New Design Using Fiber Glass Composite (FRPC) For Jimny Back Door.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
NEW DESIGN USING FIBER GLASS COMPOSITE (FRPC) FOR
JIMNY BACK DOOR
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Material) with Honours.
by
AZIANASHIMA HEEDAYU BINTI ZAINAL
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
JUDUL: New Design Using Fiber Glass Composite (FRPC) for Jimny Back Door
SESI PENGAJIAN: 2009 Semester 2
Saya
AzianaShima Heedayu Binti Zainal
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1.
2.
3.
4.
Tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
*Sila tandakan (/)
(Mengandungi maklumat yang berdarjah keselamatan
SULIT
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
(AZIANASHIMA HEEDAYU ZAINAL)
Alamat Tetap:
(MOHD YUHAZRI YAAKOB)
Cop Rasmi:
No.9, Jalan Kempas 9/2,
Kawasan Kempas Baru,
81200 Johor Bahru, Johor.
Tarikh: _______________________
Tarikh: _______________________
* Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby declare that this report entitled “NEW DESIGN USING FIBER GLASS
COMPOSITE (FRPC) FOR JIMNY BACK DOOR” is the result of my own
research except as cited in the references.
Signature
:
…………………………………….
Author’s Name
:
AzianaShima Heedayu Binti Zainal
Date
:
22nd May 2009
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 (Engineering Material) with Honours. The member of the supervisory
committee is as follow:
.....................................................
Mohd Yuhazri Bin Yaakob
(Supervisor)
ABSTRACT
This research was finding a new material to replace deep actual material produce one
product a more quality to replace back door suzuki Jimny. This research had proposing a
composite form use of material substance as glass fiber reinforcement. Apart from that,
this research too was to study mechanical features from composite material which have
been proposed. This study had use resin polyester as binder and in the form of woven
roving. As many as six composite designs was developed according to the layer of fiber
glass 24, 18, 14, 12, 10 and 6 layers with its composite design. In each composite design
stated to be deducted follow ASTM's standard. Four types of experiments mechanical
nature have been made and produce with the best results for the composites material.
Arrangement 14 is the best layers of fiber glass has been chosen and have been given
based on data stated experiment after comparing with source material Jimny's back door.
The composite best arrangement had been used to develop back door of the Jimny’s
model. The comparing data between the actual material and the composite material
shows that the composites values are similar with the actual material. By choosing
material from composite can reducing the cost and weight of the Jimny back door itself.
i
ABSTRAK
Kajian ini telah dapat mencari satu bahan baru bagi menggantikan bahan sebenar dalam
menghasilkan satu produk yang lebih berkualiti untuk menggantikan pintu belakang
suzuki Jimny. Penyelidikan ini telah mencadangkan satu rekabentuk komposit
menggunakan bahan gentian kaca sebagai bahan tetulang. Selain itu, penyelidikan ini
juga telah mengkaji ciri-ciri mekanikal daripada bahan komposit yang telah
dicadangkan. Kajian ini telah menggunakan resin polyester sebagai bahan pengikat dan
gentian kaca dalam bentuk tenunan atau anyaman. Sebanyak enam rekabentuk komposit
telah dibangunkan mengikut bilangan lapisan iaitu 24, 18, 14, 12, 10 dan enam lapisan
bagi setiap rekabentuk komposit. Setiap rekabentuk komposit tersebut telah dipotong
mengikut piawaian ASTM. Sebanyak empat jenis ujikaji sifat mekanikal telah dilakukan
dan menghasilkan keputusan yang terbaik bagi bahan komposit. Susunan lapisan
sebanyak 14 lapisan adalah yang terbaik telah diberikan berdasarkan data ujikaji tersebut
setelah dibandingkan dengan bahan asal pintu belakang Jimny. Susunan terbaik
komposit tersebut telah digunakan bagi memhasilkan satu model pintu belakang Jimny.
Perbezaan data di antara bahan asal dan bahan komposit menunjukkan nilai komposit
adalah seakan sama dengan nilai asal bahan.
ii
DEDICATION
To my beloved parents
Hj. Zainal Bin Ya’cob
Hjh. Arba’ee Binti Othman
iii
ACKNOWLEDGEMENTS
ﺒﺴ ﷲ ﺍﻠﺮﺤ ﻦﺍﻠﺮﺤﻴ
The beneficent and the merciful of ALLAH who gives strength and ability to complete
this project and thesis proposal as it are today. My sincerest appreciation that I would
like to express goes to my supervisor, Mr. Mohd Yuhazri Bin Yaakob for guiding and
supervising my final year project throughout this semester. He has been working and
researching in his early age. He taught me the composites materials excellently. To the
technician and also to the other lecturer of Faculty Manufacturing Engineering who give
commitment during the research had been made. Their advice and assistance in various
ways have been extremely helpful. They all have been very kind and generous with their
knowledge as well as their experiences. Last but not least I want to thank all my friends
and also Khairul Nizam Bin Zainuddin that have gave me advice and encouragement in
completing my Projek Sarjana Muda (PSM). Thank you very much to all and May
ALLAH bless you.
