ANALYSIS OF INTERFACIAL STRENGTH

BETWEEN FIBRE AND MICRO-DROPLET

COMPOSITES

Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Technology
in
Mechanical Engineering

by
SOORAJ S - 15BME0100
RITVIK VIPIN K - 15BME0377
NIKHIL MARTIN - 15BEM0080

Under the guidance of

Prof. Sharan C

SMEC
VIT, Vellore.

April, 2019

1
 DECLARATION

I hereby declare that the thesis entitled “Analysis of Interfacial

strength between fibre and a microdroplet” submitted by me, for the award of the degree
of Bachelor of Technology in Mechanical Engineering to VIT is a record of bonafide
work carried out by me under the supervision of Prof. Sharan Chandran.
I further declare that the work reported in this thesis has not been submitted and
will not be submitted, either in part or in full, for the award of any other degree or
diploma in this institute or any other institute or university.

Place: Vellore

Date: 27-03-19

Signature of the candidate 1

Signature of the candidate 2

Signature of the candidate 3

2
 CERTIFICATE

This is to certify that the thesis entitled “Analysis of interfacial strength between
fibre and microdroplet” submitted by S Sooraj(15BME0100), Ritvik Vipin Kumar
(15BME0377), Nikhil Martin (15BEM0080) of SMEC, VIT University, for the award
of the degree of Bachelor of Degree in Mechanical Engineering, is a record of bonafide
work carried out by him under my supervision during the period, 01. 12. 2018 to
30.04.2019, as per the VIT code of academic and research ethics.

The contents of this report have not been submitted and will not be submitted
either in part or in full, for the award of any other degree or diploma in this institute or
any other institute or university. The thesis fulfills the requirements and regulations of
the University and in my opinion meets the necessary standards for submission.

Place: Vellore

Date: 27-03-19

Signature of the Guide

Internal Examiner External Examiner

Head of the Department

Mechanical Engineering

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 ACKNOWLEDGEMENT

We would like to extend our sincere gratitude towards our project guide, Prof. Sharan Chandran
Sir for providing his invaluable guidance, comments, advices, suggestions and even sharing
knowledge throughout the course of our project. I would like to specially thank Prof. Sharan
Chandran Sir for pushing us to work harder and motivation and Dr. K. Padmanabhan Sir for his deep
research knowledge that they have shared and conveyed.

Furthermore, I would like to thank the staff and lab assistants of VIT University for the support
for otherwise, nothing would have been possible. Their kind support and helping mentality has
fueled every bit of the experimental parts of the project.

Student Name
4
Executive Summary
we are currently investigating Self-Reinforced Composites and our project deals with
composite material analysis of fibre micro droplet FRP for use as general industrial
materials, such as applications in automobile field, development of lighter aircraft
structures.

We will be analyzing the properties of the specimen through an experimental

setup as knife edge/wedge pull out mechanism and analytical methodology
using ANSYS is used to find out the interfacial strength between the micro-
droplet and the fibres.

Test and computational analysis done for 2 models for four materials

 Single fibre microdroplet model

 Multi fibre microdroplet model (single fibres, double and triple fibres)

Computational Analysis is done for the above said models in 4 materials namely

- Polypropylene,
- Nylon-6,
- Nylon 6-6,
- Polyethylene LDPE sheet/ UHMW polyethylene fibre.

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 TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
EXECUTIVE SUMMARY / ABSTRACT i
LIST OF TABLES ii
LIST OF FIGURES iii
LIST OF SYMBOLS AND ABBREVIATIONS iv

1 INTRODUCTION AND LITERATURE REVIEW 1

1.1 Introduction to “Topic” 1
1.2 Introduction to the self-reinforced polymer composite 2
1.2.1 Fabrication of Nylon6 polymer composites 5

1.3

1.4 Literature Review 20

1.5 Knowledge gained from the literature 22
1.6 Gaps identified 23
1.7 Objectives of the project 23
1.8 Motivation 24
2 METHODOLOGY AND EXPERIMENTAL WORK
2.1 Project Execution Stages 25
2.2 Technical Specifications 27

