Characterization of Fiber Reinforced Epoxy Matrix Composites with Sintered Bronze and Graphite Fillers

Abstract

The characterization of new materials is essential to fulfill the industrial demand these days. Extensive research work in the field of material science and metallurgy is going on across the world. Development of composite material is the area of interest of the researchers and laboratories. Composite material is developed by combining two or more dissimilar materials and the resultant composite exhibits superior properties. The composite materials are popular in various engineering applications like automobiles, aircraft structures and sporting goods. Polymer Matrix Composite has widespread applications due their advantages like high wear resistance, low coefficient of friction, low density, high strength to weight ratio and low cost. In this study an attempt is made to develop polymer matrix composite material for tribological application. The major requirement of material for tribological application is its high wear resistance and low friction coefficient. To achieve these requirements sintered bronze and solid lubricant, graphite is selected as filler material. Epoxy resin is selected as matrix material because of its low shrinkage, high strength and high adhesive strength properties. Epoxies can be formulated with other materials. Reinforcement provides the strength and stiffness to the composites. Short/chopped glass fiber is used as reinforcing element because of their low cost, high strength, high impact resistance and good chemical resistance. The fillers used are sintered bronze and graphite The present study focuses on processing, characterization and study of friction and wears behavior of epoxy matrix composite. The experimental investigation is carried out for mechanical and tribological characterization. In mechanical characterization, properties such as density, tensile strength and modulus, flexural strength and modulus, hardness and impact strength are estimated. The use of fiber and fillers showed enhanced mechanical properties of the composites. Tribological characterization is carried out to estimate coefficient of friction and specific wear rate using pin on disc wear setup as per ASME standards. The micrographs of worn pin surface and its debris are carried out to study wear mechanism of the composites. The decrease in specific wear rate of the composites is observed for increase in sliding distance and sliding velocity.Adaptive Neuro Fuzzy Inference System (ANFIS) Simulink model is used predict the wear rate of the composite. The results show 98% accuracy in prediction of wear rate. The polymer matrix composite developed in this study is used in bearing application (roller and race) and the contact pressure is calculated analytically. Finite Element Method is used to validate the results of contact pressure at the area of contact. The FEA results are very much close to the analytical results.