iv
TABLE OF CONTENT
CHAPTER
1.0
2.0
TOPIC
PAGES
Abstract
i
Abstrak
ii
Acknowledgement
iii
Table of Content
iv
List of Tables
x
List of Figures
xi
List of Abbreviations
xiii
List of Symbols
xiv
INTRODUCTION
1
1.1
Background
1
1.2
Objectives
2
1.3
Scopes
2
1.4
Rational of Research
2
1.5
Problem Statement
3
1.6
Expected Result
4
1.7
Flow chart for PSM 1
5
1.8
Thesis Frame Arrangement
6
LITERATURE REVIEW
7
2.1
Fiber Reinforced Composite
7
2.1.1
8
2.2
Fiber Glass
Matrix Material
9
2.2.1
Polyester
9
2.2.2
Catalyst MEKP
12
v
2.3
The Role of Temperature on
Impact properties of Kevlar/Fiberglass
2.4
composite laminates
12
2.3.1
14
Conclusion
Development of Carbon/Epoxy
Structural Components for a
High Performance Vehicle
2.5
2.6
Theory of Electroplating Technique
15
2.4.1
19
Conclusion
Thermally Induced Deformation of
Laminated Composite Structures
20
2.5.1
22
Conclusion
Longitudinal and Transverse
Damping of Unidirectional Fibre
2.7
2.8
Composites
22
2.6.1
23
Conclusion
Delamination in FRP laminates with holes
under transverse Impact
24
2.7.1
26
Conclusion
Impact response of hand Lay up and
Vacuum Infusion Thick Glass
2.9
3.0
Reinforced Laminates
27
2.8.1
29
Conclusion
Summary of Literature Review
30
METHODOLOGY
32
3.1
Introduction
32
3.2
Research Methodology of Flow Chart
33
3.3
Mechanical Testing
35
3.3.1
Impact Test
35
3.3.2
Tensile Test
38
vi
5.0
6.0
Flexural Test
42
3.3.4
Hardness Test
44
3.4
Vacuum Infusion Method
3.5
Specimen Preparation and
3.6
4.0
3.3.3
46
Composite Design
50
Summary of Methodology
52
PROTOTYPE FABRICATION
54
4.1
54
Working Procedure of Making JBD
ANALYSIS AND DISCUSSIONS
57
5.1
Hardness Test Analysis
57
5.2
Impact Test Analysis
62
5.3
Tensile Test Analysis
68
5.4
Flexural Test Analysis
76
5.5
Bill of Material for Jimny Back Door
82
CONCLUSION AND RECOMMENDATION
85
6.0
Conclusion
85
6.1
Recommendation
86
REFERENCES
87
APPENDICES
A
Gantt chart PSM 1
B
Gantt chart PSM 2
C
Table 1 of the Failure in Impact Test
D
Table 2 of the Failure in Tensile Test
E
Table 3 of the Failure in Flexural Test
vii
LIST OF TABLES
NO
TITLE
PAGES
2.1
Thermal Coefficient of Expansion for Polyester
10
2.2
Temperature Effect and the physical behavior of polyester
11
2.3
Burning Effect and the statement of polyester
11
2.4
Laminate construction combinations for vacuum bagging
13
2.5
Stacking sequence of the laminate and thickness (t) of each ply
28
3.1
The type of failure for each specimen in impact test
38
3.2
Tensile specimen geometry requirements
39
3.3
Tensile specimen geometry recommendations
39
3.4
Specimen alignment and chord modulus calculation strain ranges
41
3.5
Averages of coefficients of variation
41
3.6
The Comparison of hardness test
45
5.1
The Hardness Test data for seven specimens with nine testing
59
5.2
The average from data of testing and the difference between averages
60
5.3
Data of Impact test for seven specimens
62
5.4
The Impact Strength formula in Impact test
63
5.5
The data Impact Strength for Impact test specimens
64
5.6
The data of Young Modulus, Force, Tensile Strength and Tensile Strain
70
5.7
The data of Force, Flexural Strength and Flexural Strain
78
5.8
Raw material cost for produced a plate of composite
83
viii
LIST OF FIGURES
NO
TITLE
PAGES
1.1
The specification of new and actual material for Jimny back door.
