Chapter four Experimental work

Ch4
Experimental work
4.1 Introduction:-
In experimental work were made anew hybrid composite specimens by hand layup
vacuum bag technique with The overall fiber volume fraction of the composites was
approximately 48%. under fatigue test to find fatigue life behavior of it .
Evaluate the mechanical properties and fatigue behavior for hybrid composite used by
some tests .which are made from different fiber materials E-glass , Kevlar , and carbon,
all woven fabric in an epoxy resin(laminate composite specimen).

The experimental work procedure can be divided in many steps:-

1-Find properties of materials that would be used to made hybrid composite materials.

2- it was made eight layers of hybrid laminate composite (different orientation of

strong woven fibers Kevlar and carbon with multidirectional glass woven fiber in an
epoxy resin).
2-Design and manufacture mould to made laminate hybrid composite materials.

3- Design and manufacture chamber to make specimen under vacuum condition.

4-cut the specimens by using CNC machine to prepare the the samples for mechanical
test (tensile test, flexure tests).
5- fatigue test was done by using alternating bending machine (fully reversed R= -1)
and data logger with a strain gauge.
4.2 Matrix and reinforcement properties:-
The matrix was used is epoxy resin low viscosity(300 cps) at 20c o, the density at 20c0
is 1.05 g/cm3 . epoxy resin consist of two components and mixing ratio of 3:1 based
on weight ,or 5:2 based on volume , application time of 45 minute at approximately
200c as shown in fig.(4-2)

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Figure (4-1).shows epoxy resin(epoxy)

The fibers was used plain E-glass woven has m/A( 600 g/m2) plain Kevlar woven has
m/A(440g/m2),and carbon woven has m/A(440g/m2) as shown in fig.(4-1).

Figure(4-2). shows plain woven glass and plain woven carbon

4.2.1law of mixture
calculation of volume fraction of fibers and matrix follows[43,44]:

(1) Mc = Mf +Mm 4.1

Mf
(2) Vf = ρ
f 4.2

Mm
(3) Vm = ρ
m
4.3

(4) Vc= Vf +Vm 4.4

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Vf 4.5
(5) vf = V c

Vm 4.6
(6) vm = V c

4.3 Arrangement of lamina layers

The specimens were manufactured by hand lay-up technique each specimen made
of eight layers of composite lamina with thickness 4mm volume fraction of fibers
48% (epoxy resin matrix with different plain woven fibers E-glass,Kevlar and
carbon .
which can be classify :

1- eight layers of lamina [#0]8,[G]8 of fiber glass.

2- eight layers of lamina (two Kevlar layers up and down with six layers glass[#0] 8,
[KGGG]s.

3- eight layers of lamina (two Kevlar layers in the middle of laminate and six layers
glass[#0]8,[GGGK]s.

4- eight layers of lamina (two carbon layers up and down with six layers glass)
[#0]8[GGGC]s.

5- eight layers of lamina (two carbon layers in the middle of laminate and six layers
glass[0]8s.

6- eight layers of lamina [#0/#45/#-45/#90]s ,[G]8of fiber glass.

7- eight layers of lamina (two Kevlar layers up and down with six layers
glass)[#0/#45/#-45/#90]s,[KGGG]s.

8- eight layers of lamina (two Kevlar layers in the middle of laminate and six layers
glass[#0/#45/#-45/#90]s,[GGGK]s.

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Chapter four Experimental work

9- eight layers of lamina (two carbon layersup and down with six layers
glass)[#0/#45/#-45/#90]s,[CGGG]s.

10- eight layers of lamina (two carbon layers in the middle of laminate and six layers
glass[#0/#45/#-45/#90]s,[GGGC]s.

All these hybrid composite laminate shown in fig.(4-3),fig.(4-4)

Figure (4-3). hybrid composite laminate

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Chapter four Experimental work

[G]8

[CGGG]s [GGGC]s

[KGGG]s [GGGK]s

Figure (4-4) schematic of hybrid composite laminate

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Chapter four Experimental work

4.3.1 Preparation of the specimen

The laminates were fabricated by using mold with dimension 30cmX30cmX0.4cm

glass plates with four sheets of glass 5cmX5cmX0.4cm used as support to get
specimen 4mm thickness when put cover( glass plate 30cmx30cmx0.4cm) and weight
on it or clamped as shown in fig.(4-5).

Sheet of glass

ss

Figure(4-5). shows Mold glass plate with sheets of glass

And used two of transparency film sheets at the mold to avoid sticking between a
specimen and mold glass , abrasive and insure flattening of specimen surface.

4.3.2 Laminate process

At first it has been used sensitive scales to weight a resin and hardener( mix ratio 1:3)
for each layer and mixed together very well and then spread it on the mold very slow
to prevent a bubbles to appear on the surface of resin, brush was used to distribute
resin uniformly on the mold and then put layer of fiber on it and by using roller press
the fiber on the resin to avoid bubbles and spread the resin with fibers and again
weight resin for the second layer and a placed on the fiber and then put another layer
of fiber on the resin following the same sequence.