6
 2.2.1 ……….. 28
2.3 Design Approach Details 20
2.4 Realistic and Design Constraints addressed 32
2.5 Codes and Standards 33
3 RESULTS AND DISCUSSION 34
3.1 34
4 CONCLUSIONS 42
4.1 Contributions to the literature 43
4.2 Scope for future work 45
REFERENCES 46
PUBLICATIONS 50

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 ABSTRACT

Composite materials have been of enormous demand in the global industries due to
a lot of advantageous factors. Therefore, it is necessary to find out its properties from
the specimen and in this case, our specimen is single/multiple fibre micro droplet.

We will be analyzing the properties of the specimen through an experimental setup

as knife edge/wedge pull out mechanism and analytical methodology using ANSYS
is used to find out the interfacial strength between the micro- droplet and the fibres.

Test and computational analysis done for 2 models for four materials

 Single fibre microdroplet model

 Multi fibre microdroplet model (two or more fibres)

Computational Analysis is done for the above said models in 4 materials namely Polypropylene,
Nylon-6, Nylon 6-6, Polyethylene LDPE sheet/ UHMW polyethylene fibre.
Also the present study has focused micromechanical understanding of the microbond test, which
involves pulling a fiber out of a micro droplet which is the bead matrix through a knife-edge, in
order to measure the interfacial fracture properties. We have found a validation of one of the four
materials analysed through computational analysis using the software ANSYS. We have used
Nylon-6 reinforced composite, as the material to do the test for the purpose of understanding the
interfacial shear strength of these systems. A higher melting point Nylon-6 fabric is reinforced
with a lower melting point Nylon-6 matrix through a heat treatment process in a precise
temperature window so that it adheres to the fabric keeping the fiber intact. Very small melted
blobs of Nylon-6 matrix material is deposited on a multifibre Nylon-6. The interfacial shear
strength is then analyzed through fiber pullout mechanism and validated. Interesting applications
of SRPCs are can be used in washers, gun frames, musical Instruments and many more further
applications.

8
 LIST OF TABLES

Table No. Title Page No.

Composite measurements (single
Table 1.1 fiber) 19

Table 2.1 32

Table 2.2 33

Table 3.3 37

Table 3.4 37

Table 3.5 39

Table 3.6 40

Table 4.1 44

Table 4.2 46

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 LIST OF FIGURES

Figure No. Title Page

No.
Fig. 1.1 8
Fig. 2.1 21
Fig. 2.2 24
Fig. 2.3 26
Fig. 2.4 28
Fig. 2.5 29
Fig. 2.6 30
Fig. 3.1 34
Fig. 3.2 36
Fig. 3.3 39
Fig. 3.4 40

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 LIST OF SYMBOLS AND ABBREVIATIONS

A Interface area
D Degree

IFFS Interfacial shear stress

M Pa Mega pascal

mm Milli metre

mm2 Milli metre square

N Newton

SEM Scanning electron microscope

SRPC Self reinforced polymer composites

SS Shear strength

TS Tensile strength

 Bond strength

 Coefficient of friction

 Contact angle
 Fiber diameter

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 CHAPTER 1

INTRODUCTION AND LITERATURE REVIEW

In this chapter we are currently investigating Self-Reinforced Composites and our project
deals with composite material analysis of fibre micro droplet FRP for use as general
industrial materials, such as applications in automobile field, development of lighter aircraft
structures.

A composite material is composed of minimum of two materials, which combine their

properties and become superior to those of the individual constituents. Fibre
reinforced polymer (FRP) composites, usually with glass, carbon, polymer or natural
fibres embedded in a polymer matrix.

The many component materials and different processes that can be used make
composites versatile and efficient. They typically result in very lighter, stronger,
more durable solutions compared to traditional materials.

The primary reason composite materials are chosen for components is for its immense
weight saving factor for its relative stiffness and strength. A small example given that
carbon-fibre reinforced composite is almost five times stronger than steel of grade
1020 while having only one fifth of the counter material weight.