3
1.2
Stages for PSM 1
5
2.1
Fiber Glass type E
8
2.2
Polyester
9
2.3
Sample construction set-up for vacuum bagging
13
2.4
Micrographic cross-section of body panel
16
2.5
Bonded joint shear strength for carbon and glass fiber adherents for four
values of bond-line thickness; three values of laminate thickness;
three types of environmental preconditioning
17
2.6
The flow diagram of the surface certification of high performing vehicle
19
2.7
(a) unbalanced laminate uniform temperature increase and
(b) balanced laminate uniform temperature gradient
21
2.8
Layers model of a unidirectional composite
23
2.9
Eight nodded layered element
25
2.10
Splitting of laminae at the interface between the two resin systems and
impacted face of vinylester
29
3.1
Research Methodology Flow Chart
34
3.2
The flow chart diagram for testing implementers in laboratory
35
3.3
Geometry of specimen for Charpy
36
3.4
Impact test machine for Charpy with labeling
37
3.5
Gage location for system alignment check coupon
40
3.6
Tensile test specimen drawing
40
3.7
Universal testing machine
42
3.8
Flexural test with the three point loading test method
43
ix
3.9
The hardness scale
46
3.10
Vacuum pump for vacuum bagging
47
3.11
Resin trap
47
3.12
Spiral Tubing
48
3.13
Enkafusion nylon matting
48
3.14
Spring clamp and hose clamp
49
3.15
Composite design based on specimen preparation
52
4.1
The method in making the mold of Jimny
54
4.2
The mold of Jimny Back Door (JBD)
55
4.3
The steps in making the vacuum bagging for Jimny
55
4.4
The JImny afer the Vacuum process
56
4.5
The results of the Jimny produce excellently
56
5.1
The Hardness test in eight types of specimens with nine testing
60
5.2
The average value of seven types of specimen in nine testing
61
5.3
The average of the Impact Energy
63
5.4
The graph of the Impact Energy and the Impact Strength
65
5.5
Delamination failure of the Hinge Break
66
5.6
The complete break failure
66
5.7
The partial break failure
67
5.8
Impact energy and shear fracture of mild steel varies with temperature
68
5.9
Tensile graph of stress versus stroke strain
69
5.10
The compile data of Young Modulus in tensile test
71
5.11
The compile data of Force in tensile test
72
5.12
The compile data of Tensile Strength in tensile test
73
5.13
The compile data of Tensile Strain in tensile test
74
5.14
The failure of GAT
75
5.15
The failure of DGM
75
5.16
The failure of XGM
76
5.17
The position in testing the flexural test
76
x
5.18
Flexural graph of stress versus stroke strain
77
5.19
The force applied by bending on the specimen
77
5.20
The compile data of Force in flexural test
79
5.21
The compile data of Flexural Strength in flexural test
80
5.22
The compile data of Flexural Strain in flexural test
81
5.23
The delamination failure
81
5.24
The pull out failure
82
5.25
The slip failure
82
xi
LIST OF ABBREVIATIONS
ASTM
-
American Society for Testing and Materials
DI
-
Damage Index
E-glass
-
Electrical glass
FRC
-
Fiber Reinforced Composite
FRP
-
Fiber Reinforced Polymer
GRP
-
Glass Reinforced Plastic
HL
-
Hand Lay-up
ID
-
Inches Diameter
JBD
-
Jimny Back Door
MEKP
-
Methyl Ethyl Ketone Peroxide
PSM
-
Projek Sarjana Muda
QA
-
Quality Assurance
S-glass
-
Strength glass
UTeM
-
Universiti Teknikal Malaysia Melaka
UTM
-
Universal Testing Machine
UV
-
Ultra Violet
VI
-
Vacuum Infusion
3D
-
Three Dimension
xii
LIST OF SYMBOLS
°
-
Degree
±
-
plus minus
µ
-
micro
ε
-
Strain
%
-
Percent
Eb
-
Flexural modulus
m
-
Initial slope of the load vs. deflection curve
b
-
Width of beam tested
h
-
Thickness of beam tested
L
-
Specimen length between two support points
xiii
CHAPTER 1
INTRODUCTION
Jimny back door is the part of Suzuki Jimny model designing. The current
material of the jimny back door is a metal material that usually used in making
any type of vehicles. The shape of the jimny back door is quite in simple shape
with its specific dimension. The effect of the metal material condition is easily
to corrode and hence will produce more brittle in its mechanical properties.
Nowadays, corrosion matter must be preventing to ensure the materials
particularly made by metals mostly in all vehicles are capable to extend the
period of its life.
According to the type of fibers, the fiber glass was chosen to design the
materials. The reinforcement of a medium by a network of fibers has evolved in
the living world to be the natural solution for structures which respond to and
resist mechanical stresses. Besides, the thicknesses of the fiber laminate are the
most influences to the physical properties in making Jimny back door.