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All the plies were placed on the top of stack and then placed the glass plate on the
mold as shown in fig.(4-6).
The figure (4-7) shows the most tools were used in laminate process to make hybrid
composite specimen.

cover

Lamina

Figure (4-6). Schematic of laminate mold with lamina

Figure (4-7) tools were used in laminate process

4.3.3 Vacuum process

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After the specimen was made on the mold , it then placed in a glass chamber
30cmX30cmX30cm with thickness 8mm to bear a vacuum pressure which was
connected by pipes to a vacuum pump with pressure gauge to measure the pressure
(10psi)0.6 bar and then switch the vacuum pump on for( 8-10 minutes) to disposal
from the bubbles and also the resin spread equally on mold and excess of resin can be
drawn outside. in fig.(4-7),fig.(4-8).

figure(4-8).shows glass chamber figure (4-9).shows vaccum pump

4.3.4 Curing process

After vacuum process the cure time for epoxy resin it was 24hr or 36hr at room
temperature. After that the specimen was removed from the mold and the specimen
has cut by using a steel saw and then finished by abrasive grinding of the edge to get a
samples for mechanical tests as shown in fig.(4-9), but it was taken along time and it
doesn't get aright dimensions.

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Chapter four Experimental work

Steel saw sand paper

Figure(4-10)

so it was used CNC machine to have got the right dimension of specimen and good
shape as shown in fig.(4-10).

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Chapter four Experimental work

Figure.(4-11) CNC machine cut the specimen to

get a samples for mechanical tests

4.4 Mechanical tests

4.4.1 Tensile tests

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Chapter four Experimental work

The tensile test specimen were produced according to ASTM D 638M is shown in fig.
(4-11),fig.(4-12) which is type IV(44) ,it is used for composite materials .

Figure.(4-12) Tesile test specimen according toASTM D638 (all dimension in mm)

Figure(4-13) Specimens for tensile test

it was used a tensile testing device , type testometric micro 500 AX 25 universal
machine at a speed range( 0.5mm/min- 5mm/min) with minimum to maximum range
of loads (4N-2500N) and (40N-25000N) was utilized for the tensile and the
compression tests whose control and data acquisition are performed by a computer as
shown in fig.(4-13).

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Chapter four Experimental work

Figure.(4-14) testometric micro 500 AX 25 universal

The specimen were mounted in the grips of testing machine they should be aligned the
longitude axis of the specimen would coincide with the direction of the applied load at
speed 5mm/min according to ASTM D638 for composite materials. Load deformation
and stress –strain curve were plotted during the test as shown in fig.(4-14).

Figure.(4-15) Specimen in machine (tensile test)

4.4.2 Flexure test

Flexural testing device used type tachometric micro 500 AX 25 universal machine
flexural testing specimen can be tested as a simply supported beam (three point
bending).
The flexure testing specimen were produced according to ASTM D 690-00(45) for
high –strength reinforced composites as in the fig.(4-15).

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Chapter four Experimental work

Figure.(4-16) Flexure testing specimen according to ASTM D790-02

(all dimension in mm)

The span to depth ratio shall be chosen such that failure occur in the outer fibers and is
due only to the bending moment . span to depth ratio larger than 16:1 may be
necessary (32:1or 40:1 are recommended).and it was produced specimen 4mm thick so
the span to depth ratio was chosen 32 shown in fig.(4-16).

.
Figure(4-17) Flexure testing specimens
The specimen rests on two supports and was loaded by means of the loading nose
midway between the supports at speed 0.01mm/min/min and the specimen deflected

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Chapter four Experimental work

until ruptured occur in outer surface of test spicemen or until maximum strain 5% is
reached which ever ocuur first as shown in fig.(4-17).

Figure.(4-18 ) testometric micro 500 AX 25 universal with flexure specimen

4.4.3 Fatigue test

4.4.3.1 Introduction
The experiments were carried out using a HSM20 alternating bending machine which
was developed for flexure fatigue test cantilever beam specimens as shown in
fig.(4-18).

Figure (4-19). Alternating bending fatigue machine

Fatigue test specimen with its dimension was shown in fig.19

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Chapter four Experimental work

Figure (4-20) fatigue testing specimen

Figure.(4-21) Fatigue testing spicemen with dimension in mm

It was used with alternating bending machine a data logger to measure the strain of the
force applied to the specimen it is shown in the fig.20 .

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Chapter four Experimental work

Figure.(4- 22) Data logger

It was used a strain gage which was connected to data logger to sense the strain of the
force applied to the sample as shown in fig.(4-22) .