Composites also have particular advantages as well as disadvantages, which should

be considered at the specifying stage. Composites are not always right material for
every single job.

However, a major driving force behind the development of composites has been that
the permutation and combination of the several required reinforcement and the matrix
can be changed to meet the required final properties of the desired component. To
state an example, if the final component needs to be resisting fire, a fire-retardant
matrix can be used in the and hence the end material will be fire retardant.

Also coming to durability factor, composites don’t rust, which is very crucial,
especially in environments that are either marine or be it chemical. The need for
maintenance and painting is very low or even eliminated.
The excellent fatigue resistance feature of composites can increase product lifespan by
many times in many applications.

Other added functionality of composites are that they are thermal insulators which is
good for fire and blast protection or cryogenic applications.

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Applications of composites can be mentioned below

Sports industry: Used in bicycles, golf, boats, badminton, tennis and hockey.

Transportation industry: Used in ships, railway coaches and truck bodies.

Aerospace industry: Components associated with aerospace vehicles, satellites and

missiles are fully composite materials. They are also used in doors, nose, wing parts,
fuel tanks, inboard flaps, edges, pressure tanks, stators, turbo motor and structural
parts.

Automotive industry: They are adversely used in making car bodies especially in
motorsports industries. Other components such as drive shafts, fuel tank, hoods and spoilers
are also result of composite materials.

Endeavors to improve the large scale manufacturing strategies utilized are progressively
required so as to acquire the ideal material quality easily. The ideal material quality isn't an
obvious objective for Self-reinforced composites in light of the fact that the quality and
durability of these composites rely upon the properties (for example the quality and
sturdiness) of the fiber/framework interface. In this way, a strategy for evaluating the
interfacial properties must be set up to help the plan of Self-reinforced composites.
Nonetheless, how to assess these essential interfacial properties remains a disputable issue
among scientists of composite materials.

Test techniques utilizing single-fiber and multi-fiber composites, for example, pullout,
microbond, and pushout tests, are useful in the debonding procedure of the interface from the
general failure procedure of a composite. Specifically, the microbond test is a straightforward
fiber pullout strategy for assessing shear failure of the fiber– grid interface. The microbond test
includes hauling a fiber out of a composite network (for example bead) through a blade edge
(as appeared in Fig1.1), joined by the debonding at the fiber– lattice interface, and after that it
assesses the interfacial break properties dependent on the subsequent strength required in the
pullout. This system is very valuable for little distance across filaments, for example, carbon
and Nylon-6 strands, on the grounds that the fiber pullout can be finished without fiber
breakage. In any case, it has much of the time been brought up that the microbond test neglects
to evaluate the "genuine" interfacial properties speaking to the interfacial break, halfway in
light of the fact that the interfacial properties got from the microbond test utilizing customary
information decrease methods (for example the found the average value of interfacial shear
quality (IFSS)) are not predictable with those decided utilizing other test techniques. Likewise,

13
numerous scientists have revealed huge information dissipate as a restricting part of the
microbond test. This bother is brought about by the way that the micromechanical displaying
for the microbond test has not been very much created and the general failure process amid the
test isn't surely knew. This issue must be settled by the contribution of a point by point
numerical investigation.

Figure 1.1

1.1 AN INTRODUCTION TO SELF REINFORCED POLYMER (SRP) COMPOSITES:

Polymer composites and especially thermoplastic composites are ending up increasingly more
typical in various enterprises, for example, aviation, automobile, construction and numerous
others which require light weight and superior material properties. This pattern is because of
polymer composites offering superior materials with insignificant weight when contrasted and
progressively customary materials, for example, high quality steels.

The trend of expanded use implies it is ending up considerably more critical to have the
capacity to reuse segments produced using fiber reinforced polymer composites. Materials
made of thermoplastics can be just re-softened and re-formed into new parts, anyway this is
beyond the realm of imagination with the consideration of filaments, for example, glass or
carbon as these can't be liquefied down. Hence, the composite materials must be shredded and
utilized as low performance short fiber reinforced polymer composites. To fulfill the need of
recyclable fiber fortified polymer composites, strands which can be melted alongside the
polymer lattice and be good with that dissolve must be utilized; this has led to the improvement
of Self Reinforced Polymer (SRP) composites.