This research can be proven that the fiber glass is the qualify material hence
most appropriate material and suitable compare to the metal by performing
multiple tests such as tensile test, flexural test, impact test and hardness test.
The fiber glass have been strongly proven and verify because the usage of this
material in modifying the shape in any vehicle with multiple part as the
accessories for the vehicles. In designing jimny back door using fiber glass
strongly can be produce excellently.
1
1.2
Objectives:
(a)
Propose a new composite design using synthetic fiber material for Jimny
Back Door.
(b)
Test and analyze of the proposed composite on mechanical properties.
(c)
New design for Jimny back door using the proposed composite material.
1.3
Scopes:
(a)
Literature review on existing Jimny back door.
(b)
Study on synthetic fiber available in automotive industrial.
(c)
Study the matrix for using hand layout or vacuum infusion technique.
(d)
Study mechanical properties such as tensile, hardness, impact, flexural.
(e)
Developed prototype of Jimny back door by using the proposed design.
1.4
Rational of Research:
(a)
To find a material for replacing the actual material in produces a best
material and efficient for Jimny back door.
(b)
Shown a potential of FRP in the industrial field of automotive that can
be used widely.
(c)
Reduce materials cost in making high performance vehicles body plane.
2
1.5
Problem Statement:
The comparing for current material of metal and the new material of fiber glass
shows the problems that can be state and be solving in making the best way of
upgrading the Jimny back door. Fiber glass is better to be used in many
specifications and their properties in mechanical and physical.
Light in
Weight
(effect load
on vehicle)
High
perform
hardness on
surface
Uniform
fiber easily
made shapes
Hard to
corrode
attack by
environment
Cheaper
cost in
materials
used
Fiberglass
Metal
Easy to
corrode
attack by
environment
Cost of
materials is
expensive
Heavy in
weight
(effect load
on vehicle)
Surface
easier to
dent from
hard impact
Not
uniformly to
be made
shapes
Figure 1.1: The specification of new material of fiberglass and the actual material of metal for
Jimny back door (Anonymous, 2005).
From the diagram in Figure 1.1 shown, the comparison can be made between
the current metal material of Jimny back door and the new material of fiber
3
glass reinforcement that used. In describing the diagram, the fiber glass is hard
to be corroding when having an attack by the environment compare to the metal
material which easily corroded as defined as the destruction or deterioration of a
material because of reaction with its environment.
The light weight of the fiber glass makes the material highly easy to use and
decreasing the load on the vehicle. The metal are high in weight thus the
material will increasing the vehicle’s load. Increasing the vehicle’s load will
increase the petrol usage besides effect in handling the vehicle. Other than that,
the fiber glass can protect it shape and surface by high perform in hardness even
though the material is more brittle compare to the metal material. The metal are
easily be dent in hard impact on the material shape and surface.
In other hand, the material of fiber glass easily be uniform in any shapes by
followed the molding specification while the material use more cheaper in cost
and not as expensive as the metal material which are cannot be uniformly
shaped.
1.6
Expected Result
A composite material reinforced by fiber glass in the form of woven roving can
be produced based on the best layer number to replace the actual material of
Jimny back door.
4
1.7
Flow Chart for PSM 1
Choose Topic of PSM and supervisor
Meeting with supervisor for the topic that
been choose last week
Starts making introduction, objective and
scopes of research.
Submit, discuss
introduction with
supervisor.
No
Yes
Find relevant Literature review and do an
analysis
Proceed with Gantt chart, flow chart,
rational of research and problem statement
Searching journal for literature review in
Chapter 2
No
Validated
Yes
Find those tests in lab and equipment
needed
Preparation PSM 1 report and oral
presentation
A
Figure 1.2: Stage for PSM 1
5
1.8
Thesis Frame Arrangement
This project is done with 6 main chapters which are introduction, literature
review, methodology, design, result and discussion.
Chapter one briefly
explained the objective, scope, problem statement, rational of research, research
methodology and research frame arrangement.
Chapter two is a literature
review which consist the definition of fiber reinforced composite (FRC), raw
material of woven roving and matrix material, vacuum infusion technique and
some of the previous research for fiber reinforced polymer (FRP). Chapter
three is mentioned about how the way of project whereas stated the method and
technique that will be used from beginning process until final process. The
chapter also included the test and analyze for the product. In chapter four will
precede the new design with accurate dimensions using CATIA software to
produce the product. For chapter five, all the gathered result based on the test of
the specimens and fiber reinforced composite properties is attached.
For
chapter six, it will be discussed and analysis the fiber reinforced composite
properties on the specimens that already carried out. Here, the best specimen
condition to inhibit the impact, tensile, flexural and hardness tests will obtain
according to ASTM.
