DEVELOPMENT AND CHARACTERIZATION

OF MULTIFUNCTIONAL COMPOSITES
USING MACHINE VISION

NANDHA KUMAR G – 312217114065

VITHYA C.K.M – 312217114127
RATHAN RAJIV SINGH – 312217114315
VELLORE CHAKRI REDDY – 31227114321

PROJECT GUIDE : Dr . K.S JAYAKUMAR

 INTRODUCTION
• To fabricate and analyze a multifunctional composite for
damage detection applications using glass fiber combined with
optical fiber.
• Perform mechanical testing and create a image using
MATLAB by those readings
• The optical fiber attenuation will be compared before and after
the impact
• The results will be formulated to identify the crack
propagation by non evasive technique

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 LITERATURE SURVEY
• Self-sensing structural composites in aerospace engineering -
The impact of an aircraft composite structure is a random
transient event that needs to be monitored on-line
continuously.
• Self-sensing structural composite materials refer to structural
materials that can sense their own condition (strain, stress,
damage and temperature), without embedded or attached
sensors.

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 LITERATURE SURVEY
• There are different approaches to assessing the
structure that influence the selection of parameters.
We can classify them in three basic categories,
namely static monitoring, dynamic monitoring, and
system identification and modal analysis, and these
categories can be combined. Each approach is
characterized by advantages and challenges, and
which one (or ones) will be used depends mainly on
the structural behaviour and the goals of monitoring.

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 MOTIVATION
• Structural Health Monitoring is important in the maintenance
of safety in structural systems
• It has significant potential in future space exploration missions
and a robust and reliable nondestructive damage identification
and assessment capability
• A monitoring system is essential to predict a timely
maintenance, and disaster refrainment
• Proactive measures can be taken before hand if the damages
are detected at the early stages and hence saving the life of
many residents

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 OBJECTIVE
• This project is about the detection of internal crack in
a material using reinforced optic fiber bundle. There
are many external crack detection techniques
available but when we look upon internal crack there
are only few techniques available which is complex
and expensive. So, to overcome this problem we
adopted this internal crack detection technique which
is compact and cheap.

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 METHODOLOGY
MATERIAL PROCUREMENT

WEAVING OF OPTIC FIBER WITH

GFRP SHEET

FABRICATION OF THE COMPOSITE

TESTING THE SPECIMEN

ANALYZING THE ATTENUATION

PROPERTIES

7 EVALUATING
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THE RESULTS
 DETAILS OF PROJECT
• Materials and fibers are selected and procured.
• Fabrication of composite is done
• Mechanical testing is done to find the strength and stiffness of
the composite.
• Using the testing readings, image is created using Matlab to
distinguish the damaged area from the composite.

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 MATERIALS AND FIBERS
GLASS FIBER:

 Glass fiber reinforced plastic (GFRP)

commonly known as fiberglass is a synthetic amalgamated
material made up of plastic and extremely fine fibers of
glass.
 Bi directional glass fiber with
length 3m and thickness 2.5 mm

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 OPTICAL FIBER

Plastic optical fiber or PMMA fiber
is an optical fiber that is
made out of polymer that transmits light
through the core of the fiber.
 PMMA optical fiber of length 40m
and thickness 2mm

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 LUX METER

 Lux meter are used for measuring

light intensity
 A lux meter works by using a photo
cell to capture light. The meter then
converts this light to an electrical current.
Measuring this current allows the device to calculate
the lux value of the light it captured.The measure of
the lux light meter varies depending on the light's intensity
and distance.

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 EPOXY RESIN & HARDENER:
 Epoxy resins are
characterised by their very good electrical
properties and chemical
resistance, good strength and low absorption of
moisture. They are linear polymers produced by
condensing epichlorohydrin with
bisphenol A.
 Epoxy Resin (LY556) 1Kg &
Hardener (HY951) 100 Grams

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 FABRICATION

The attenuation of
Epoxy resin will be
the optical fibers
The Optical fibers applied in-between The composite mat
will be checked for
will be weaved the laminates to will subjected to
its luminescence
into GFRP sheet improve its various testing
before and after
strength
testing

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 SCHEMATIC DIAGRAM

Light
source

Optical fiber

 Glass fiber reinforced plastic sheet [GFRP]

Lux meter
 Optical fiber weaved in GFRP sheet
 Epoxy resin and hardener mixture

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 SCHEMATIC DIAGRAM

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 STEPS INVOLVED IN FABRICATION OF
COMPOSITE
STEP 1 :

[before weaving] [After weaving]

First the GFRP is cutted in to square pieces and the optical fiber is
weaved in to the GFRP with the spacing of 2cm

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 STEP 2 :

100 grms of epoxy resin and 10 ml of hardener is mixed

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 STEP 3 :

A lamination sheet which is coated with a thin layer of wax is placed over
the aluminium sheet and then epoxy resin and hardener mixture is coated
over then laminated sheet using a paint brush.