1.2 Fabrication of Self reinforced composites(Nylon6):

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A higher liquefying point Nylon-6 texture is strengthened with a lower melting point Nylon-6
grid by a heat treatment process just below the conditioning temperature so the matrix softens
and sticks to the texture keeping the fiber intact. There is a fundamental job for the interfacial
properties of the composites in the assurance of their overlay level mechanical properties.
Small melted blobs of Nylon-6 matrix material is kept on a heap of Nylon-6 strands removed
from the texture and by utilizing a microvise as an extra installation, the interfacial shear quality
is examined through fiber pullout. By utilizing the contact edge of the blob the interfacial shear
quality is determined. Fascinating uses of SRPCs are can be utilized in washers, weapon
outlines, Gears, Toothbrush.
Trials demonstrate that the shear strength and the tensile strength of SRPC are equivalent. This
is additionally because of the idea of attachment between the fibres and the matrix and in this
way it ends up vital to break down the interfacial properties. In spite of the fact that there is no
standard test technique system for assessing the interfacial properties, many test strategies were
created by different researchers, viz. the fragmentation technique, fiber pull out technique and
the fiber push-in technique. Of these, the single fiber pull out and the more exact multiple fiber
pull out test technique (as it is measurably found the middle value of) are progressively
mainstream in light of the exactness and the simplicity of taking care of and assessment.
Because of the natural dissipate in the test outcomes, it was chosen to receive the multi fiber
microbond pull out test strategy for the previously mentioned SRPCs to get factually critical
normal qualities for the interfacial properties. This test is neither micromechanical nor full scale
mechanical, however is mesomechanical in nature, which makes it extremely intriguing, as it
is relied upon to the conquer any hindrance between micromechanical gauges and the large
scale mechanical assessments.

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 Figure 1.2

1.3 Literature Review:

Microbond pullout system for acquiring Fiber or matrix interfacial shear

strength:

In this paper the present investigation has concentrated on accomplishing a micromechanical

comprehension of the microbond test, which includes pulling a fiber out of a globule of matrix
(for example, droplet) through a knife- edge, so as to evaluate the interfacial break properties
of fiber-strengthened composites. According to the microbond test results network splitting
happened amid the fiber pullout, notwithstanding the debonding at the fiber– framework
interface. Fiber-fortified plastics (CFRPs) are as of now being examined for use as general
mechanical materials, for example, in vehicle applications, because of the ongoing
improvement of lighter flying machine structures. In these applications, endeavors to improve
the large scale manufacturing systems utilized are progressively required so as to get the ideal
material quality easily. The ideal material quality isn't an obvious objective for fiber-
strengthened composites on the grounds that the quality and durability of these composites rely
upon the properties (for example the quality and strength) of the fiber/grid interface. In this
way, a strategy for evaluating the interfacial properties must be set up to help the structure of
fiber-fortified composites. In any case, how to assess these essential interfacial properties
remains a disputable issue among analysts of composite materials.

16
Test strategies utilizing single-fiber show composites, for example, pullout, microbond, and
pushout tests, are useful in extricating the debonding procedure of the interface from the
general harm procedure of a composite. Specifically, the microbond test (Miller et al., 1987) is
a straightforward fiber pullout procedure for assessing shear failure of the fiber– lattice
interface. The microbond test includes pulling a fiber out of a globule of lattice (for example
bead) through a blade edge (as appeared in Fig. 1), joined by the debonding at the fiber–
framework interface, and afterward it assesses the interfacial crack properties dependent on the
subsequent power required in the pullout. This procedure is very helpful for little measurement
strands, for example, carbon filaments, in light of the fact that the fiber pullout can be finished
without fiber breakage. In any case, it has much of the time been brought up that the microbond
test neglects to measure the ''genuine" interfacial properties speaking to the interfacial break,
incompletely on the grounds that the interfacial properties acquired from the microbond test
utilizing customary information decrease strategies (for example the found the middle value of
interfacial shear quality (IFSS)) are not steady with those decided utilizing other test strategies
(HerreraFranco and Drzal, 1992). Also, numerous specialists, (for example, Zinck et al. (2001))
have announced huge information dissipate as a constraining part of the microbond test. This
burden is brought about by the way that the micromechanical demonstrating for the microbond
test has not been all around created and the general harm process amid the test isn't surely
knew. This issue must be comprehended by the commitments of a nitty gritty numerical
investigation.

