Mechanical Behavior & Water Absorption Of Metal Matrix Composite (Tin+Rice Husk) Fabricated Via Permanent Mould Casting (Experiment With 5% WT And 15% WT Rice Husk).

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MECHANICAL BEHAVIOR & WATER ABSORPTION OF METAL

MATRIX COMPOSITE (TIN+RICE HUSK) FABRICATED VIA

PERMANENT MOULD CASTING: (EXPERIMENT WITH 5%

WT AND 15% WT RICE HUSK)

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design) (Hons.)

SYED MUHAMMAD HAZWAN BIN SAYED ALI B050910259

890507015613

FACULTY OF MANUFACTURING ENGINEERING 2013

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∕

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: MECHANICAL BEHAVIOR & WATER ABSORPTION OF METAL MATRIX COMPOSITE (TIN+RICE HUSK) FABRICATED VIA PERMANENT MOULD CASTING: (EXPERIMENT WITH 5% WT AND 15% WT RICE HUSK)

SESI PENGAJIAN: 2012/13 Semester 2

Saya SYED MUHAMMAD HAZWAN BIN SAYED ALI

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan (√)

SULIT

TERHAD

∕ TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

No. 52, Lorong Bukit Setongkol 26, Perkampungan Cenderawasih,

25200 Kuantan,Pahang Darul Makmur Tarikh: _________________________

Disahkan oleh:

Cop Rasmi:

Tarikh: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

3rd June 2013

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DECLARATION

I hereby, declared this report entitled “Mechanical Behavior & Water Absorption of Metal Matrix Composite (Tin+Rice Husk) Fabricated via Permanent Mould Casting: (Experiment with 5% wt and 15% wt Rice Husk)” is the results of my own research

except as cited in references.

Signature : ………

Author’s Name : Syed Muhammad Hazwan Bin Sayed Ali

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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design) (Hons.). The members of the supervisory committee are as follow:

……… (Principal Supervisor)

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ABSTRAK

Projek ini bertajuk ‘Tindak Balas Mekanikal dan Penyerapan Air dari Bahan Campuran ( Timah + Serkam Padi) melalui Penuangan Acuan Kekal (Ujikaji meliputi: 5% wt and 15% wt Serkam Padi )’ bertujuan mengkaji sifat-sifat mekanik bahan untuk menghasilkan production tooling iaitu Edge Clamp. Objektif kajian ini adalah bertujuan untuk mencari komposisi yang paling sesuai dalam menghasilkan Edge Clamp antara timah dan serkam padi bagi menggantikan bahan yang sedia ada untuk membuat production tooling. Selain itu, penggabungan antara serat semula jadi (serkam padi) dan bahan logam (timah) dapat menghasilkan bahan yang bersifat teknologi hijau disamping dapat menjimatkan kos dan menguatkan lagi struktur logam tersebut. Projek ini dimulakan dengan merekabentuk berberapa spesimen sebagai uji kaji untuk mencari komposisi yang terbaik bagi menghasilkan Edge Clamp; dan antara ujian yang telah dibuat adalah ujian tegangan, ujian kekerasan, ujian penyerapan air dan ujian lenturan. Kerja-kerja merekabentuk spesimen dan acuan dibuat menggunakan SolidWork 2010 dengan merujuk standard ASTM memastikan semua proses itu akan berjalan dengan baik mengikut spesifikasi. Setelah merekabentuk acuan, proses pemotongan dilakukan dengan mengunakan pemotong laser di proses pembuatan. Dalam penghasilan spesimen, terdapat beberapa proses yang terlibat seperti proses tuangan dan proses mencampurkan bahan-bahan tersebut. Keputusan untuk semua ujian dibincangkan berdasarkan kekuatan mereka, ciri-ciri keanjalan dan kekerasan. Akhir sekali, komposisi bahan yang sesuai telah Berjaya diputuskan untuk menghasilkan Edge Clamp.

