before
use. These kits are useful in many home and boat repair applications.
 Aerospace: In the aerospace industry, among others, epoxy is used as a
structural glue that is reinforced with glass, Kevlar, boron, or carbon fiber. This
option is particularly used in the aerospace industry because of epoxy resin’s
high-performance mechanical properties and resistance to environmental
deterioration.
 Biology: Durcopan is a water-soluble epoxy used for embedding electron
microscope samples in plastic for sectioning and imaging.
23
Selecting Epoxy Resins
Since epoxy resins perform well under extreme conditions, when they are
combined with carbon or other fibers, they produce composite materials with the
properties that are beneficial in many applications. Their unique, high-performance
characteristics make them well-suited to work in many environments that offer
extreme conditions. The resin, modifier, and cross-linking agent can be switched
up to create a custom epoxy that performs under very specific conditions.

Reactive diluents free matrix system with a very long pot life. The reactivity
can be adjusted by varying the accelerator content. The system has very good high
temperature performance after post cure and exhibits good mechanical and
dynamic properties.

Epoxy Resin LY 556

Properties of Epoxy resin LY-556: 1. Visual aspect -Clear, pale yellow

liquid 2. Viscosity at 250 C -10000-12000 MPa s 3. Density at 250 C -1.15-1.20
gm/cm3 4. Flash point -1950 C 3.1.2.

Hardener:

For getting the properties to be improved, the resin should undergo curing
reaction in which the liner epoxy resin structure changes to form three-dimensional
cross-linked thermo set structure. This curing reaction takes place by adding a
curing agent called hardener in a ratio of 10:1 to Epoxy resin. The following
reaction is an exothermic reaction of resin takes place. The curing agent or
hardener is triethyltetramine (HY-951) is also supplied from Coimbatore.

24
NATURAL FIBERS
Properties of fibers
Coir is an abundantly and cheaply available lignocellulosic fibre extracted
from the dried husk of ripened coconuts (Cocos nucifera). It is known to have good
wearability and durability but has greater water retention property. Coir fiber
epoxy composites are environmentally friendly materials that are biodegradable
and can reduce solid waste production. Coir fiber is a natural fiber extracted from
the coconut fruit that has good mechanical properties, but its adhesion to the
polymer matrix is weak. Modifying the coir fiber is important to create a
composite with good performance. Some chemical methods used to modify coir
fiber include:

 Alkalization

 Acetylation

 Benzoylation

 Silane treatment

 Microwave treatment

 Alkali treatment

 Acetic anhydride modification

 3-aminopropyltriethoxysilane modification

Physical Properties of Coir Fibre

Ultimate length 0.6 mm

Single fibre Density 1.4 g/cc

25
 Tenacity 10 g/ tex

Breaking Elongation 30%

Moisture regain at 65% RH 10.5%

Chemical properties of fibers

Coir fibers, also known as coconut fibers, have the following chemical
composition:
 Cellulose: 43.44%
 Lignin: 45.84%
 Pectin and related compounds: 3.00%
 Hemicellulose: 0.25%
 Water solubles: 5.25%
 Ash: 2.22%

Mechanical properties of fibers

Coir fibers have some competitive advantages over the other natural fibers
like low cost, low density, higher elongation at break, and lower elastic
modulus19,20. Furthermore, coir fiber generally exists 1.1 to 1.5 g/cm3 density,
105 to 593 MPa tensile strength, and 2 to 8 GPa Youngs modulus 20.

26
 CHAPTER - 5
EXPERIMENTAL SET UP

27
 CHAPTER - 5
EXPERIMENTAL SET UP

Composite fabrication Composites were fabricated using hand lay-up

technique. The matrix was prepared by properly mixing Epoxy LY556 and
hardener HY951 in a ratio of 10:1 by weight with continuous stirring until
the viscosity of the mixture reduces and the entrapped air bubbles get
released. The air bubbles from the mixture can further be removed by
vacuum. Then the chemically treated fibers with varied weight ratio of fibers
wrt. to epoxy matrix (5 wt%, 10 wt%, 15 wt%) were added and well mixed
with it.
The mold was then sprayed with silicon spray to assist for easy
removal of the composite after fabrication. The mixture was then poured onto
the mold and covered by silicon paper followed by glass plate. A weight of
5kg was put over the glass plate for removal of trapped air inside the mixture.
Curing of epoxy matrix compose occurs at room temperature over a period of
24-48 hours. After 48 hours the mold was broken and the fabricated
composites were ejected out.
MOULDINGS
Compression molding is the process of molding in which a preheated
polymer is placed into an open, heated mold cavity. The mold is then closed with a
top plug and compressed in order to have the material contact all areas of the mold.
This process is able to produce parts with a wide array of lengths, thicknesses, and
complexities. The objects it produces are also high in strength, making it an
attractive process for a number of different combinations.