6
NEW DESIGN USING FIBER GLASS COMPOSITE (FRPC) FOR
JIMNY BACK DOOR
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Material) with Honours.
by
AZIANASHIMA HEEDAYU BINTI ZAINAL
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
JUDUL: New Design Using Fiber Glass Composite (FRPC) for Jimny Back Door
SESI PENGAJIAN: 2009 Semester 2
Saya
AzianaShima Heedayu Binti Zainal
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1.
2.
3.
4.
Tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
*Sila tandakan (/)
(Mengandungi maklumat yang berdarjah keselamatan
SULIT
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
(AZIANASHIMA HEEDAYU ZAINAL)
Alamat Tetap:
(MOHD YUHAZRI YAAKOB)
Cop Rasmi:
No.9, Jalan Kempas 9/2,
Kawasan Kempas Baru,
81200 Johor Bahru, Johor.
Tarikh: _______________________
Tarikh: _______________________
* Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby declare that this report entitled “NEW DESIGN USING FIBER GLASS
COMPOSITE (FRPC) FOR JIMNY BACK DOOR” is the result of my own
research except as cited in the references.
Signature
:
…………………………………….
Author’s Name
:
AzianaShima Heedayu Binti Zainal
Date
:
22nd May 2009
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 (Engineering Material) with Honours. The member of the supervisory
committee is as follow:
.....................................................
Mohd Yuhazri Bin Yaakob
(Supervisor)
ABSTRACT
This research was finding a new material to replace deep actual material produce one
product a more quality to replace back door suzuki Jimny. This research had proposing a
composite form use of material substance as glass fiber reinforcement. Apart from that,
this research too was to study mechanical features from composite material which have
been proposed. This study had use resin polyester as binder and in the form of woven
roving. As many as six composite designs was developed according to the layer of fiber
glass 24, 18, 14, 12, 10 and 6 layers with its composite design. In each composite design
stated to be deducted follow ASTM's standard. Four types of experiments mechanical
nature have been made and produce with the best results for the composites material.
Arrangement 14 is the best layers of fiber glass has been chosen and have been given
based on data stated experiment after comparing with source material Jimny's back door.
The composite best arrangement had been used to develop back door of the Jimny’s
model. The comparing data between the actual material and the composite material
shows that the composites values are similar with the actual material. By choosing
material from composite can reducing the cost and weight of the Jimny back door itself.
i
ABSTRAK
Kajian ini telah dapat mencari satu bahan baru bagi menggantikan bahan sebenar dalam
menghasilkan satu produk yang lebih berkualiti untuk menggantikan pintu belakang
suzuki Jimny. Penyelidikan ini telah mencadangkan satu rekabentuk komposit
menggunakan bahan gentian kaca sebagai bahan tetulang. Selain itu, penyelidikan ini
juga telah mengkaji ciri-ciri mekanikal daripada bahan komposit yang telah
dicadangkan. Kajian ini telah menggunakan resin polyester sebagai bahan pengikat dan
gentian kaca dalam bentuk tenunan atau anyaman. Sebanyak enam rekabentuk komposit
telah dibangunkan mengikut bilangan lapisan iaitu 24, 18, 14, 12, 10 dan enam lapisan
bagi setiap rekabentuk komposit. Setiap rekabentuk komposit tersebut telah dipotong
mengikut piawaian ASTM. Sebanyak empat jenis ujikaji sifat mekanikal telah dilakukan
dan menghasilkan keputusan yang terbaik bagi bahan komposit. Susunan lapisan
sebanyak 14 lapisan adalah yang terbaik telah diberikan berdasarkan data ujikaji tersebut
setelah dibandingkan dengan bahan asal pintu belakang Jimny. Susunan terbaik
komposit tersebut telah digunakan bagi memhasilkan satu model pintu belakang Jimny.
Perbezaan data di antara bahan asal dan bahan komposit menunjukkan nilai komposit
adalah seakan sama dengan nilai asal bahan.
ii
DEDICATION
To my beloved parents
Hj. Zainal Bin Ya’cob
Hjh. Arba’ee Binti Othman
iii
ACKNOWLEDGEMENTS
ﺒﺴ ﷲ ﺍﻠﺮﺤ ﻦﺍﻠﺮﺤﻴ
The beneficent and the merciful of ALLAH who gives strength and ability to complete
this project and thesis proposal as it are today. My sincerest appreciation that I would
like to express goes to my supervisor, Mr. Mohd Yuhazri Bin Yaakob for guiding and
supervising my final year project throughout this semester. He has been working and
researching in his early age. He taught me the composites materials excellently. To the
technician and also to the other lecturer of Faculty Manufacturing Engineering who give
commitment during the research had been made. Their advice and assistance in various
ways have been extremely helpful. They all have been very kind and generous with their
knowledge as well as their experiences. Last but not least I want to thank all my friends
and also Khairul Nizam Bin Zainuddin that have gave me advice and encouragement in
completing my Projek Sarjana Muda (PSM). Thank you very much to all and May
ALLAH bless you.