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 STEP 4 :

First layer of GFRP is paced and the epoxy resin mixture is coated over
the GFRP evenly using a paint brush

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 STEP 5 :

A metal roller is used to enhance the penetration of the resin in to the GFRP
sheet

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 STEP 6 :

Now for the second layer the woven GFRP sheets a placed over the first GFRP
sheet and again the mixture of resin is coated over the woven sheet using a
paint brush and a roller is used to allow the resin to pass through the sheets
properly .

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 STEP 7:

A final layer of GFRP is placed over the second layer and again the mixture of
epoxy resin and hardener is coated and rolled using a metal roller .

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 STEP 8:

Over the final layer of GFRP a laminated sheet which is coated by wax is
placed and a bar made of rubber is used to remove air bubbles and helps to
even out the thickness of the composite

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 STEP 9:

Finally the composite is closed by an another aluminum sheet which helps to

set the composite and some weights are placed over the aluminum sheet to
flatter the composite.

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 STEP 10:

The composite is allowed to dry for 5 hours after that both the aluminum
sheets are removed and the composite further dried in sunlight for a day .

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 MECHANICAL TESTING
• Full characterization of the properties of anisotropic and
inhomogeneous composite materials, for use in
demanding structural applications, requires a wide range
of mechanical tests. Determination of bulk
propertiesrequires tension, compression and shear tests.
• Tests need to be conducted over a range of
temperatures on materials that may have been
conditioned in a variety of environmental conditionssuch
as high humidity and immersion in fluids.

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 TESTING
MECHANICAL TESTING :
 Tensile testing
 Compression testing
 Shear testing
 Flexural testing
 Impact testing – Drop ball testing

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 TESTING
TESTILIE TESTING
 Tensile testing is used to measure the force required to
break a composite specimen and the extent to which the
specimen stretches or elongates to that breaking point. Tensile
tests produce a stress-strain diagram, which is used to determine
tensile modulus.
COMPRESSION TESTING
 Compression testing methods provide a means of
introducing a compressive load into the material while preventing
it from buckling. Compression tests are performed for composite
materials that are in the form of a relatively thin and flat
rectangular test specimen such as laminate panels.

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 TESTING
SHEAR TESTING
 In-Plane Shear Testing measures the response of material in
the plane of lamination. It may be performed by pulling a
specimen in tension using a +/- 45 degree layup. In addition to
the shear strength of the material, this method provides data on
shear strain and elasticity.

FLEXURAL TESTING
 Flexural tests are generally used to determine the structural
modulus or flexural strength of the material.

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 TESTING
FLEXURAL TESTING
 The material is laid horizontally over two point of contact
and then a force is applied to the top of the material through
either one or two points of contact until the sample fails.
 The maximum recorded force is the flexural strength of that
particular sample. Flexural testing measures the force required to
bend a beam of plastic material and determines the resistance to
flexing or stiffness of a material.
 Flex modulus is indicative of how much the material can flex
before permanent deformation.

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 TESTING
IMPACT TESTING
 Impact Testing of composite is performed to determine
the impact resistance or toughness of materials by calculating the
amount of energy absorbed during fracture. The impact test is
performed at various temperatures to uncover any effects
on impact energy.
DROP BALL TESTING
 A drop test is a method of testing the Composite Material by
Droping Steel balls of various weights and sizes. This will help
us to know about the hardness of the material at varios loads
acting simultaneously at uniform intervals.