Figure.(4-23 )strain gauge

4.5. Alternating bending machine

I t is devised used for flexure fatigue test , at one end of a heavy steel plate is mounted
an electric motor and starter contactor . the motor shafts carries pulley with belt derive
to accouter shaft so that different ratio of speed can be arranged , for testing plastic it
would be usual to work at a half of the motor speed.the cantilever test specimen in the
form of rectangle strip is held horizontally above the eccentric by a heavy portal frame

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 Chapter four Experimental work

with an adjustable clamp on the cross beam . The clamp can moved horzintly and the
clamp was chanced for anew sample because the standard of sample was wide 10mm
and length 100 ,so for new sample the clamp manfacure in new dimensions and new
connecting rod to get effective strain as shown in fig.(4-22)

specimen

New clamp

New connecting rod

Figure.(4-24) new clamp and connecting rod with specimen

Figure.(4-25) Specimen with anew changes

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Chapter four Experimental work

The cross beam can be moved vertically so that the defalcation of the cantilever can be
varied from ±20mm for alternating stress to one way only deflection for fluctuating
stress as shown in fig.(4-24)

Connecting rod

Cross beam

Figure.(4-26) cross beam and connecting rod

4.5.1 Data logger

The data logger TDS-530 manfucatered by Tokyo sokki Kenkyujo company
Data logger is used for automatic measurement of multipoint such as strain
gauges ,strain gauge type converter , thermo couple …eltc. High speed measurement
of 0.04 second for 1 point , it has a high resulation (0.1X10 -6strain) mode is mounted
and strain measrument 1000 points can be measured in 0.4 second.

4.5.2 Strain gages

Strain gages was used type Tokyo Sokki Kenkyujo , it was adhesive to connecting rod
to sense astrain of connecting rod (tensile strain) and then measure by data logger .
Connecting rod was manufactured from aluminum so the type strain gage that chose
was FLA-3T-120-23-3LT , it is used to aluminum specimen length of it 3mm and

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Chapter four Experimental work

resistance is 120Ὠ with a lead wire 3m long , type of adhesive was used P 2 this
adhesive made up of main component and hardening agent. This adhesive exhibit
excellent resistance to moisture and chemicals. coating the strain gauge to protect it
from moisture , heating was used type N 1, the coating N1 is applied flexible when dry
and have no constrictive effect on the test specimen as shown in fig.(4-26), fig.(4-27)
,fig.(4-28)

Figure.(4-27) strain gauage on the connecting rod

`
Figure (4-28 ) adhesive (drug A and drug B) Figure (4-29) coating N1 to protect strain gauge

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Chapter four Experimental work

4.5.3 Strain gauge installation procedure

Surface treatment

Strain gauge installation

Adhesive curing

Strain gauge installation

check

Lead wire connection

coating

4.5.4 Attaching a strain gauge

1- All moisture, grease, scale, rust, paint, etc. was removed from installation area to a
provide a shiny metallic surface on which the strain gauge was installed.
2- Abrasive paper was used to a brade an area slightly larger than the strain guage to
be installed. The type of paper 400 grads for aluminum specimen (connecting rod).
3- the surface was cleaned with industrial tissue with asmall amount of a slovant such
as acetone,continue cleaning until the tissue has come away cleanas shown in fig.29.
4- the position of strain gauge was marked on the connecting rod by pencil 4h.
5- the drag B was mixed with drag A by three drops of drag B(1%) with 10g of drag A
by using a sense scale as shown in fig.30, mixed it for 5 minutes and applied a small
amount from it on the spicemen (conneting rod) and the back of a strain gauge , the
strain gauge was align with position marks , and then with polyethylene sheet was
plced over the strain guage with applied aconstant pressure by a thump or by using
clamp with a pieces of rubber as shown in figure(4-31).

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Chapter four Experimental work

6- the gauge wire and lead wire was slacked and fixed with with atape and with
swisser the lead wire of strain gauge was rised to prevent any contact it with the suface
of the connecting rod .
7- the strain guage was left for 24 hours and then could used to measurements .
8- the strain guage resistance was checked by digital resistance meter (120Ὠ).
9- the strain guage was coated by N1 , the test spicemen surface was cleaned the same
way as for strain gauges was insalation and left it for 24 hours.

figure(4-30) acetone and alcohol

Figure(4-31). Weight drag A and drag B by scale sense

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Chapter four Experimental work

Figure.(4-32) clamp with pieces of rubber to install the strain gauge

4.6 The procedure of fatigue test

Before the alternating bending fatigue machine started work when the number of
cycles is zero the strain reading was taken by data logger when the connecting rod
reached the lower point which the maximum deflection is implied and it is the
maximum force effecting the specimens, as number of cycles increased many reading
were taken each reading present the maximum force affect the specimens. As shown
in fig(4-31).

Strain gauge
Specimen

Connecting rod

Figure(4-33) .Schematic drawing of the crank and connecting rod showing the machine at lower
point and the imposed deflection is maximum.

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