28
 Compression molding is a method of molding in which the molding
material, generally preheated, is first placed in an open, heated mold cavity. The
mold is closed with a top force or plug member, pressure is applied to force the
material into contact with all mold areas, while heat and pressure are maintained
until the molding material has cured.

The process employs thermosetting resins in a partially cured stage, either in

the form of granules, putty-like masses, or preforms. Compression molding is a
high-volume, high pressure method suitable for molding complex, high strength
fiberglass reinforcements.

Advanced composite thermoplastics can also be compression moulded with

unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand.
The advantage of compression moulding is its ability to mold large, fairly intricate
parts. Also, it is one of the lowest cost molding methods compared with other
methods such as transfer molding and injection molding; moreover it wastes
relatively little material, giving it an advantage when working with expensive
compounds.

MOULD PREPARATION

Epoxy LY556 of density 1.15–1.20 g/cm3, mixed with hardener HY951 of

density 0.97–0.99 g/cm3 is used to prepare the composite plate. The weight ratio of
mixing epoxy and hardener is 10:1. This has a viscosity of 10-20 poise at 2500°C.
Hardeners include anhydrides (acids), amines, polyamides, dicyandiamide etc.
Mould used in this work is made of well-seasoned teak wood of 290 mm X 290
mm X 3 mm dimension with five beadings. The fabrication of the composite
material was carried out through the hand lay-up technique.

29
 The top, bottom surfaces of the mould and the walls are coated with remover
and allowed to dry. The functions of top and bottom plates are to cover, compress
the fiber after the epoxy is applied, and also to avoid the debris from entering into
the composite parts during the curing time. Epoxy is both the basic component and
the cured end product of epoxy resins, as well as a colloquial name for the epoxide
functional group. Epoxy resins, also known as poly epoxides are a class of reactive
pre polymers and polymers which contain epoxide groups.

FABRICATION PROCEDURE

The top, bottom surfaces of the mould and the walls are coated with remover
and allowed to dry. The functions of top and bottom plates are to cover, compress
the fiber after the epoxy is applied, and also to avoid the debris from entering into
the composite parts during the curing time.

The moulds are cleaned and dried before applying epoxy. The fibers were
laid uniformly over the mould before applying any releasing agent or epoxy. After
arranging the fibers uniformly, the epoxy resin was applied over the fibers and then
they were compressed for a few hours in the mould. Then the compressed form of
fibers (coconut coir) is removed from the mould. Following figures (3-5) shows the
three different samples which is prepared by compression moulding process.

30
Fig.3.1. moulding box 290 x 290 mm

31
RAW MATERIALS TAKEN (WHOLE WEIGHT)

32
MOULDING RATIO

MATERIALS POLYMER COIR FIBER 1

100% 95% 05%

100% 90% 10%

100% 85% 15%

Fig.3.3. After Moulding – 290mm length 290mm width and 10mm height

Coconut coir fibre 5% Coconut coir fibre 10% Coconut coir fibre 10%

33
CUTTING OF SAMPLES

• We prepared total 4 samples for testing, all 3 samples are reinforcement added samples in
different ratios.

• We are having one pure samples

• Composition of the materials are given in previous slide.

• All the samples are 120 x 20 mm (l and b) size with 20mm thickness.

• After Moulding the reinforced materials we are going to take 5 tests to check the flexural,
tensile, compression, impact and water absorbtion test.

34
 CHAPTER - 6

MATERIAL TESTING

35
 CHAPTER - 6

MATERIAL TESTING

INTRODUCTION

The mechanical testing of composite structures to obtain parameters such as

strength and stiffness is a time consuming and often difficult process. It is,
however, an essential process, and can be somewhat simplified by the testing of
simple structures, such as flat coupons. The data obtained from these tests can then
be directly related with varying degrees of simplicity and accuracy to any
structural shape. The test methods outlined in this section merely represent a small
selection available to the composites scientist. Some, such as the tensile coupon
test, are widely recognized as standards.

TENSILE TEST

Specimen for tensile testing has been cut from all samples according to the
ASTM D638 standard. This test is used to find the Ultimate Tensile Strength of
materials. Tensile testing utilizes the classical coupon test geometry as shown
below and consists of two regions: a central region called the gauge length, within
which failure is expected to occur, and the two end regions which are clamped into
a grip mechanism connected to a test machine.

