Compression Moulding Machine Research Articles

Improved Design and Fabrication of a Compression Moulding Machine with Performance Evaluation

This study explores the advancements in the design and performance of an improved compression moulding machine aimed at efficiently recycling various plastic wastes, with an emphasis on Polyethylene Terephthalate (PET). With global plastic waste accumulation posing severe environmental challenges, enhancing recycling technologies is imperative. The re-designed machine was tested at operating temperatures of 200°C, 250°C, and 300°C, highlighting the critical role of temperature and processing duration in determining product quality. Theoretical heating times were found to be shorter than actual times due to real-world inefficiencies such as heat loss and thermal conductivity variations. Weight loss during heating, attributed to the evaporation of volatile components and thermal degradation, was observed. The formation of air pores in samples with extended heating times underscored the necessity for precise process control. The PET melting process initiated effectively at approximately 250°C. The improved machine demonstrated significant potential in enhancing recycling efficiency and versatility.

Mechanical characterization and study on morphological properties: Natural and agro waste utilization of reinforced polyester hybrid composites

Eco-conscious products are currently garnering significant attention due to their abundant availability and versatile applications in various engineering contexts. The distinctive properties of natural fibers make them readily substitutable for synthetic fibers. A substantial one million tonnes of fiber waste, primarily composed of paddy straw fiber, is generated globally. The research emphasis revolves around the adoption of the Waste to Wealth technique, a highly efficient process aimed at repurposing waste materials. This approach plays a pivotal role in curbing air pollution, specifically by preventing the incineration of the residual portion of paddy straw fiber on agricultural lands. The study involves the collection of paddy straw fiber from agricultural fields, with subsequent extraction facilitated by an extracting machine. Employing a chemical treatment process enhances the adhesion properties between the fiber and matrix. Consequently, comprehensive fiber tests, including the single fiber test, fiber tenacity, and fiber fineness, were meticulously examined for both treated and untreated fibers. The reinforcements and matrix were taken by the weight percentage of 50:50 with different fiber length (25, 50, 75, 100 mm) using the compression moulding machine with 300 mm × 300 mm × 3 mm dimensions. After making the laminates, the samples were cut as per the ASTM standard. The mechanical and morphological behavior of the hybrid fiber-reinforced polyester composites were evaluated, and the water absorption property in the concerned laminates was studied.

Effect of moisture on the sensing capabilities of piezoelectric actuator/sensor pairs on flax fibre reinforced composite laminates

The sensitivity of the piezoelectric actuators’ response to the moisture uptake has been investigated on flax fibre reinforced composite laminates. Non-woven flax fabric was impregnated with epoxy and composite laminates were fabricated using hand lay-up and cured in a compression moulding machine. The laminates were initially impacted with a drop-weight impact machine at a low energy level, with the aim to generate an artificial surface crack that will allow the moisture to enter the fibre-matrix interface more effectively. A set of piezoelectric actuators and sensors were adhered on the surfaces of the composite panels in a specific rectangular arrangement to allow for wave capturing at various directions. The wave characteristics of the samples were extracted in pristine stage and then the samples were impacted and immersed in distilled water until saturation. At regular intervals after the water immersion, the panels’ weight was measured using a laboratory scale and the wave propagation characteristics of the materials ware measured in order to investigate the gradual effect of moisture on the capabilities of the actuators and sensors. The propagation of stress waves in the dry and wet samples was investigated and the effect of moisture absorption was examined experimentally using piezoelectric wafers until the saturation was reached. Finally, a continuum damage mechanics layerwise time domain spectral finite element model, both for the composite laminate and the rich resin layers, was also developed to simulate the materials’ performance under impact and evaluate the wave propagation within the material at the dry state.

Experimental analysis of sugarcane and coconut shell fibre impregnated with glassfiber composite for aircraft application

Natural fibers' adaptability, sustainability, and environmental friendliness make them useful in a variety of sectors and applications. Sugarcane bagasse and coconut shell, which are made from industrial waste, have great promise as a sustainable substitute for traditional materials. How sugarcane bagasse, coconut shell, and glass fiber interact with an epoxy composite matrix is the subject of the present experimental investigation. The Semi Compression Moulding Machine (SCMM) was used to make the following compositions: 50 % matrix, 20 %-30 % sugarcane fiber, 10 %-25 % glass fiber, and 5 %-10 % coconut shell fiber. The ASTM-compliant composite plate structure that was built has a tensile strength ranging from 20 to 25 MPa and a tensile fatigue failure stress of 7 to 8 MPa, all tested over a range of 14,000 to 16,000 cycles. The scanning electron microscope (SEM) was used for morphology examination, while X-ray diffraction (XRD) was employed for crystalline properties. The use of natural fibers impregnated into glass fiber reinforced composites allowed for the creation of low density, very stable materials, which were essential for the skin and control surfaces of aircraft.