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ABSTRACT

The project entitled ‘Mechanical Behavior & Water Absorption of Metal Matrix Composite (Tin+Rice Husk) Fabricated via Permanent Mould Casting: (Experiment with 5% wt and 15% wt Rice Husk)’ attempts to investigate the mechanical properties of the material to produce production tooling that Edge Clamp. The objective of this study aims to find the most suitable composition to produce Edge Clamp between tin and rice husk to replace existing materials to make production tooling. In addition, the merger of natural fiber (rice husk) and metals (tin) can produce substances that are green technology beside able to save costs and strengthen the structure of the metal. This project started by fabricating the specimens as an experiment to find the best composition for producing Edge Clamp and; the tests that were done are the tensile test, hardness test, water absorption test and bending test. Specimen design works and mold design made using SolidWork 2010 by referring an ASTM standard to ensure that all processes will be running smoothly follow the specification. After designing, mold is translated from computer aided drawing to the actual shape using a laser cutting machine in the manufacturing process. In the production of specimens, there are several processes involved, such as casting and mixing the material. Discussion for all tests based on their strength, elasticity features and force. Finally, the suitable material composition successfully decided for producing Edge Clamp.

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DEDICATION

Specially dedicated to my family, Academic Supervisor, All my friends as well who have

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ACKNOWLEDGEMENT

Bissmillahirrahmanirrahim,

Alhamdulillah, with the source and guidance of ALLAH s.w.t, I managed to complete the final year project. It is always a pleasure to remind the fine people at Universiti Teknikal Malaysia Melaka (UTeM) for their sincere guidance I received to uphold my training as well as theoretical skills in engineering.

First and foremost, I would like to thank to my supervisor of this project, Mr. Hazman Bin Hasib for the valuable guidance and advice. He inspired me greatly to work on this project. His willingness to motivate me contributed tremendously to my project. I also would like to thank him for showing me some example that related to the topic of my project. Besides, I would like to thank the authority of Universiti Teknikal Malaysia Melaka (UTeM) for providing me with a good environment and facilities to complete this project. Besides that, I would like to thank Dr. Taufik who was abundantly helpful and offered invaluable assistance, support and guidance. Without his knowledge and assistance this study would not have been successful. Meanwhile, to my partner Nurfarahain Binti Mohd Fadzil who had given me her advices, opinions and suggestion in completing my final year project during 28 weeks of studies at Universiti Teknikal Malaysia Melaka (UTeM). I have benefited not only in technical skill but also in interpersonal skill.

Last but not least, deepest thanks and appreciation to my parents, family, special mate of mine, and others for their cooperation, encouragement, constructive suggestion and full of support for the report completion, from the beginning till the end. Also thanks to all of my friends and everyone, those have been contributed by supporting my work and help me during this final year project till it is fully completed.

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TABLE OF CONTENT

Abstrak i

Abstract ii Dedication iii

Acknowledgement iv Table of Content v List of Tables viii

List of Figures ix List Abbreviations, Symbols and Nomenclatures xi

CHAPTER 1: INTRODUCTION 1

1.1.Background 1

1.2.Problem statement 3 1.3.Scope 3 1.4.Objective 4 2. Gs CHAPTER 2: LITERATURE REVIEW 5

2.1.Workholding Devices 5 2.1.1. Edge Clamp 6

2.2.Material Selection for Clamp 7 2.2.1. Tin 7 2.2.1.1. Tin Application 9 2.2.2. Natural Fibers 9

2.2.2.1. Types of Natural Fibers 10

2.2.2.2. Natural Fiber Composites 11

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2.3.Type of Mechanical Testing 13