Microbond test Experimental details:

The microbond test is a basic fiber pullout procedure for assessing shear failure of the fiber–
matrix interface. The microbond test includes pulling a fiber out of a bead of matrix (for
example droplet) through a knife edge joined by the debonding at the fiber– framework
interface, and afterward it assesses the interfacial fracture properties dependent on the
subsequent power required in the pullout. This strategy is very helpful for little measurement
filaments in light of the fact that the fiber pullout can be finished without fiber breakage. Also,
numerous researchers have revealed noteworthy information disperse as a constraining part of
the microbond test. This burden is brought about by the way that the micromechanical
displaying for the microbond test has not been very much created and the general harm process
amid the test isn't surely knew. This issue must be comprehended by the commitments of a

17
detailed numerical examination. Ongoing looks into have added to finite element (FE)
displaying of the fiber pullout and pushout tests. These models address the interfacial failure
amid the tests, using interface components installing the harm procedure zone onto the fiber–
framework interface. This structure had been as often as possible connected to the crack at the
fiber– lattice interface in composites, first in Nutt and Needleman (1987), and afterward
reached out in Tvergaard (1990), and so on. In most interface components, the model of the
harm procedure zone was developed dependent on the traditional crack mechanics. (This kind
of model was alluded to as an implanted procedure zone (EPZ) display in Hutchinson and
Evans, 2000.) Overall, these ways to deal with interfacial break are additionally powerful for
the demonstrating of single-fiber test strategies. Also, the anticipated aftereffects of the
debonding process amid the tests can be used to get interfacial crack properties (quality and
durability) of the composites through their fitting to the test data. In applying these ways to
deal with the displaying of microbond tests for little measurement strands, be that as it may, a
few troubles emerge. In microbond tests, genuine examinations uncover that piece of every
bead stays on the fiber after it is hauled out of the network (Zinck et al., 2001), and along these
lines the fiber pullout can't be portrayed by the debonding everywhere throughout the interface
(for example unadulterated debonding process). The coupling impacts of network
disappointment and debonding process on the test outcomes ought to be talked about so as to
sensibly separate the interfacial break properties dependent on the microbond test. This point
has not been talked about in the micromechanical demonstrating and examination of the
microbond test.

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 Fig 1.3 Blob sheared

Fiber fragmentation test:

Tensile strength of most fibres is known to be essentially subject to the gauge length, because
of the arbitrary appropriation and variation sizes of imperfections along the fiber surface.
Around 50 examples in each measure length were tried. The measure lengths of testing
examples were 2, 5, 10, 20 and 100mm, respectively. An average diameter across of 50 glass
filaments was estimated by an optical magnifying microscope (Nikon: HEX-DX) appended
with an aligned eye piece. The distance across of a fiber was estimated at three unique focuses,
and the base estimation of the deliberate breadth was picked. A single fiber was set on a paper
edge and after that was waxed by Scotch tape in the inside line on the two finishes. The epoxy
cement was utilized to fix the fiber set up. Rigidity was estimated utilizing the all-inclusive
testing machine (Lloyd instruments Co. Ltd, LR-5K) connected with 100 N load cell. The
cross-head speed was 0.5 mm/min.