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 TESTING SPECIMEN

Steel Ball Drop Test

On a Material

DAMAGED AREA

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 MEASUREMENT

 Intensity of light varies when it is passes through

damaged area of composite

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 Table 1 – Light Intensity Readings of Sample A (Optic
Fibre Dia 1mm)
SAMPLE A – Size: 300*300*7

S.NO X ( IN 10^3 LUX) Y (IN 10^3 LUX)

1 12.55 10.11
2 6.95 9.27
3 9.22 9.16
4 9.85 12.13
5 11.97 11.99
6 11.93 12.13
7 11.96 5.42
8 10.98 4.31
9 6.42 7.14
10 6.31 6.91
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11 12.21 8.92
 Table 2 – Light Intensity Readings of Sample B (Optic
Fibre Dia 2mm)
SAMPLE B – Size : 300*300*7
S.NO X ( IN 10^3 LUX) Y ( IN 10^3 LUX)
1 29.95 30.13
2 30.01 29.95
3 10.03 4.91
4 30.15 30.31
5 22.13 9.98
6 25.07 20.07
7 29.98 30.33
8 29.94 30.47
9 28.85 30.16

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 RESULTS & DISCUSSION
• We made two samples A, B of three dimensions made up of
glass fiber mat and the optic fiber is induced into the sample in
X and Y axis. Then the sample is subjected to flexural test and
drop impact test and the sample gets damaged and the light is
passed through the optic fiber and the intensity of light is
measured using the lux meter and the change in intensity of
light before and after testing is depicted in the graph. If there
is a change in intensity of light it is understood that there is a
damage in the material.
• This application is used in PCB board, reinforced cement
concrete etc.

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 OBSERVATION – SAMPLE A
Difference in Light Transmission in Row-X

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 OBSERVATION - SAMPLE A
Difference in Light Transmission in Row-Y

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 OBSERVATION – SAMPLE B
Difference in Light Transmission in Row- X

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 OBSERVATION – SAMPLE B
Difference in Light Transmission in Row- Y

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 RESULTS & DISCUSSION
• This application is used in PCB board, reinforced cement
concrete etc.
• The effect of this result on the wider world is that, this
technique can be employed in the construction site which are
located in the earthquake prone zones so that we can identify
the internal cracks in the building and protect them before
major accident occurs in future.

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 CONCLUSION
• There are many external crack detection techniques available
but when we look upon internal crack there are only few
techniques available which is complex and expensive. So, to
overcome this problem we adopted this internal crack
detection technique which is compact and cheap. The scope of
our study is to solve the general problem which occurs during
manufacturing of a product which exposes the final material
under stress.

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 FUTURE SCOPE OF THE PROJECT
• In the first place, monitoring is naturally linked with safety.
Unusual structural behaviors are detected in monitored
structures at an early stage; therefore, the risk of sudden
collapse is minimized, and human lives, nature and goods are
preserved.
• In the future, we can use micro level optical fiber embedded in
the bone to check the damaged bone is healed or not.

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 EXPECTED OUTCOMES

Self Sensing Composite

Damage Detection using the responses
The composite will be
able to sense the Disaster Evasion
The damages can be
structures` weakness detected to the range
and immediately notify of few millimeters and Structure collapsing
it using the data proactive measures can and other disasters can
be taken be avoided and many
human lives can be
saved

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 ACKNOWLEDGE THE SUPPORTING
AGENCY
S.P. ASSOCIATES – Adhesives and glue supplier in chennai

ADDRESS - 27, Vinayagar Koil Street,

Little Mount, Saidapet,
Chennai, Tamil Nadu 600015

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 REFERENCES
1. Culshaw, B. and Dakin, J., 1I0pticai Fiber Sensors - System
and Applications”, Volume 2, Norwood, MA., Artech House,
Inc.,1989.
2. Hale, K.F., 0ptical Fiber Sensors for Inspection Monitoring”,
The Institute of Physics, Vol. 15 (1984), pp. 129-135.
3. Enckell, M., Evaluation of a large-scale bridge strain,
temperature and crack monitoring with distributed fibre optic
sensors. Journal of Civil Structural Health Monitoring, 1(1), 37-
46, 2011.
4. Leka, G. Lawrence and Bayo, Eduardo, “A Close Loop at the
Embedment of Optical Fibers into Composite Structures” ,
Journal of Composites, Technology Research, 1989, pp. 106-112.

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 REFERENCES
5. Garoushi S, Lassila LV, Vallittu PK. The effect of span length
of flexural testing on properties of short fiber reinforced
composite. JMater Sci 2012;23(2):325–8.
6. J.L. MASSINGILLJR., R.S. BAUER, in Applied Polymer
Science:21st Century, 2000.
7. Ritter, J.E., Helfinstine, J.D., "0VD Process Modification
forImproved Optical-Fiber Strength Reliability", Corning
Technical ReportTR-66 March 1987. 8. Banthia, N, Mindess, S,
Bentur, An Impact testing of concrete using a drop-weight impact
machine. Exp Mech 1989; 29: 63–69.

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 Thank you

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