iv
TABLE OF CONTENTS PAGE
DECLARATION APPROVAL
DEDICATION ABSTRACT i
ABSTRAK ii ACKNOWLEDGEMENTS iii
TABLE OF CONTENTS
iv LIST OF TABLES
vii LIST OF FIGURES
ix LIST OF APPENDICES
xiv LIST OF ABBREVIATIONS
xv LIST OF PUBLICATIONS
xvii
CHAPTER 1.
INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 4
1.3 Objectives
6 1.4
Scope 6
1.5 Thesis Organization
7
2. LITERATURE REVIEW
8
2.1 Introduction
8 2.2
Composites 8
2.2.1 Metal Matrix Composite MMC 11
2.2.2 Ceramic Matrix Composite CMC 12
2.2.3 Polymer Matrix Composite PMC 12
2.2.3.1 Natural Fibre Reinforced Polymer Composites 13
2.3 Filler
14 2.3.1 Types of Reinforcement
17 2.3.2 Organic Fibre Reinforced Polymer Composites
18 2.3.3 Inorganic Fibre Reinforced Polymer Composites
23 2.3.4 Stone Wool
27 2.4
Matrices 30
2.4.1 Functions of the Matrix in Composites 31
2.4.2 Thermoset 32
2.4.3 Thermoplastic 32
2.4.3.1 Polyethylene 33
2.5 Finite Element Analysis FEA
36 2.5.1 Analysis System ANSYS
38 2.6
Summary 41
v
3. METHODOLOGY
43
3.1 Introduction
43 3.2 Preliminary
Investigations 45
3.2.1 Materials Selection 45
3.2.2.1 Matrix 45
3.2.2.2 Filler 46
3.2.3 Experimental Matrix 47
3.3 Processing of Composites
48 3.3.1 Filler Characterization
48 3.3.2 Polymer and Filler Treatment
50 3.3.2.1 Treatment for Polymer
50 3.3.2.2 Treatment for Filler
51 3.3.3 Compounding
53 3.3.4 Hot Compression Molding
54 3.3.5 Specimentation
56 3.4
Preliminary Experimental 57
3.5 Finite Element Modelling
57 3.5.1 Pre-Processing
58 3.5.2 Analysis
62 3.5.2.1 Formulation
64 3.5.3 Post-Processing
68 3.6
Mechanical Tests 69
3.6.1 Tensile Test 70
3.6.2 Flexural Test 72
3.6.3 Shore Hardness Test 74
3.7 Morphology Observation
76 3.8
Model Validation 77
3.9 Summary
77
4. RESULTS AND DISCUSSION
78
4.1 Introduction
78 4.2
Results of Modelling 78
4.2.1 Tensile Test 79
4.2.2 Flexural Test 82
4.3 Characterization of Composites
86 4.3.1 Tensile Properties
87 4.3.1.1 Yield Strength
89 4.3.1.2 Tensile Strength
90 4.3.1.3 Tensile Modulus
92 4.3.1.4 Ductility
94 4.3.1.5 Morphology Observation of Tensile Fracture Surface
95 a
20wt Stone Wool Reinforced HDPE 95
b 60wt Stone Wool Reinforced HDPE
97 4.3.1.6 Summary of Finding in Tensile Properties
98 4.3.2 Flexural Properties
101 4.3.2.1 Flexural Strength
103 4.3.2.2 Flexural Strain
104 4.3.2.3 Flexural Modulus
105
vi
4.3.2.4 Morphology Observation of Flexural Fracture Surface 107 a
20wt Stone Wool Reinforced HDPE 107
b 40wt Stone Wool Reinforced HDPE
108 c
60wt Stone Wool Reinforced HDPE 109
4.3.2.5 Summary of Finding in Flexural Properties 110
4.3.3 Hardness Properties 113
4.4 Model Validation
115 4.4.1 Distance between Fibre
115 4.4.2 Tensile Test
118 4.4.3 Flexural Test
121 4.5
Summary 124
5. CONCLUSION AND RECOMMENDATIONS FOR