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 Fig 1.4 Load vs extension

The standard and gradual MFC specimens were set up as appeared in Fig. 2(a) and (b),
individually. Spacebars filling in as a between fiber partition were prepared. After a multi-fiber
was set down between the spacebars, the finish of a fiber was fixed by Scotch tape. The
component of two-composed multi fiber examples was 3 mm wide, 25 mm check length, and
1 mm thickness. The setups of the single and the ordinary MFCs with three and five strands,
where all between fiber separating was a similar extent .The arrangement of the continuous
MFC example, in which the between fiber dividing (di) was expanded step by step with
appropriately numerous separation of fiber distance across as pursues; 1 time: 30 mm; multiple
times: 60 mm; multiple times: 90 mm; multiple times: 120 mm; multiple times: 150 mm;
multiple times: 210 mm;10 times: 300 mm; and around multiple times: 500 mm, individually.
Entomb fiber partition is characterized as either between fiber separating isolated by fiber
distance across (di/do) or fiber width separated by between fiber dispersing (do/di),
individually. It is to demonstrate the correlation of the outcomes relying upon two unique
definitions, di/do and do/di.

Multi-fiber was installed in the exibilized epoxy utilizing Jasmine restoring agents on a
silicon shape. After these examples were left at room temperature for 24 h, they were
precured at 80C for 2 h and postcured at 120C for 1 h. After the fiber position and the
straightness were checked cautiously with an optical microscope, the inadmissible examples
were disposed of. After the example was taken out from the form, it was cleaned by the
standard metallographic method to acquire the smooth surface and same thickness. Mass
epoxy examples were pliable tried by a general testing machine (10 KN load cell, 1 mm/min

20
cross-head speed rate). A set comprising of three examples was tried and the pressure versus
the strain bend was drawn. For setting up the MFCs, the degassed pitch blend was thrown
into a silicon shape. Every fiber was situated at a half profundity of the example thickness. In
the wake of relieving, the examples were sufficiently straightforward to watch the smaller
scale disappointment modes. The examples were tried subsequent to maturing for 3 days at
room temperature and mugginess to equilibrate.

IFSS of the MFCs was examined by the multi-fiber fragmentation test. The interfacial
disappointment happening on the individual fiber was watched by means of an optical
magnifying microscope with a uniquely structured tractable machine. Amid testing, the
example was stressed steadily and the fibres were fractured into little sections inside the
matrix. As the tensile stress was connected further, the crack procedure proceeded until break
never again happened in the fiber. At this strain, a section length is known as a critical
fragment length, lc. The basic piece length of the individual fiber was estimated and the
smaller scale disappointment modes were watched by means of an enraptured light
microscope.

The Path to Maturity for Self Reinforced Polymer Composites:

The Self Reinforced Polymer (SRP) composites industry in general has pushed ahead
altogether lately with various organizations creating business items for various industry
divisions, for example, the car business, individual defensive gear and sports insurance. The
focal point of this paper will be to condense the discoveries of an ongoing over multi year
improvement venture which has been as of late finished. The point of the work has been to
define proficient and cost effective producing forms while keeping up the most noteworthy
mechanical properties the materials can offer. The paper will present novel shaping strategies
and post-preparing advances, including coating, bonding and trimming, created to permit the
assembling of high caliber, financially prepared items. Assembling forms that are utilized to
frame segments from these materials will be examined alongside the contemplations to be
considered, that are explicit to SRP composites, for example, precise temperature control to
keep away from over warming of the reinforcement fibres/tapes and degradation of the
materials properties.

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Polymer composites and especially thermoplastic composites are winding up increasingly
more typical in various ventures, for example, aerospace, automotive, construction and
numerous others which require light weight elite materials [1]. This pattern is because of
polymer composites offering superior materials with negligible weight when contrasted and
progressively customary materials, for example, high quality steels. This pattern of expanded
use implies it is winding up considerably more essential to have the capacity to reuse parts
produced using fiber strengthened polymer composites. Materials made of thermoplastics can
be just re-liquefied and re-formed into new segments, anyway this is beyond the realm of
imagination with the consideration of strands, for example, glass or carbon as these can't be
softened down. Along these lines, the composite materials must be destroyed and utilized as
lower execution short fiber strengthened polymer composites. To satisfy the need of
recyclable fiber strengthened polymer composites, filaments which can be dissolved
alongside the polymer network and be perfect with that liquefy must be utilized; this has led
to the advancement of Self Reinforced Polymer (SRP) composites.