The samples for tensile test are shown in the below fig.6. The samples are
prepared under the specification of ASTM-D638.

36
 EPOXY -COCONUT (COIR) POWDER
TENSILE STRENGTH
Specimen Cross
A Width Area Tensile Strength
(0.5MM) (mm) Thickness (mm2 ) Load (N) (N/mm2 )
A1 11.4 4.1 46.74 400 8.56
A2 10.6 10.6 112.36 350 3.11
A3 10.6 10.6 112.36 300 2.67
Average 10.867 8.433 90.487 350 4.78

Specimen Cross
B Width Area Tensile Strength
(1.0MM) (mm) Thickness (mm2 ) Load (N) (N/mm2 )
B1 10.0 2.7 27 276 10.22
B2 10.2 3.8 39.14 360 9.2
B3 10.0 5.5 55 228 4.15
Average 10.067 4.000 40.380 288.000 7.857

Specimen Cross
C (1.5 Width Area Tensile Strength
MM) (mm) Thickness (mm2 ) Load (N) (N/mm2 )
C1 10.3 2.5 26.1 165 6.2
C2 10.5 6.2 63 685 10.86
C3 10.2 5.2 54.4 409 7.86
Average 10.333 4.633 47.833 419.667 8.307

37
38
IMPACT TEST

Before looking at impact testing let us first define what is meant by

'toughness' since the impact test is only one method by which this material
property is measured. Toughness is, broadly. A measure of the amount of energy
required to cause an item - a test piece or a bridge or a pressure vessel - to fracture
and fail. The more energy that is required then the sougher the material.

The area beneath a stress/strain curve produced from a tensile test is a

measure of the toughness of the test piece under slow loading conditions.
However, in the context of an impact test we are looking at notch toughness, a
measure of the metal's resistance to brittle or fast fracture in the presence of a flaw
or notch and fast loading conditions.

The samples for impact test are shown in the below fig.7. The samples are
prepared under the specification of ASTM-D256-90.

EPOXY -COCONUT (COIR) POWDER

IMPACT TEST
Specimen
A LOAD Cross Area Impact value
(0.5MM) (KJ) (mm2 ) (KJ/m2)
A1 200 0.027 5.4
A2 220 0.03914 8.61
A3 250.0 0.055 17.75
Average 223.333 0.040 10.587

Specimen Width Cross Area Impact value

B (mm) (mm2 ) (KJ/m2)

39
(1.0MM)

B1 300 0.0257 7.73

B2 350 0.063 22.05
B3 450 0.05304 23.87
Average 366.667 0.047 17.883

Specimen
C (1.5 Width Cross Area Impact value
MM) (mm) (mm2 ) (KJ/m2)
C1 220 0.4674 10.28
C2 350 0.11236 39.33
C3 350 0.11236 39.33
Average 306.667 0.231 29.64666667

40
FLEXURAL STRENGTH TEST

ASTM D790 is used to determine the flexural strength of plastics and

composites. Flexural strength is the measure of a material's ability to resist
cracking or breaking under bending stress. When designing a product that needs to
withstand loading or containing pressure, it is important to know which material or
combination of materials will do the best job.

Flexural analysis was carried out at room temperature through three-point

bend testing as specified in ASTM D 790, using universal testing machine. The
speed of the crosshead was 5 mm/min. five composites specimens were tested for
each sample and each test was performed until failure occurred.

Flexural strength was calculated from the Equation.

f = (3PL) / (2bd2 )

Where,

P = Load at a given point on the load deflection curve in Newton (Peak load)

L = support span in mm

b = width of the samples in mm

d = thickness of the samples in mm.

The samples for flexural strength test are shown in the below fig.8. The
samples are prepared under the specification of ASTM D 790.

EPOXY -COCONUT (COIR) FIBER

FLEXURAL TESTS
Specimen Width Deflection
A (0.5MM) (mm) Thickness Load (N) (mm)
41
A1 52 5.5 130 1.95
A2 50.6 4.4 140 2.019
A3 53.6 4.9 160 2.192
Average 52.067 4.933 143.3333 2.05366667

Specimen Width Deflection

B (1.0MM) (mm) Thickness Load (N) (mm)
B1 54.8 4 90 2.18
B2 53.4 4.4 130 2.63
B3 53 4.7 130 3.34
Average 53.733 4.367 116.667 2.717

Specimen Width Deflection

C (1.5 MM) (mm) Thickness Load (N) (mm)
C1 52.0 3.7 80 1.748
C2 52 4.5 130 1.591
C3 53.4 3.6 130 2.387
Average 52.467 3.933 113.333 1.909

42
43
WATER ABSORPTION TEST

For the water absorption test, the specimens are dried in an oven for a specified
time and temperature and then placed in a desiccator to cool. Immediately upon
cooling the specimens are weighed. The material is then emerged in water at
agreed upon conditions, often 23°C for 24 hours or until equilibrium.

