Experimental development of FRP pultrusion moulds

Materials Today: Proceedings xxx (xxxx) xxx

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Experimental development of FRP pultrusion moulds A. Naga Sai Ranganayakulu, D. Dev Singh ⇑, B. Sridhar Babu, T. Vishnu Vardhan Department of Mechanical Engineering, CMR Institute of Technology, Hyderabad, India

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Article history: Received 23 May 2019 Received in revised form 2 July 2019 Accepted 3 July 2019 Available online xxxx Keywords: Pultrusion machine Fiber-Reinforced Polymer(FRP) Mold/Die CNC-program & simulation Creo parametric & simulator 4.0 (Pro-E)

a b s t r a c t The paper work describes the pultrusion process and also selection of die raw material which is suitable for the production of constant cross-section composites of any desired length. It is a manufacturing process for producing various cross-section products in a mass production. As the product quality is purely depending upon the mold, such as the parameters of mold design, material of construction, mold length, hold down hole size & location, heat zones. And the process parameters like heating rate, pulling speed and the curing kinetics of resin system influent the mold quality. Die length, width & thickness of design will be standardized, based on the design die fabrication is done with the help of the Computer Numerical Control (CNC) machine, by using this P20 & EN8 dies, production was taken out and done experimental test on end product, based on the experimental & numerical test results and also finishing & quality. Comparing the two end product based on the result and quality of product taken from the P20 & EN8 dies, by the end of this composites production which was taken from the P20 die have best results, finishing & quality compare to EN8. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.

1. Introduction

2. Experimental procedure

A Pultrusion Composite consists of reinforcing materials [1–3], a laminating organic compound that binds the composite along, probably a egress mat to enhance the composite surface look, chemical resistance and weather resistance, and a range of adjuvant material like pigments to impart color, accelerators to cure the laminating organic compound, internal agent, inert fillers, [4–6] etc. In several foreign countries composites products pay’s a major roll compare other material products.

2.1. Pultrusion die: design

1.1. FRP mechanical design criteria The principal employed in the structural style with FRP is compared to coming up with steel or Aluminum. The Fig. 1 shows the typical stress-strain curves in the different material property’s, the yield point was compare with the steel, concrete, cast iron, timber and FRP, within this stress-strain curves of the different material based on the load and elongation was defined. The main material stress-strain curves are shown in the Fig. 1. ⇑ Corresponding author. E-mail address: [email protected] (D.D. Singh).

The pultrusion die design was done on the bases of profile design and as well as number of profile cavity [7]. Based on this reason only the die design will be done by using 3D Modelling Software. The software which was used in this project is CREO-3.0. (Pro-E). a. Profile design: In this design process profile was standardize at required size as shown in Fig. 2. b. Design considerations: The design Consideration was done, based on the end product profile size as shown in Fig. 3. c. Die Cavity: in this Die cavity shows how the pultrusion molds was designed as shown in Fig. 4. d. Die length: The Die length was also standardize based on the Profile & die cavity as shown in Fig. 5. 2.2. Numerical test for end product 2.2.1. End product process On a general test basis, the epoxy resin is selected for composites manufacture in bases of the polyesters and vinyl esters, the

https://doi.org/10.1016/j.matpr.2019.07.612 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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Fig. 1. Typical stress-strain curves.

Fig. 4. Die cavity.

2.2.2. Numerical Test considerations In this numerical test was consider three major test process those are a) Tensile strength, b) Compressive strength & c) Bending strength. Calculation formulas for the tensile, compression & bending methods.

r¼ e¼

Fig. 2. Profile design.

superior chemical and temperature resistance up to 150 °C (300°F). Both can be important to the pultruded profile applications, but equally attractive are the improved physical properties, fatigue, creep resistance and toughness as well as a better electrical insulating and the maintenance, of these advantages under hot/wet environments typified by water saturation up to 121 °C (250°F). To this process the help of the some chemicals like Resin, Reinforcement, Curing agents, Fillers, Mould release, prepared the chemical mixture. So this mixed resin liquid was send along with the glass fiber into the liquid phase of the die/mould it react with temperature and convert into the solid compound/a shape profile material and it come out through the solid phase as known as dynamic zones within a pultrusion die as shown in the Fig. 6.