MICROSTRUCTURE OF CB/SIO2 HYBRID REINFORCED SOLID TYRE TREAD COMPOUND CONTAINING GROUND TYRE RUBBER AND THEIR EFFECT ON FATIGUE RESISTANCE

The possibility of improving the properties of rubber compounds containing ground tyre rubber (GTR) is an active research area. This study investigates the microstructure of carbon black filled tyre tread compound containing 20 phr GTR and compares the microstructure with those of similar compounds reinforced with hybrid carbon black/precipitated silica (CB/SiO2). In the compounds reinforced with hybrid filler, amount of the GTR was maintained at 20 phr, while the amount of the hybrid filler (CB/SiO2 ) were in the ratios 55/5, 50/10 and 45/15 respectively. The compounds were mixed by two-step mixing method using internal mixer and two-roll mill. The vulcanisation of each rubber compound was carried out on a compression moulding machine at 150. Results obtained from scanning electron microscopy of the fractured surfaces showed that the ingredients in the control sample that was not filled with GTR were well dispersed and distributed. The micrograph of the sample containing GTR and mixed at 60 showed that GTR was not very compatible with the matrix. Improved mixing was achieved with increased mixing temperature. The addition of precipitated silica at 5 phr resulted in poor dispersion. The dispersion improved as the amount of silica increased to 10 phr and 15 phr respectively. Results obtained from flex fatigue test show that the compounds filled with hybrid CB/SiO2 in the ratios 50/10 and 45/15 phr exhibited no crack after 1000 cycles due to good dispersion. It is recommended that hybrid CB/SiO2 reinforcement at optimal amount of silica should be utilised to fill rubber compounds containing GTR in order to improve the properties of the vulcanisates.

Hexagonal Boron Nitride Nanoplatelets Filled Polyphenylene Sulphide Nanocomposites: Influence on Thermal and Dielectric Properties

The Hexagonal Boron Nitride (hBN) nanoplatelets are synthesized using a wet chemical method. X-Ray Diffraction (XRD) shows the hBN nanoplatelets exfoliates along the (002) plane. Transmission Electron Microscope (TEM) observation shows the exfoliated hBN nanoplatelets. The hBN nanoplatelets and polyphenylene suulfiude (PPS) physical mixture are solvent processed using ethyl alcohol. It involves two step processing with the first step of ultrasonic treatment of hBN nanoplatelet in ethyl alcohol followed by mixing it with PPS powder and further sonication. This mixed powder of PPS and hBN nanoplatelets are hot pressed using a compression moulding machine. With more addition of hBN nanoplatelets in PPS matrix shows the enhancement in dielectric constant. In addition, the dispersion of hBN nanoplatelets in the PPS matrix increases the crystallinity and thermal stability.

MECHANICAL BEHAVIOUR OF CARBON AND JUTE FIBERS REINFORCED ALUMINIUM LAMINATES FABRICATED IN DIFFERENT STACKING SEQUENCES

In this research work, the mechanical properties of aluminium laminates having carbon fiber reinforcement and carbon-jute fibers reinforced aluminium laminates fabricated in different stacking sequences are studied. Here the fiber metal laminates are manufactured through the hand layup technique. A compression moulding machine was used to press the laminates during the production process. In this study, carbon and jute fibers along with thin aluminium sheets are used as reinforcement. Four different stacking sequences were selected. Each arrangement is symmetric and consists of ten layers of reinforcements. The fabricated laminates were subjected to tensile, compressive, flexural, hardness and impact tests. The test results show that the laminate L2 with outermost layers of carbon fibers revealed the highest tensile strength of 268 MPa, followed by L4 laminate with jute fibers outer layers having a tensile strength of 226 MPa. Whereas, the laminates L1 and L3 with outer layers of aluminium sheets show improved flexural and impact strength along with high hardness value. The flexural strengths are 246 MPa and 204 MPa respectively. Impact strength of 36 MPa, 32 MPa and hardness value of 64 HVN and 62 HVN respectively.

THE STUDY OF USING NATURAL FILLERS ON THE BIODEGRADATION PROPERTIES OF VIRGIN/WASTE LOW DENSITY POLYETHYLENE AND VIRGIN/WASTE HIGH DENSITY POLYETHYLENE COMPOSITES.