iv
TABLE OF CONTENT
CHAPTER
1.0
2.0
TOPIC
PAGES
Abstract
i
Abstrak
ii
Acknowledgement
iii
Table of Content
iv
List of Tables
x
List of Figures
xi
List of Abbreviations
xiii
List of Symbols
xiv
INTRODUCTION
1
1.1
Background
1
1.2
Objectives
2
1.3
Scopes
2
1.4
Rational of Research
2
1.5
Problem Statement
3
1.6
Expected Result
4
1.7
Flow chart for PSM 1
5
1.8
Thesis Frame Arrangement
6
LITERATURE REVIEW
7
2.1
Fiber Reinforced Composite
7
2.1.1
8
2.2
Fiber Glass
Matrix Material
9
2.2.1
Polyester
9
2.2.2
Catalyst MEKP
12
v
2.3
The Role of Temperature on
Impact properties of Kevlar/Fiberglass
2.4
composite laminates
12
2.3.1
14
Conclusion
Development of Carbon/Epoxy
Structural Components for a
High Performance Vehicle
2.5
2.6
Theory of Electroplating Technique
15
2.4.1
19
Conclusion
Thermally Induced Deformation of
Laminated Composite Structures
20
2.5.1
22
Conclusion
Longitudinal and Transverse
Damping of Unidirectional Fibre
2.7
2.8
Composites
22
2.6.1
23
Conclusion
Delamination in FRP laminates with holes
under transverse Impact
24
2.7.1
26
Conclusion
Impact response of hand Lay up and
Vacuum Infusion Thick Glass
2.9
3.0
Reinforced Laminates
27
2.8.1
29
Conclusion
Summary of Literature Review
30
METHODOLOGY
32
3.1
Introduction
32
3.2
Research Methodology of Flow Chart
33
3.3
Mechanical Testing
35
3.3.1
Impact Test
35
3.3.2
Tensile Test
38
vi
5.0
6.0
Flexural Test
42
3.3.4
Hardness Test
44
3.4
Vacuum Infusion Method
3.5
Specimen Preparation and
3.6
4.0
3.3.3
46
Composite Design
50
Summary of Methodology
52
PROTOTYPE FABRICATION
54
4.1
54
Working Procedure of Making JBD
ANALYSIS AND DISCUSSIONS
57
5.1
Hardness Test Analysis
57
5.2
Impact Test Analysis
62
5.3
Tensile Test Analysis
68
5.4
Flexural Test Analysis
76
5.5
Bill of Material for Jimny Back Door
82
CONCLUSION AND RECOMMENDATION
85
6.0
Conclusion
85
6.1
Recommendation
86
REFERENCES
87
APPENDICES
A
Gantt chart PSM 1
B
Gantt chart PSM 2
C
Table 1 of the Failure in Impact Test
D
Table 2 of the Failure in Tensile Test
E
Table 3 of the Failure in Flexural Test
vii
LIST OF TABLES
NO
TITLE
PAGES
2.1
Thermal Coefficient of Expansion for Polyester
10
2.2
Temperature Effect and the physical behavior of polyester
11
2.3
Burning Effect and the statement of polyester
11
2.4
Laminate construction combinations for vacuum bagging
13
2.5
Stacking sequence of the laminate and thickness (t) of each ply
28
3.1
The type of failure for each specimen in impact test
38
3.2
Tensile specimen geometry requirements
39
3.3
Tensile specimen geometry recommendations
39
3.4
Specimen alignment and chord modulus calculation strain ranges
41
3.5
Averages of coefficients of variation
41
3.6
The Comparison of hardness test
45
5.1
The Hardness Test data for seven specimens with nine testing
59
5.2
The average from data of testing and the difference between averages
60
5.3
Data of Impact test for seven specimens
62
5.4
The Impact Strength formula in Impact test
63
5.5
The data Impact Strength for Impact test specimens
64
5.6
The data of Young Modulus, Force, Tensile Strength and Tensile Strain
70
5.7
The data of Force, Flexural Strength and Flexural Strain
78
5.8
Raw material cost for produced a plate of composite
83
viii
LIST OF FIGURES
NO
TITLE
PAGES
1.1
The specification of new and actual material for Jimny back door.