E¼

f a

r E

r e

ð1Þ ð2Þ ð3Þ

In the tensile test one end is fixed based on the boundary condition during the simulation test of the specimen was consider the length is 500 mm, where force is acting in opposite direction as shown in the Fig. 7. In the compression test both end are placed in between the press plates of fixed ends by using boundary condition during the simulation test of the specimen was consider the length is 200 mm where force is acting as shown in Fig. 8. In the bending test the both end are fixed and forces is acting in the centre of the beam by using boundary condition during the simulation test of the specimen was consider the length 500 mm where force is acting at centre of the beam as shown is Fig. 9.

Fig. 3. Design considerations.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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Fig. 9. Boundary condition of both fixed ends in bending test.

Table 1 Mechanical properties. Fig. 5. Die length.

Properties

P20(Metric)

EN8(Metric)

Hardness, Brinell Tensile strength, Ultimate Tensile strength, Yield Elongation at break (in 50 mm) Modulus of elasticity Compressive strength

300 965–1030 Mpa 827–862 Mpa 20% 205 Gpa 862 Mpa

201 620 Mpa 415 Mpa 25% 190–210 Gpa 250 Mpa

Table 2 Tensile simulation result. Load

Max. Stress

Displacement

10 kg 25 kg 50 kg

0.547 Mpa 1.102 Mpa 2.834 Mpa

0.0042 mm 0.0095 mm 0.022 mm

Table 3 Production with (P20) result. Fig. 6. Dynamic zones within a Pultrusion Die.

Loady

Max. Stress

Max. Displacement

10 kg 25 kg 50 kg

0.807 Mpa 1.752 Mpa 5.634 Mpa

0.009 mm 0.026 mm 0.35 mm

Table 4 Production with (EN8) result.

Fig. 7. Boundary condition of one end fixed in Tensile Test.

Load

Max. Stress

Max. Displacement

10 kg 25 kg 50 kg

1.262 Mpa 2.576 Mpa 8.425 Mpa

0.012 mm 0.042 mm 0.55 mm

Table 5 Compressive simulation result. Load

Max. Stress

Max. Displacement

25 kg 35 kg 50 kg

2.56 Mpa 4.84 Mpa 7.25 Mpa

1.05 mm 2.16 mm 3.63 mm

2.3. Material selection for molds

Fig. 8. Boundary condition of both fixed ends in compression test.

Alloy steel is that the favoured material for any type of die construction and usually for the material & grades based on the premise of their machinability, toughness, polishability, wear resistance, durability, and economy, though it’s usually the tool life of pultrusion die additionally needs surface lubricity, unharness characteristics and corrosion resistance, properties which can solely be achieved with surface treatment. Consequently the bulk of pultrusion dies mix a 30-40Rc steel with a tough chrome (70Rc) surface plate zero.025–0.075 mm (0.001–0.003 in.) thick.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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Table 6 Compressive Test (P20) & (EN8) result. Load

Production with (P20) Max. Displacement

Production with (EN8) Max. Displacement

25 kg 35 kg 50 kg

4 mm 6 mm 8.5 mm

6 mm 8 mm 11 mm

Table 7 Bending simulation result. Load

Max. Stress

Max. Displacement

25 kg 35 kg 50 kg

20.26 Mpa 46.04 Mpa 72.85 Mpa

0.5 mm 1.16 mm 2.93 mm Fig. 11. Cavity – milling & radius.

Table 8 Bending Test (P20) & (EN8) result. Load

Production with (P20) Max. Displacement

Production with (EN8) Max. Displacement

25 kg 35 kg 50 kg

2 mm 5 mm 6.5 mm

3 mm 6.5 mm 9 mm

Another treatment to boost the surface hardness is particle nitriding, whereas different pultrudes value more highly to use a through-hardened steel of around 55-60Rc [8,9]. By this manner 2 alloy steel was selected for pultrusion Die producing those materials are P20 & EN8 steel the mechanical properties as shown in Table 1. Fig. 12. Bellmouth radius.

