Comprehensive Exam

Progress Report

Presenter: Subramaniasarma Sreenivasan (GS 31060)

Supervisor: Prof Dr Shamsuddin Sulaiman

Co-Supervisor: Prof. Madya Dr Mohd Khairol Anuar

Prof. Madya Ir Dr B.T. Hang Tuah
Prof. Madya Dr. Khalina Abdan
 Research Work

‘Kenaf Reinforced Thermoset Composite

For Injection Moulding’.
 Problem Statements

• The current trend in the industry is to produce multiple walled, complex shaped
and green products.

• A handful of researchers have actually carried out research or studies in the

development of bio-composite material made from natural fibre such as kenaf.
However most of these researches are limited to creating a new replacement
material. Most of these research do not identify the processing problems faced
when these material are brought into the industry. Hence many of these material
are not applied or used in the industry.
.
• There are also limitations in using natural fibers for reinforcement in injection
moulding for parts multiple wall thickness parts. At the same time applying
lignocellulosic fiber as a filler material are extremely challenging in terms of filling
and the cure distribution generated in cavity moulds. Furthermore, understanding
the cure behaviour through simulation results will be helped to indentifying how
well moulded part quality from shrinkage and warpage.
 Problem Statements

• Our review indicates that limited research has been conducted on the use of
lignocellulosic filler reinforced thermoset composite materials for moulded
multiple thickness walled parts using injection moulding process. Therefore,
this research investigated the optimization of moulding process and the
processability of lignocellulosic filler-reinforced polymer composite materials
with respect to filling, in-cavity residual stresses, volumetric shrinkage and
warpage for multiple thickness walled parts in the injection moulding
process.

• There are also problems which arise during the manufacturing process of
the glass fibres. Glass fibres pose a serious health hazard, such as
poisoning during the process of creation of the glass fibres which normally
are around 17 -25 micrometers.
 Hypothesis

• If an acceptably homogenous kenaf-polymer mixture can be achieved, then

a new viable material for injection moulding can be achieved, thus making a
viable replacement material for manufacturing process specifically injection
moulding.
 Research objectives

1. To select and verify the most suitable surface treatments for kenaf fibers to be
applied as reinforcement material.

2. To study the effect of impregnation percentage and fiber length on physical,

mechanical and thermal properties of the composite material

3. To study the flow of natural fiber reinforced BMC in comparison to Glass fiber
reinforced BMC.

4. To study and develop the molding parameters.

5. To verify the final composite using Software simulation.

6. To verify the final composite products flow and compatibility using an actual
injection mold and molding machine
 Research Scopes

• Minimum Thickness of multiple thickness walled part is 0.5 mm, maximum

thickness is 5 mm

Unit: mm
Length: 300 mm
Fig. 1 A Depiction of the final part that will be used for Height : 50 mm
simulation and mass production
Width: 150 mm
(Isometric View)

• Process involved is injection moulding process. The analysis processing

parameters focus on post filling stage (packing pressure, packing time,
mould temperature and cooling time).
 Research Scopes

• Numerical analysis using commercial software, Autodesk MoldFlow Insight

2011.

• Material :
UP + 10%wt kenaf (Trade name: BMC)
UP + 20%wt kenaf (Trade name: BMC)
UP + 30%wt kenaf (Trade name: BMC)

• Investigation on in-cavity flow behaviour, volumetric shrinkages and

warpage.

• The optimization assisted by Analysis of Variance (ANOVA).

 Methodology

1) Surface Treatments.
Silane and Sodium hydroxide has been used to treat the fiber surfaces. A comparison has been made and it was found that silane namely glycidoxypropyltrimethoxy-
silane was the best surface treatment in terms of fiber bonding and micromechanical interfacial Stresses.

2) Materials
a) Fibers- Comparison of basic mechanical properties between kenaf and glass

Fibres Tensile Young’s Elongation at

Propertie Diameter
Density strength modulus break
s/Fibers (µm)
(gcm-3) (MPa) (GPa) (%)
Kenaf 1.2–1.45 20–200 930 53 1.6
E-glass 2.55 17 3400 73 2.5
 Methodology