3
1.2
Stages for PSM 1
5
2.1
Fiber Glass type E
8
2.2
Polyester
9
2.3
Sample construction set-up for vacuum bagging
13
2.4
Micrographic cross-section of body panel
16
2.5
Bonded joint shear strength for carbon and glass fiber adherents for four
values of bond-line thickness; three values of laminate thickness;
three types of environmental preconditioning
17
2.6
The flow diagram of the surface certification of high performing vehicle
19
2.7
(a) unbalanced laminate uniform temperature increase and
(b) balanced laminate uniform temperature gradient
21
2.8
Layers model of a unidirectional composite
23
2.9
Eight nodded layered element
25
2.10
Splitting of laminae at the interface between the two resin systems and
impacted face of vinylester
29
3.1
Research Methodology Flow Chart
34
3.2
The flow chart diagram for testing implementers in laboratory
35
3.3
Geometry of specimen for Charpy
36
3.4
Impact test machine for Charpy with labeling
37
3.5
Gage location for system alignment check coupon
40
3.6
Tensile test specimen drawing
40
3.7
Universal testing machine
42
3.8
Flexural test with the three point loading test method
43
ix
3.9
The hardness scale
46
3.10
Vacuum pump for vacuum bagging
47
3.11
Resin trap
47
3.12
Spiral Tubing
48
3.13
Enkafusion nylon matting
48
3.14
Spring clamp and hose clamp
49
3.15
Composite design based on specimen preparation
52
4.1
The method in making the mold of Jimny
54
4.2
The mold of Jimny Back Door (JBD)
55
4.3
The steps in making the vacuum bagging for Jimny
55
4.4
The JImny afer the Vacuum process
56
4.5
The results of the Jimny produce excellently
56
5.1
The Hardness test in eight types of specimens with nine testing
60
5.2
The average value of seven types of specimen in nine testing
61
5.3
The average of the Impact Energy
63
5.4
The graph of the Impact Energy and the Impact Strength
65
5.5
Delamination failure of the Hinge Break
66
5.6
The complete break failure
66
5.7
The partial break failure
67
5.8
Impact energy and shear fracture of mild steel varies with temperature
68
5.9
Tensile graph of stress versus stroke strain
69
5.10
The compile data of Young Modulus in tensile test
71
5.11
The compile data of Force in tensile test
72
5.12
The compile data of Tensile Strength in tensile test
73
5.13
The compile data of Tensile Strain in tensile test
74
5.14
The failure of GAT
75
5.15
The failure of DGM
75
5.16
The failure of XGM
76
5.17
The position in testing the flexural test
76
x
5.18
Flexural graph of stress versus stroke strain
77
5.19
The force applied by bending on the specimen
77
5.20
The compile data of Force in flexural test
79
5.21
The compile data of Flexural Strength in flexural test
80
5.22
The compile data of Flexural Strain in flexural test
81
5.23
The delamination failure
81
5.24
The pull out failure
82
5.25
The slip failure
82
xi
LIST OF ABBREVIATIONS
ASTM
-
American Society for Testing and Materials
DI
-
Damage Index
E-glass
-
Electrical glass
FRC
-
Fiber Reinforced Composite
FRP
-
Fiber Reinforced Polymer
GRP
-
Glass Reinforced Plastic
HL
-
Hand Lay-up
ID
-
Inches Diameter
JBD
-
Jimny Back Door
MEKP
-
Methyl Ethyl Ketone Peroxide
PSM
-
Projek Sarjana Muda
QA
-
Quality Assurance
S-glass
-
Strength glass
UTeM
-
Universiti Teknikal Malaysia Melaka
UTM
-
Universal Testing Machine
UV
-
Ultra Violet
VI
-
Vacuum Infusion
3D
-
Three Dimension
xii
LIST OF SYMBOLS
°
-
Degree
±
-
plus minus
µ
-
micro
ε
-
Strain
%
-
Percent
Eb
-
Flexural modulus
m
-
Initial slope of the load vs. deflection curve
b
-
Width of beam tested
h
-
Thickness of beam tested
L
-
Specimen length between two support points
xiii
CHAPTER 1
INTRODUCTION
Jimny back door is the part of Suzuki Jimny model designing. The current
material of the jimny back door is a metal material that usually used in making
any type of vehicles. The shape of the jimny back door is quite in simple shape
with its specific dimension. The effect of the metal material condition is easily
to corrode and hence will produce more brittle in its mechanical properties.
Nowadays, corrosion matter must be preventing to ensure the materials
particularly made by metals mostly in all vehicles are capable to extend the
period of its life.
According to the type of fibers, the fiber glass was chosen to design the
materials. The reinforcement of a medium by a network of fibers has evolved in
the living world to be the natural solution for structures which respond to and
resist mechanical stresses. Besides, the thicknesses of the fiber laminate are the
most influences to the physical properties in making Jimny back door.