2.4. CNC Machining process In the 2-Cavity Die we have bottom plate and top plate, based on that die plates the machining process is done by Step by Step as shown in Fig. 6. In the machining process we have follow four major steps to remove the material. The major steps in material removing process are,

c. Bellmouth radius: This is the final step in CNC that was Bellmouth radius, this was process was done at ends of the Die plates as shown in the Fig. 12.

3. Experimental results a. Step Milling: in this step milling process the 1st layer of raw material will be removed in the die plates as shown in Fig. 10. b. Cavity – Milling & radius: In this process 2nd layer of raw material was removed then after cavity radius was done as shown in Fig. 11.

3.1. Product testing 3.1.1. Tensile Strength simulation and experimental are shown in Fig. 13 and Fig. 14 with respectively and corresponding results in Table 2, Table 3 and Table 4. Simulation Test Experimental Test This Tensile Strength Test was done under the Test Method/Process of composites material-ASTM D3039.

3.1.2. Compressive Strength simulation and experimental are shown in Fig. 15 & Fig. 16 with respectively and corresponding results in Table 5 and Table 6. Simulation Test Experimental Test

Fig. 10. Step milling.

This Compressive Strength Test Method/Process was done under composites – ASTM D3410.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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Fig. 13. Tensile Strength a) Max. Stress & b) Max. Displacement.

Fig. 14. Tensile strength experiment.

Fig. 15. Compressive strength a) Max. Stress & b) Max. Displacement.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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Fig. 16. a) Compressive test for end product from a) P20 Die & b) EN8 Die.

Fig. 17. Bending Strength a) Max Stress & b) Max. Displacement.

Fig. 18. Bending Test of end product from a) P20 Die & b) EN8 Die.

3.1.3. Bending Strength simulation and experimental are shown in Fig. 17 & Fig. 18 with respectively and corresponding results in Table 7 and Table 8. Simulation Test Experimental Test This Bending Strength Test Method/Process was done under composites – ASTM 7264.

4. Conclusion This work main objective is to check the Quality of production form two type of Die material and compare with main three Test Processes under the Test Method of composites material ASTMD3039, ASTM-D3410 and ASTM-7264. With the help of this test method process we can compare the Die’s. In P20 material have High Carbon compare to EN8 material due to that, we can take the production very smoothly, best

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612

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finishing, best quality and the life time of this die is more then EN8, we can take production any time and longer period in production line but this die raw material is costly than to the EN8. By the use of EN8 have Low Carbon due to that, the production of the composites material is not smooth, finishing and also quality, this Die can use only for short Period of production and this die raw material is not a costly compare to P20 material. For the best composites production, Quality and longer period production line, the P20 material is most suitable for pultrusion process.

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[2] R. Gorthala, J.A. Roux, J.G. Vaughan. Resin flow, cure and heat transfer analysis for pultrusion process, Compos. Sci. Technol. [3] Aleksandr krasnovskil, Iliya kazakov. 200. Result of an experimental investigation into the Determination of the Optimal Speed of Pultrusion for Large-Sized composite Rod- volume-2 JEAS, 21-26 [4] Handbook of Pultrusion Technology by Raymond Meyer. [5] Pultrusion for engineers by Trevor F Starr. [6] Composites manufacturing – Material, product, and Process Engineering, Sanjay.K.Mazumdar, Ph.D. [7] SVS Hydraulics – Composites Manufacture Company. [8] www.azom.com – Die Material Properties. [9] www.astmsteel.com – Die Material Properties.

References [1] Basuki R. Suratno, Yiuwin Mai, Lin Ye, Simulation of temperature and curing profiles in pultruded compositerods, Compos. Sci. Technol.

Please cite this article as: A. N. S. Ranganayakulu, D. D. Singh, B. S. Babu et al., Experimental development of FRP pultrusion moulds, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.07.612