v
TABLE OF CONTENT
CHAPTER TOPIC
PAGES
Abstract Abstrak
Dedication Acknowledgement
iv Table of Content
v List of Tables
vii List of Figures
viii List of Abbreviations
List of Symbols ix
i ii
iii iv
v ix
x xii
xiv
1.0 INTRODUCTION
1
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scope 3
1.5 Rational of Research 4
1.6 Research Methodology 5
1.7 Thesis Frame 6
2.0 LITERATURE REVIEW
8
2.1 Introduction 8
2.2 Previous Invention of Plastic Mould 10
2.3 Mould 12
2.4 Plastic Materials 13
2.4.1 Thermoplastics 13
2.4.1.1 PVC Film 14
2.4.2 Thermosets 16
vi 2.4.2.1 Polyester Resin
18 2.4.2.2 Epoxy Resins
19 2.4.2.3 Summary of Resin
19 2.5 Fibres
20 2.6 Overview of Thermoset Composite Fabrication
21 2.6.1 Hand Lay Up Process
21 2.6.2 Spray Up Process
22 2.6.3 Vacuum Bag Autoclave Process
23 2.6.4 Resin Transfer Moulding Process
25 2.6.5 Vacuum Assisted Resin Infusion
Moulding VARIM Process 26
2.6.6 Summary of Thermoset Composite Fabrication
28
2.7 Non Destructive Testing 29
2.7.1 Visual Inspection 29
3.0 METHODOLOGY
30
3.1 Introduction 30
3.2 Methodology of Flow Chart 30
3.3 Materials Selection 31
3.3.1 PVC Film 32
3.3.2 Polyester Resin 33
3.4 Process Equipments 35
3.4.1 Woven roving fibreglass type E 35
3.4.2 Polyester resin
35 3.4.3
Hardener MEKP 35
3.4.4 Released agent gel coat
36 3.4.5
Plastic tape 36
3.4.6 Vacuum pump
36 3.4.7
Resin trap 36
3.4.8 Spherical tube
37 3.4.9
PU tube 37
3.5 Experimental Design 37
vii 3.5.1 Design 1: Simple Design
38 3.5.2 Design 2: Medium Design
38 3.5.3 Design 3: Complex Design
39 3.6 Processing
40 3.6.1 Original VARIM Process
40 3.6.2 Modification on VARIM Process
41 3.6.2.1 Procedures
44 3.7 Testing of the Product
45 3.7.1 Mould Capability
46 3.7.2 Surface Finish Quality
46 3.7.3 Complexity Manufacturing
48
4.0 EXPERIMENTAL WORKS OF NEW
TECHNIQUE 49
4.1 Introduction 49
4.2 Experimental Procedure 49
4.2.1 Simple Design Fabrication 50
4.2.2 Medium Design 52
4.2.3 Complex Design 54
5.0 RESULTS AND DISCUSSION
58
5.1 Introduction 58
5.2 Mould Capability Analysis 59
5.3 Surface Quality Analysis 62
5.4 Complexity Manufacturing Analysis 67
5.4.1 Design 1: Simple Design 68
5.4.2 Design 2: Medium Design 68
5.4.3 Design 3: Complex Design 69
5.5 Mechanical Properties Analysis 70
5.6 Summary of Analysis 72
viii
6.0 CONCLUSION AND RECOMMENDATIONS