A study was carried out to check the effect of natural filler on the degradation properties of virgin and waste LDPE and virgin and waste HDPE. Samples were collected and compounded with Maleic Anhydride as a compatibilizer between the polymer matrix and PLA, starch and charcoal. Using the two-roll mix and the compression moulding machine for compounding, samples were moulded and cut according to specifications for the test. Tests carried out were done according to ASTM for water absorption, soil burial and QUV. Results showed as the amount of natural filler increased, it improved water absorption up to 42 days for both virgin LDPE and HDPE, while it took 180 days for samples with more percentage of natural fillers to record mass loss due to degradation. The SEM result confirmed a lot of cracks and holes as a result of immiscibility from the poly blends and which aided with high water absorption and degradation. The QUV results also showed degradation of all samples after exposure time in the accelerated weathering test.

Tribo-mechanical analysis of magnesium-based fibre metal laminates for structural applications

Fibre metal laminates (FML) play a significant role in the aircraft industry. The present work is to achieve a high load bearing structure and wear resistant FML for airbus cargo floors and doors. An innovative attempt has been made to reveal the mechanical and tribological properties of the FML (Glass/AZ91D/Glass). The glass fibre used is of bi-diagonal fabric to enhance the shear properties of the FML. The laminates were prepared by hand layup technique, which was post compressed to a uniform shape in the compression moulding machine. Mechanical tests such as tensile, flexural, and low-velocity impact were conducted on the FML samples. The mechanical properties of the magnesium-based FML exhibit an excellent tensile strength of 227.3 MPa, the flexural strength of 231.3 MPa, and the energy absorbed by the plate are 93.648 J. These results were promising, and comparatively better than the conventional laminates in the case of load bearing structures. The wear was tested in Pin-on-Disc and the wear resistance was also found to be better than conventional laminates. The micro-structural analysis along the wear regime shows a prominent wear resistance and fewer cracks, due to the presence of AZ91D in the laminates.

Influence of Nanofillers on the Mechanical Characteristics of Natural Fiber Reinforced Polymer Composites

For the first time, natural fibers are being considered as a viable alternative to traditional synthetic fibers. These bio-composites were created using epoxy resin, nano-sized fine nano-tamarind shell ash particles, and water hyacinth fibers in this experimental work. Nano tamarind shell ash particles (0, 1, 3, 5, 7, and 9 wt. percent) were mixed with epoxy resin and water hyacinth fibers to create six different composite mates by the compression moulding machine. The composite specimens are prepared from the mats using the water jet machining method, according to ASTM specifications. Mechanical properties of composite specimens have been determined using tensile, flexural, and impact tests under standard testing circumstances. According to the test results, the composites with nano tamarind shell ash particles in the weight percentage of five percent greatly improve their tensile and flexural capabilities. Increased incorporation of fine nano tamarind shell ash particles in composite specimens has reduced their impact energy and impact strength.

In-Situ Synthesis and Property Evaluation of High-Density Polyethylene Reinforced Groundnut Shell Particulate Composite

In-situ synthesis of high-density polyethylene (HDPE) reinforced groundnut shell particulate (GSP) composite with treated GSP within the range of 10-30 wt% at 10 wt% has been achieved. The adopted technique used in the production of the composite is melt mixing and compounding using two roll mills with a compression moulding machine. Properties such as hardness, tensile strength, impact energy and water absorption analysis were examined. The result revealed that addition of GSP increases the hardness value from 22.3 to 87 Hv. However, the tensile strength progressively decreased as the GSP increases in the HDPE. This trend arises due to the interaction between neighbouring reinforced particulate which appears to influence the matrix flow, thereby inducing embrittlement of the polymer matrix. It was also observed that water absorption rate steadily increased with an increase in the exposure time and the absorbed amount of water increases by increasing the wt% of the GSP. Analysing the obtained results, it was concluded that there were improvements in the hardness, tensile strength, impact energy and water absorption properties of the HDPE-GSP polymer composite when compared to unreinforced HDPE. On these premises, GSP was found as a promising reinforcement which can positively influence the HDPE properties of modern composites.

Effect of face sheet on the flexural and tensile characteristics in GLARE laminates

ABSTRACT The present study is carried out to study Glass Fibre Reinforced Aluminium Laminate (GLARE) structures and to evaluate their flexural and tensile properties. The GLARE specimens were fabricated using hand layup with vacuum bag moulding process wherein the aluminium sheets and E-Glass fibre woven mats of fixed thickness are bonded together by application of epoxy resins. Three different thicknesses of aluminium alloy (0.2 mm, 0.3 mm and 0.4 mm) Al-2024 T3 are used for the purpose of the study. The aluminium sheets are stacked together by application of epoxy resin between the sheets and are cured under a compression moulding machine under constant pressure. The overall thickness of the specimen is maintained constant for 2 mm. The samples were subjected to a three-point bending and tensile test as per ASTM D790 and ASTM D3039 standards, respectively, to evaluate their mechanical properties. The results indicate that the tensile strength of the composites is maximum for the specimen with aluminium 2024 T3 face sheet with a minimum thickness of 0.2 mm; however, with the increase in the thickness, the tensile strength is found to be decreasing.