2.3.1. Tension 13

2.3.2. Compression 15

2.3.3. Torsion 15

2.3.4. Bending (Flexure) 16

2.3.5. Fatigue Testing 16

2.3.6. Hardness 17

2.4.Metal Casting 18

2.4.1. Sand Casting 18

2.4.2. Permanent Casting 20

CHAPTER 3: METHODOLOGY 22

3.1.Flow Chart 23

3.2.Problem Identification, Objective and Scope Research 24

3.3.Material Selection 24

3.4.Specimen Fabrication 25

3.4.1. 3D Drawing 25

3.4.2. Detail Drawing 27

3.4.3. Laser Cutting Process 27

3.4.4. Casting Process 29

3.4.5. Mechanical Testing 32

3.4.5.1. Tensile Test 33

3.4.5.2. Rockwell Hardness Test 35

3.4.5.2.1. Procedure of Rockwell Test 35

3.4.5.3. Flexural Test 38

3.4.5.4. Water Absorption Test 39

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CHAPTER 4: RESULT AND DISCUSSION 42

4.1.Specimen Mould 42

4.2.Specimen for Material Testing 43

4.3.Flexural Testing 45

4.4.Tensile Testing 49

4.5.Hardness Testing 53

4.6.Water Absorption Testing 56

CHAPTER 5: CONCLUSION AND RECOMMENDATION 58

5.1.Conclusion 58

5.2.Recommendation 59

REFERENCES 60

APPENDICES 64

A GANT CHART 64

B DETAIL DRAWING 66

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LIST OF TABLES

2.1 Material properties for Tin 8

2.2 Mechanical Properties of Natural Fibers 10

2.3 Main Composition of Rice Husk 12

3.1 Casting Process on specimen mould 29

3.2 Dimensions of Specimen for Tensile Test 34

3.3 Water Absorption Process 40

4.1 Dimension Specimen ASTM E 8M 45

4.2 Result for Flexural Test 46

4.3 Dimension Specimen ASTM E 8M 49

4.4 Result for Tensile Test 50

4.5 Results for 5% Composition Hardness Test 53

4.6 Results for 15% Composition Hardness Test 54

4.7 Results for 5% Composition Water Absorption Test 56

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LIST OF FIGURES

1.1 Example of Clamping on the Machine Working Table; 1 1) Clamping in the machine vice;

2) Clamping directly onto the machine table.

1.2 The classification of different natural fibers 2

2.1 Rice Husk 12

2.2 (a) A standard tensile-test specimen before and after pulling, 14

showing original and final gage lengths. (b) Stages in specimen behavior in a tension test 2.3 A typical torsion-test specimen; it is mounted between the 15

two heads of a testing machine and twisted 2.4 Two bend-test methods for brittle materials: 16

(a) three-point bending; (b) four-point bending 2.5 Typical Components of Two-part Sand Casting 19

2.6 Basic steps of sand molding in a flask with permanent pattern 20

2.7 Example of Permanent Casting 21

3.1 3D model specimen hardness and water absorption test 25

3.2 3D model specimen flexural test 26

3.3 3D model specimen tensile test 26

3.4 Stainless Steel Plate 28

3.5 Cutting Process by Laser Cutting Machine 28

3.6 Example of Universal Test Machine 33

3.7 Rockwell Hardness Tester 35

3.8 Rockwell hardness testing principle 36

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3.10 Testing Specimen 38

3.11 Example of Universal Test Machine with three points bending 39

Flexure fixtures 3.12 Example of Water Absorption Test 39

4.1 Specimens’ Mould before Casting 42

4.2 Pouring Molten Metal into the Mould 43

4.3 Tensile Test Specimen 44

4.4 Hardness and Water Absorption Test Specimen 44

4.5 Flexural Test Specimen 45

4.6 Result for Flexural Test 46

4.7 Sample of 5% composition flexural test 47

4.8 Sample of 15% composition flexural test 47

4.9 Tensile Testing 50

4.10 Sample of 5% composition tensile test 51

4.11 Sample of 15% composition tensile test 51

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LIST OF ABBREVIATION AND SYMBOLS