This research can be proven that the fiber glass is the qualify material hence
most appropriate material and suitable compare to the metal by performing
multiple tests such as tensile test, flexural test, impact test and hardness test.
The fiber glass have been strongly proven and verify because the usage of this
material in modifying the shape in any vehicle with multiple part as the
accessories for the vehicles. In designing jimny back door using fiber glass
strongly can be produce excellently.
1
1.2
Objectives:
(a)
Propose a new composite design using synthetic fiber material for Jimny
Back Door.
(b)
Test and analyze of the proposed composite on mechanical properties.
(c)
New design for Jimny back door using the proposed composite material.
1.3
Scopes:
(a)
Literature review on existing Jimny back door.
(b)
Study on synthetic fiber available in automotive industrial.
(c)
Study the matrix for using hand layout or vacuum infusion technique.
(d)
Study mechanical properties such as tensile, hardness, impact, flexural.
(e)
Developed prototype of Jimny back door by using the proposed design.
1.4
Rational of Research:
(a)
To find a material for replacing the actual material in produces a best
material and efficient for Jimny back door.
(b)
Shown a potential of FRP in the industrial field of automotive that can
be used widely.
(c)
Reduce materials cost in making high performance vehicles body plane.
2
1.5
Problem Statement:
The comparing for current material of metal and the new material of fiber glass
shows the problems that can be state and be solving in making the best way of
upgrading the Jimny back door. Fiber glass is better to be used in many
specifications and their properties in mechanical and physical.
Light in
Weight
(effect load
on vehicle)
High
perform
hardness on
surface
Uniform
fiber easily
made shapes
Hard to
corrode
attack by
environment
Cheaper
cost in
materials
used
Fiberglass
Metal
Easy to
corrode
attack by
environment
Cost of
materials is
expensive
Heavy in
weight
(effect load
on vehicle)
Surface
easier to
dent from
hard impact
Not
uniformly to
be made
shapes
Figure 1.1: The specification of new material of fiberglass and the actual material of metal for
Jimny back door (Anonymous, 2005).
From the diagram in Figure 1.1 shown, the comparison can be made between
the current metal material of Jimny back door and the new material of fiber
3
glass reinforcement that used. In describing the diagram, the fiber glass is hard
to be corroding when having an attack by the environment compare to the metal
material which easily corroded as defined as the destruction or deterioration of a
material because of reaction with its environment.
The light weight of the fiber glass makes the material highly easy to use and
decreasing the load on the vehicle. The metal are high in weight thus the
material will increasing the vehicle’s load. Increasing the vehicle’s load will
increase the petrol usage besides effect in handling the vehicle. Other than that,
the fiber glass can protect it shape and surface by high perform in hardness even
though the material is more brittle compare to the metal material. The metal are
easily be dent in hard impact on the material shape and surface.
In other hand, the material of fiber glass easily be uniform in any shapes by
followed the molding specification while the material use more cheaper in cost
and not as expensive as the metal material which are cannot be uniformly
shaped.
1.6
Expected Result
A composite material reinforced by fiber glass in the form of woven roving can
be produced based on the best layer number to replace the actual material of
Jimny back door.
4
1.7
Flow Chart for PSM 1
Choose Topic of PSM and supervisor
Meeting with supervisor for the topic that
been choose last week
Starts making introduction, objective and
scopes of research.
Submit, discuss
introduction with
supervisor.
No
Yes
Find relevant Literature review and do an
analysis
Proceed with Gantt chart, flow chart,
rational of research and problem statement
Searching journal for literature review in
Chapter 2
No
Validated
Yes
Find those tests in lab and equipment
needed
Preparation PSM 1 report and oral
presentation
A
Figure 1.2: Stage for PSM 1
5
1.8
Thesis Frame Arrangement
This project is done with 6 main chapters which are introduction, literature
review, methodology, design, result and discussion.
Chapter one briefly
explained the objective, scope, problem statement, rational of research, research
methodology and research frame arrangement.
Chapter two is a literature
review which consist the definition of fiber reinforced composite (FRC), raw
material of woven roving and matrix material, vacuum infusion technique and
some of the previous research for fiber reinforced polymer (FRP). Chapter
three is mentioned about how the way of project whereas stated the method and
technique that will be used from beginning process until final process. The
chapter also included the test and analyze for the product. In chapter four will
precede the new design with accurate dimensions using CATIA software to
produce the product. For chapter five, all the gathered result based on the test of
the specimens and fiber reinforced composite properties is attached.
For
chapter six, it will be discussed and analysis the fiber reinforced composite
properties on the specimens that already carried out. Here, the best specimen
condition to inhibit the impact, tensile, flexural and hardness tests will obtain
according to ASTM.
6