Effect of Surface Modification on the Properties of Polypropylene Matrix Reinforced with Coir Fibre and Yam Peel Particulate.

Polypropylene composites reinforced with coir fibre and yam peel particulate were produced using compression moulding machine. Treated and untreated coir fibres were used; 1.5 M NaOH was used for the treated coir fibres. Yam peel was grouped into two, treated and untreated; the treated was modified using 1 M solution of NaOH and HCl in the proportion of 30% and 70%, respectively. The yam peel which was sun-dried for 14 days was pulverized and sieved to −45 µm. Samples were developed using treated and untreated reinforcements (TCF/YPP and UCF/YPP) at constant coir fibre proportion (15%) and varied amount of yam peel particulate (2, 4, 6, and 8 wt.%). The hybrid composite samples developed were probed for mechanical properties and thermal and wear behaviour. The level of particles agglomeration at the fibre-matrix interface was examined using scanning electron microscope. The results show that sample reinforced with treated 4 wt.% coir fibre and yam peel particulate had optimum mechanical properties. However, the thermal conductivity of composite samples increased with fibre addition. All composite samples developed had better resistance to abrasion when compared to the control sample.

Compressive properties of 3D braided flax fiber textile fabric reinforced PLA composites

In this study, fabric woven using 3D braided flax yarn is used to reinforce Poly Lactic Acid (PLA) composites. Solid braiding technique is used to convert the typical yarns into braided yarn and further these yarns are used to prepare woven fabric. Finally, composites are fabricated through layer stacking method using hot-press hydraulic compression moulding machine. Compression and shrinkage tests are performed on the braided composites. The braided flax fiber composite results are compared with the as received PLA polymer results. Results showed significant enhancement in the compression properties of PLA composites due to the braided fabric reinforcement. These properties are further increased with the increase in filler content respectively. Thermal shrinkage of the braided flax fiber composites is lower than the PLA polymer. This is due to the higher thermal sustainability property associated with the braided flax fiber.

Exploration on Mechanical Behaviours of Hyacinth Fibre Particles Reinforced Polymer Matrix‐Based Hybrid Composites for Electronic Applications

Biocomposites with polylactic acid (PLA), nanosilica parts, and water hyacinth fibres have been developed in this experimental study. By changing the weight percentage of nanosilica particulate matter (0, 2, 4, 6, and 8 percent) with PLA and water hyacinth fibres, five composite mates were produced through a double screw extruder and compression moulding machine. According to the ASTM standards, the process to machine, the composite specimens have been adopted from the water jet machining process. The tensile, compression, flexural, impact, hardness, and water absorption tests were performed on the composite specimens to assess various mechanical properties and absorbance behaviour. The test findings reveal the significant improvement in the tensile and flexural properties of the composites. Composites contain 6 percent of the fine nanosilica particles by weight. Concerning adding the growing weight percentage (4 percent) of nanosilica particles to the composites, the water absorption properties of the composites have significantly improved. The tensile strength of 6% nanosilica mixed specimens showed the highest tensile stress rate as 36.93 MPa; the value was nearly 3.5% higher than the 4% nanosilica mixed composite specimens.

Experimental investigation on mechanical properties of flax/banana/ industrial waste tea leaf fiber reinforced hybrid polymer composites

In the present research, work focus has been given to determine mechanical properties of biodegradable industrial waste tea leaf fiber (WTLF), banana and flax fiber reinforced hybrid polymer composites using experimental approach. Banana fibers and WTLF were alkali treated with 5% NaOH solution. The hybrid composite laminates were manufactured using manually operated compression moulding machine with the volume fraction of 40:60 (Fiber: Matrix). As per ASTM standard, the mechanical characteristics were studied. The experimental results showed excellent mechanical characteristics for 5 wt% WTLF and 25- wt% banana fiber reinforced hybrid composites. The fractography analysis of untreated and alkali treated composites were examined using Scanning Electron Microscopy (SEM) and results revealed that superior mechanical bonding existed between fiber and polymer in case of alkali treated fiber composites.