% - Percentage

° - Degree

2D - 2 dimensional

3D - 3 dimensional

Al - Aluminum

CAD - Computer Aided Design

Cm - centimetres

FDM - Fused Deposition Modelling

G - Grams

GPa - Giga Pascal

HV - Hardness - Vickers

J - Joule

J/kg.K - Joule per Kilogram.Kelvin

K - Kelvin

Kg - kilograms

kg/m3 - Kilogram per Meter cubic Kg/m-s - Kilogram per Meter Second-1 L x W x H - Length x Width x High

m - Meters

mm - millimetres

MPa - Mega Pascal

C - Degree Celcius

RP - Rapid Prototyping

Sn - Stannum (Tin)

STL - Stereolithography

UTeM - University Teknikal Malaysia Melaka USD/kg - US Dollar/Kilogram

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W/m.K - Watt per Meter.Kelvin

RH - Rice Husk

UTS - Universal Testing Machine

YS - Yield Strength

N - Newton

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CHAPTER 1 INTRODUCTION

1.1 Background

One of the work holding devices that is used to securely hold the position and prevent movement of the part against the locator throughout the machining cycle is a clamp. The term clamp is used when the tool is temporary use for positioning and holding components during working process. Some clamp is used for temporary, as in positioning component while others are intended to be permanent. The clamp must not damage or deform the part and must be strong enough to hold the part and to resist movement. The material used to produce the clamp must be from the high toughness and high hardness to prevent clamping force damaging or bending to part and some kind of recycle material can be used.

Figure 1.1: Example of Clamping on the Machine Working Table; 1) clamping in the machine vice; 2) clamping directly onto the machine table.

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For this project, Tin (Sn) was use as the main materials because the material is cheaper than other material and can recycled. Tin (Sn) have low hardness, low melting point, low toughness of material properties and high ductility of material; and because of that, involving the reinforced material Rice Husk Fibres is important to increase the hardness and strength. Natural fibre is a type of renewable sources and a new generation of reinforcements and supplements for polymer based materials (Mei-po Ho et. al., 2012).

Natural fibres can be divided based on their origin, derivations of plant, animal and mineral types which are detailed shown in Figure 1.2

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Natural fibre is one of the excellent reinforced materials that are tough and hard and have found to be a potential reinforcement. The different natural fibres sisal and rice husk fibres seem to be promising materials because of the high tensile strength of sisal fibre and the toughness of rice husk fibre (Jacob et. al., 2004).

1.2 Problem Statement

There is a major weakness in the edge clamp for milling table production in the current production tool design in the industry, and the weakness is the cost to produce the edge clamp is high. This is due to material use for edge clamps are made from metal such as stainless steel, carbon steel and other metals. The cost also includes the fabrication of the tools and the material. Other than that, even though the metals are one of the best materials for tooling production, but metal is not green technology material. This is the reason of use Tin as the composition in producing production tooling because it is easy to find, cheap and recyclable. As the rice husk is a natural fibre, it cannot stand alone to make a product and need combination with other metals such as Tin to make the properties much stronger than before. Therefore, in this report, the enhancement plans for quality improvement and cost reduction by applying Tin and Rice husk will be well proposed. For the process, sand casting process will be applied in this project because sand casting is one of the easier techniques of casting.

1.3 Scope

This final year project was mainly about the analysis of the composite material base on the composition between Tin (Sn) and Rice Husk Fibres that will apply in the experiment to get the suitable result in making production tooling. Besides that, an experiment will be conducted by making specimen to be test. In order to make the specimen, the process that involve is hot press. Other experiment and material will be not covered in this research because of time limitation. Besides that, design and analysis of the edge clamp, fabrication of edge clamp and fabrication of mold pattern using rapid prototype also will be not covered in this research.

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1.4 Objective

The objectives of this research are to:

1. To find the suitable composition between Tin (Sn) and Rice Husk Fibers 2. To test each of composition base on hardness, flexural, water absorption and

tensile strength.