b) Resin- Unsaturated polyester blended with the required inhibitors are

used.
Components Ratio Description
Resin 68.88% Unsaturated Polyester neat resin. Serves as base for the composite.
LPI Styrene monomers - Most polyester resins are viscous, pale coloured
liquids consisting of a solution of polyester in a monomer which is
usually styrene. The addition of styrene in amounts of up to 50%
29.52% helps to make the resin easier to handle by reducing its viscosity. The
styrene also performs the vital function of enabling the resin to cure
from a liquid to a solid by 'cross-linking' the molecular chains of the
polyester, without the evolution of any by-products.
PBQ Para-Benzoquinone – This is a inhibitor that increases the gel time of
the composite allowing it for more suitable flow and control of flow
0.03%
during molding. Pbq also plays a part in increasing the spiral flow
time, thus resulting in better
Trig C Trigonox C (tert-Butyl peroxybenzoate) is a monofunctional peroxide
which is used for the crosslinking of polyolefins as well as natural
0.49% rubber and synthetic rubbers. Trigonox C may also be used for the
curing of unsaturated polyester, vinylester and thermoset acrylic
resins at elevated temperatures
Trig-21 OP 50 Trigonox-21-OP50 (tert-Butyl peroxy-2-ethylhexanoate) is an initiator
1.08% for the curing of unsaturated polyester resins in the temperature
range of 100-140 °C.
Total 100%
 Methodology
c) Fillers
The fillers are mixed in the Z-blade kneader prior to being mixed with the
wet components. The components, ratio and the functions are listed in the
below table.

Components Ratio Function

CACO3 The CaCO3 which is around 2-6 micrometer particles, will provide
a low uniform viscosity in the polyester, by controlling the CaCO3
particle size distribution and purity further mixture evenness is
98.24% achieved.
SAK ZSP Zinc stearates are insoluble in polar solvents, but more soluble in
aromatic compounds and chlorinated hydrocarbons when heated.
Their main application areas in BMC are to be used as release
agents and lubricants which can be easily incorporated. The
outstanding clarity and heat stability properties of crystal clear
zinc stearate grades make them particularly suitable for impact
and crystal grade polystyrene and other clear polymers. Zinc
stearate functions as an acid scavenger and processing aid in
certain polyolefin applications.

1.75%
Total 100%
 Methodology

d) The Kneading Process.

The wet and the dry components are mixed in the Z-Blade kneader first. Once a steady rpm of 45±5 is achieved,
the fibers are then added and mixed. During the mixing process, the rpm of the kneader is monitored, it is
agreed that an acceptably homogenous mixture is achieved when the rpm is stable. Another method practiced
was the use of dip-sticks. A dip-stick was dipped into the mixture and the surface was observed to check for
any uncoated fibers.

Fig. 2. Kneading. Fig. 3. Mixing RPM.

 Methodology

3) Machines
a) The kneading was done in Wah Ma (M) Sdn. Bhd., using a twin
blade mixer model YD-NH 5 kg mixer.

b) Injection Moulding to be done at Wah Ma (M) Sdn. Bhd., using a Meiki 150
ton machine.

4) Simulation
The simulation to be done using Autodesk Moldflow using thermoset injection
Moulding process, with fill and pack analysis.
 Methodology

5) Testing and material characterization

6) Analysis of variance (ANOVA) will be conducted to quantitatively analyze the

significant contributions of the processing parameters on the in-cavity flow
behaviour, volumetric shrinkages and warpages.
 Progress report

Achievement for Objective 1: Paper submitted to materials research Innovations dated 10 Dec 2013. Waiting for feed back

Objectives
Objective 2: To study the effect of
impregnation percentage and fiber
length on physical, mechanical and
thermal properties of the composite
material
Objective 3 and 4: To study the
flow of natural fiber reinforced BMC
in comparison to Glass fiber
reinforced BMC. To study and
develop the molding parameters.
Objective 5: To verify the final
composite using Software
simulation.
Objective 6: To verify the final
composite products flow and
compatibility using an actual
injection mold and molding
machine
Final Thesis 1st Draft Submission
Progress report
Current Status Expected Paper submission date
All tests completed. 31 January 2014
Currently in the stage of writing the Targeted Journal: Materials and
paper Design
myphd\Paper 3\mechanical thermal
and Electrical properties.xlsx
Currently being studied. 31 March 2014
Targeted Journal: Materials and
Design
Currently conducting thermal 31 May 2014
conductivity, TGA and DSC Targeted Journal: Materials and
analysis for software data fitting. Design
Pending results of objective 5 31 July 2014
Targeted Journal: Materials and
Design
Pending results of objective 5 31 August 2014
 Conclusion

• The limitation of this research is lack of numerical simulation to be used to

verify direct experimental results. Focusing on numerical simulation initially
helped researchers to understand about the flow behaviour which caused
shrinkage and warpage defects.

• Therefore, the recognized material data properties from database of

numerical software, comparison findings from literatures and also simulation
results from analysis on post-filling stage able to bring these finding into
useful conclusion.

• This research is also an early pioneer in the field of natural fiber reinforced
polymer composite which focuses on multiple thickness walled parts
injected by injection moulding process