Characterization of Biocomposites from Polylactic Acid and Cellulose of Oil Palm Empty Fruit Bunch

<p class="western"><span lang="EN-GB">Biocomposites are polymers reinforced with natural fibers, such as cellulose. This research aims to synthesize cellulose from Oil Palm Empty Fruit Bunch (OPEFB) and biocomposites from PLA and cellulose. In this study, cellulose was obtained through alkalization, hydrolysis, and bleaching of OPEFB. Biocomposites production was carried out by mixing PLA and cellulose using the extrusion method. In the extrusion method, PLA and cellulose of OPEFB were mixed using an extruder above the melting point of PLA of 170°C. The output product of an extruder was then pressed using a compression moulding machine to form biocomposites. The tensile strength of biocomposites had a smaller value than pure PLA, whereas the modulus young of biocomposites with 5% by weight of cellulose had a higher value than pure PLA. The decrease in the mechanical properties of biocomposites was caused by poor adhesion between PLA and cellulose. The water absorption of biocomposites was greater than pure PLA, which was influenced by cellulose's characteristics as hydrophilic and PLA is hydrophobic. Also, the higher water absorption in biocomposites accelerated the weight loss of biodegradability.</span></p>

Mechanical property analysis on bamboo-glass fiber reinforced hybrid composite structures under different lamina orders

Natural fiber composites are playing the leading role in the recent research fields for their abundance of availability and comparable strength to weight ratio with the synthetic fiber composites. With this motivation, a low modulus fiber (bamboo fibers) hybridized with a high modulus fiber (Glass fibers) epoxy composites are taken for this work to evaluate their desirable mechanical properties. Usually strength of composite specimens is optimized by changing the ply orientation and volumetric ratio of fiber and matrix. But, in this analytics, a novel approach has been followed in which the hybrid composite laminates have been fabricated with five different lamina orders (B/B/B/B, B/G/B/B, G/B/G/B, G/B/G/G and G/G/G/G) using compression moulding machine. Various strength tests such as tensile, flexural and impact strength analyses have been performed. The strength values of the five specimens have been compared under the proposed loading conditions for choosing the better combination of hybrid composite structure exhibiting high strength. To validate the results, numerical analysis has also been made using ANSYS software.

Characterization of Sisal/Polypropylene Composites Treated with Plasma

In this study, sisal/polypropylene composites were experimentally investigated for their flexural, thermal and water absorption characteristics. The effect of oxygen (O), argon (Ar) and ammonia (NH3) plasmas on the surface of the sisal fibre as well as the effect of the sisal fibre content on the above mentioned properties was studied. The composite laminates (4 mm thick) were processed by hand lay-up technique by using a compression moulding machine, with the mould temperature of 165oC and the pressure of 6.89 x 102 kPa for 15 minutes. Specimen preparation and testing were carried out as per ASTM standards. Flexural data obtained showed that the plasma-treated sisal fibre-reinforced polypropylene offered superior flexural properties compared to untreated laminates, which indicated better adhesion between the sisal fibre and the untreated polypropylene matrix. Thermal investigations revealed that the sisal/polypropylene composite had its thermal stability in between that of the fibre and the matrix. Furthermore, the water absorption studies indicated that plasma treatment decreased the water uptake of the laminates, thereby leading to better fibre-matrix adhesion. Morphological studies were carried out by using SEM to complement the results.

Development of Ecofriendly Snail Shell Particulate-Reinforced Recycled Waste Plastic Composites for Automobile Application.

The increase in demand for thermoplastics as a light-weight material for automobile application and other commercial purposes prompts more research into the available polymer resources. In this research, the possibility of enhancing the performance of recycled waste plastics (RWP) as polymer-based composites was examined. Particulate snail shell was obtained by grounding and sieving snail shells to obtain 53–63 μm passing which was used as reinforcement in the recycled waste plastics. The composites were developed by adding varying proportions of the snail shell particulate (SSP) to RWP using a randomly dispersed process in a hot compression moulding machine maintained at 190°C for 7 min. Selected properties of SSP-reinforced RWP composites were examined. The results showed an appreciable enhancement in the properties of composites developed compared to an unreinforced RWP matrix that serves as control. The ultimate tensile strength was enhanced by about 64%, while Young's Modulus and impact strength were enhanced by 37% and 29%, respectively. Wear and water repellant potentials were highly enhanced with the addition of 15 wt% of SSP with values of about 52% and 91%, respectively. This revealed that high content of the SSP contributes to the improvement of the strain-hardening potentials of the developed composites. The results showed that this composite material can be suitably adapted for use in the interior of automobiles as door sills or the floor panel.