3. To proposed the production tool design for edge clamp design with the suitable material.

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CHAPTER 2 LITERATURE REVIEW

The literature review is definitely to the ideas and knowledge on a topic that we cover. This chapter will briefly explain about the problem issue, research objective and the methodology that supported by the establish knowledge that review from journals, books articles and close source from the internet. In Chapter 2, project report provided the introduction to the specimen that used in order to make strap clamp. Hot press machine to make the specimen is reviewed in this chapter. Besides that, this chapter review of the types of testing will be used for this project such as tensile test, surface roughness test and hardness test. Furthermore, material properties of Tin, Rice Husk and Silicon Carbide which is the materials used to produce the clamp by using sand casting process also include in this chapter. The sand casting process also consists in this review but not to detail.

2.1 Workholding Devices

The term workholder, as applied to jig and fixture design, has designed to accommodate a variety of workpiece sizes and shapes. Chucks, collets, and vises are universal workholders. In general terms, the complete jig and fixture family is described as workholders. The term is used to identify the complete group of production tools. The main purpose of a workholder or clamping devices is to securely hold the position of the part against the locators throughout the machining cycle (Hoffman, 2004). To do this, the clamp used must meet the following conditions:

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1. The clamp must be strong enough to hold the part and resist movement 2. The clamp must not damage or deform the part.

3. The clamp should be fast-acting and allow rapid loading and unloading of parts.

The function of a clamp is to hold a part against the locators during the machining cycle. To be effective and efficient, clamps must be planned into the tool design. Some of clamping devices for milling and machining centres that is extensive to use are:

(a) Strap clamp (b) Cam clamp (c) Toggle Clamp (d) Push pull clamp (e) Edge clamp

2.1.1 Edge Clamp

The clamp should always contact the work at its most rigid point. This prevents the clamping force from bending or damaging the part. The part must be supported if the work is clamped at a point where the force could bend the part (Hoffman, 2004). Edge clamp in particular, for pressing edge parts onto the edges of workpieces extending between an upper side and an underside, comprising a clamp body, a first clamping jaw adapted to abut on the underside of the workpiece for fixing the clamp body on the workpiece and a means for generating clamping pressure by means of an actuating element for acting upon an edge pressure element acting on the edge part, which is as simple as possible to handle and can be fixed securely in position on the workpiece it is suggested that the clamp body have guide means, along which the clamp jaws are guided for displacement towards one another and away from one another and that a

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securing in position of the clamp body on the workpiece can be achieved by displacing the clamping jaws in the guide means in the direction towards the workpiece (Klimach et. al., 2000).

2.2 Material Selection for Clamp

Material selection is a step in the process of designing any physical object. In the context of material selection for clamp, the main goal is to minimize cost while meeting the suitable performance for the clamp. Systematic selection of the suitable material for a given application begins with properties and costs of candidate materials. The performance of an engineering element is limited by the properties of the material of which it is made, and by the shapes to which this material can be formed (Ashby and Cebon, 1993).

2.2.1 Tin

Tin is a silvery-gray metallic element which has been used by humans for thousands of years. The symbol is Sn, from the Latin stannum, and its atomic number is 50, placing it with other metals such as antimony and aluminum. Almost every continent on Earth has a source of tin, usually in the form of cassiterite, an oxide mineral. The word for the metal appears to have been borrowed from a pre-Indo-European language. Old forms of German and Dutch, among other languages, have cognates of the word, but the roots are somewhat unclear. The Tin is used in pure form in storage tanks for pharmaceutical chemical solutions, as electrodes of capacitors, and fuse wire and as organ pipes. The applications usually use alloyed with some lead

Cramb (2005) stated smelted copper had been rarely pure and it is clear that by 2500 B.C. The Sumerians had predicted that if different ores were blended together in the smelting process with a different type of copper, it will flow more easily and will stronger after forming and was easy to cast. In 2500 B.C., an axe head exposed that it contained 11% tin and 89% copper. This is the discovery of Bronze. Though, by 2000

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B.C. copper implements contained very little tin as local reserves of tin had been exhausted. The Sumerians were required to travel to find the necessary ores. Bronze was a much more useful alloy than copper as farm implements and weapons could be made from it. Nonetheless, it needed the discovery of tin to become the alloy of choice.