The aggregates should be weighed (Weight 'A'). iv) The aggregates should then be
placed in an oven at a temperature of 100 to 110oC for 24hrs. It should then be
removed from the oven, cooled and weighed (Weight 'B'). Formula used is Water
absorption = [(A – B)/B] x 100%.

EPOXY -COCONUT (COIR) FIBER

RATE OF WATER ABSORPTIVITY
Average % of
Weight of the Water
Dry Pieces Water Absorption
Specimen Weight (gm) Content (gm) (%)
A 3.0 3.25 8.3
B 5.6 6.8 21.43
C 5.6 6.9 23.21

44
 CHAPTER – 7
RESULT AND DISCUSSION

45
 CHAPTER – 7
RESULT AND DISCUSSION

Tensile Test

Tensile test result shows that the Peak load for sample 1 and sample 2 are
817.595 N and 1115.142 N respectively but for sample 1, peak load is 1179.702 N.
Ultimate tensile strength for sample 2 and sample 3 are 20.964N/mm2 and 28.596
N/mm2 respectively but for sample 1 is 30.244 N/mm2 . From these results it is
found that the ultimate tensile strength and peak load of sample 3 is higher than the
sample 1 and sample 2.

Because of high proportion of fiber gives better load carrying capacity to the
sample 3 from among the sample 1 and sample 2.

Impact Test

Impact test result shows that the sample 3 which contains 35% fiber and
65% resin having more impact value than the sample 1 and sample 2. Because of
high proportion of fiber gives good bonding strength to the sample 3 from among
the sample 1 and sample 2.

Flexural Strength Test

Flexural Strength test results show that the flexural strength and peak load
for the sample 3 is higher than the sample 1 and sample 2. Among this result
sample 2 is highly better than the other two samples. Because of high proportion of
fibers gives better flexural strength from among the sample 1 and sample 2.
Among this result sample 3 is highly better than the other two samples.

46
 Natural fibers are made of cellulose, hemicellulose and lignin. Preparation of
polymer–cellulose composites are hindered by the highly hydrophilic nature of
these fibers while the polymers used for matrix preparation are usually
hydrophobic creating compatibility issues resulting in loss of mechanical
properties after moisture uptake. Due to the poor compatibility, surface of fibers
must be modified so as to make it less hydrophilic and improve the interface
interaction between the fiber and the matrix. The effect of different treatments
(washing with water, treatment with alkali also known as mercerization and
bleaching) on tensile and thermal properties of coir composites with
starch/ethylene vinyl alcohol copolymers (EVOH). SEM characterization of fiber
surface morphology showed that mercerization produced the most desirable result
with increased gluing between fiber and matrix and 53% increase in tensile
strength compared to composites with raw fibres. It also further ameliorates fiber–
matrix adhesion for better stress distribution between matrix and the fibres.

Tensile Impact Average % of

Specimen C Strength value Deflection Water
(1.5 MM) (N/mm2 ) (KJ/m2) (mm) Absorption (%)
1 4.78 10.587 2.053667 8.3
2 7.856667 17.883 2.717 21.43
3 6.318 14.235 1.909 23.21

47
48
CONCLUSION

49
 CONCLUSION

The incorporation of coir fibers in the ratio of 15% of fiber and 85% of resin
in to the Epoxy matrix showed the moderate improvement in the tensile, impact
and flexural strength properties of the composites. From the results of Impact,
Tensile properties and Flexural Strength test report, it conclude that the sample 2
(10% fiber and 90% resin) composite material have the higher impact value, higher
load carrying capacity, higher ultimate tensile strength and also having higher
flexural strength which was obtained from the impact, flexural strength and tensile
tests.

So this ratio fiber performs well on mechanical characteristics better than

other ratio of Fibers. The hybridization of these natural fibers has provided
considerable improvement of tensile, impact and flexural strength when compared
to individual reinforcement. This is mainly due to transfer of loads among the
fibers and eventually it is evident that the material obtained from the compression
moulding with coconut coir fibre in the ratio of 10% of fiber and 90% of resin is
the most suitable replacement in most of the modern equipment.

50
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