Table 2.1: Material properties for Tin (CES Cambridge)

General Properties

Density 7.26e3 -7.27 kg/m^3

Price 12.9 – 14.2 USD/kg

Mechanical Properties

Young modulus 41 – 45 GPa

Yield strength (elastic limit) 7 – 15 MPa

Tensile strength 11 – 18 MPa

Flexural strength (modulus of rupture) 30 – 40 MPa

Elongation 55 – 75 % strain

Hardness - Vickers 3 – 5 HV

Fatigue strength at 10^7 cycles 4 – 9 MPa

Fracture toughness 15 – 30 MPa.m^1/2

Thermal Properties

Melting point 230 – 232 °C

Maximum service temperature 90– 100 °C Thermal conductor or insulator Good conductor

Thermal conductivity 60 – 61.5 W/m.°C

Specific heat capacity 216 – 228 J/kg.°C

Electrical Properties

Electrical conductor or insulator Good conductor

Eco

Properties

Embodied energy, primary production 35 – 40 MJ/kg CO2 footprint, primary production 1.9 – 2 kg/kg

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1.2 Problem Statement

1.3 Scope

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4 1.4 Objective

The objectives of this research are to:

1. To find the suitable composition between Tin (Sn) and Rice Husk Fibers 2. To test each of composition base on hardness, flexural, water absorption and

tensile strength.

3. To proposed the production tool design for edge clamp design with the suitable material.

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CHAPTER 2

LITERATURE REVIEW

2.1 Workholding Devices

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1. The clamp must be strong enough to hold the part and resist movement 2. The clamp must not damage or deform the part.

3. The clamp should be fast-acting and allow rapid loading and unloading of parts.

(a) Strap clamp (b) Cam clamp (c) Toggle Clamp (d) Push pull clamp (e) Edge clamp

2.1.1 Edge Clamp

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securing in position of the clamp body on the workpiece can be achieved by displacing the clamping jaws in the guide means in the direction towards the workpiece (Klimach et. al., 2000).

2.2 Material Selection for Clamp

2.2.1 Tin

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Table 2.1: Material properties for Tin (CES Cambridge)

General Properties

Density 7.26e3 -7.27 kg/m^3

Price 12.9 – 14.2 USD/kg

Mechanical Properties

Young modulus 41 – 45 GPa

Yield strength (elastic limit) 7 – 15 MPa

Tensile strength 11 – 18 MPa

Flexural strength (modulus of rupture) 30 – 40 MPa

Elongation 55 – 75 % strain

Hardness - Vickers 3 – 5 HV

Fatigue strength at 10^7 cycles 4 – 9 MPa

Fracture toughness 15 – 30 MPa.m^1/2

Thermal Properties

Melting point 230 – 232 °C

Maximum service temperature 90– 100 °C Thermal conductor or insulator Good conductor Thermal conductivity 60 – 61.5 W/m.°C Specific heat capacity 216 – 228 J/kg.°C Electrical

Properties

Electrical conductor or insulator Good conductor

Eco

Properties

Embodied energy, primary production 35 – 40 MJ/kg CO2 footprint, primary production 1.9 – 2 kg/kg

Mechanical Behavior & Water Absorption Of Metal Matrix Composite (Tin+Rice Husk) Fabricated Via Permanent Mould Casting (Experiment With 5% WT And 15% WT Rice Husk).

UNIVERSITI TEKNIKAL MALAYSIA MELAKA