A novel microbond-fiber bundle pullout technique to evaluate the interfacial

properties of self -reinforced composites:

The composites having the matrix and the reinforcement made out of a similar material
however handled through various techniques are known as the Self Reinforced Polymer
Composite (SRPC) frameworks. They have a practically identical shear and tensile strength
not at all like the glass or carbon fiber fortified composites. A Polypropylene self-reinforced
composite is explored here to understand the interfacial shear quality of these frameworks.
Polypropylene (PP) is a thermoplastic polymer with a wide scope of melting temperature due
to stereochemistry. A higher liquefying point PP texture is reinforced with a lower dissolving
point PP framework by a heat treatment process just underneath the conditioning temperature
so the lattice mollifies and holds fast to the texture keeping the fiber unblemished. There is a
fundamental job for the interfacial properties of the composites in the assurance of their cover
level mechanical properties. Modest dissolved masses of PP grid material is kept on a heap of
PP strands separated from the texture and by utilizing a microvise as an extra installation, the
interfacial shear quality is broke down through fiber pullout. By utilizing the contact edge of
the mass and by thinking about the frictional properties of the material, the interfacial shear

22
quality is determined. Fascinating utilizations of SRPCs are in transport, air, ocean and land
load holders, ultra light structures and electronic bundling because of their high explicit
properties.

In microbond pull-out technique, the interfacial contact area is kept at a small value so that
there is a high probability that debonding will occur before fibre rupture and before
significant matrix deformation. In the event that the force required in shearing the interfacial
bond is more prominent than that which the fiber can sustain in tension, the fiber will break
first and prematurely end the bond strength estimation. The microbond procedure begins with
embeddings fibres through a little gap made on the minor PP sheet so that the lattice shapes a
concentric bead around the PP fiber pack after network softening (Fig.1 (a)). When the
network has cemented with a contact edge, the fiber width and the bead (mass) measurements
are estimated and used to decide the interfacial contact region (Fig 1 (b)). A microvise grasps
the bead on an Instron 8801 while the fiber group moves descending, shearing the droplet off
the bundle.

1.4 Knowledge gained from the literature review:

From the literature we picked up information on fabrication of Nylon-6 self-reinforced polymer

composites .We likewise picked up learning on various techniques of manufacture of (SRPC).
We comprehended different mechanical portrayals and we got knowledge in application of
Nylon-6.

1.5 Gaps identified:

After a thorough literature review ,we have chosen to work on the assessment of interfacial
properties of self reinforced composites ie the material we have picked is Nylon-6.For this
purpose the method that we have chosen is Microbond test.

 Nylon-6 is used as a fiber.

 Nylon-6 is used as a Matrix.
1.6 Objectives of the project:

• To prepare samples for microbond multiple pullout test

23
• Analyze the blob dimensions and fibre dimensions by microscopy
• Direct, microbond pullout test
• Assess the interfacial properties like interfacial shear strength and peak debonding force
etc.
• To conduct fractography by utilising scanning electron microscope.

1.7 Motivation:

24
 CHAPTER 2

2.METHODOLOGY AND EXPERIMENTAL WORK:

2.1 Project execution stages:
The following steps are followed in the execution of project.
 Papers were studied about ASME Standards for Microbond test to find the required
procedures
 Studying papers about the self-reinforced composite materials and computational
simulations were referred and studied.
 Solidworks model preparation of 4 material models.
 ANSYS simulation of four material models with different fibre/microdroplet setups.
 Obtained Nylon- 6 from Industrial Fabrics store at Chennai.
 Prepared the Nylon- 6 samples which is required for the evaluation of interfacial
properties.
 Dimensional properties of Nylon-6 samples were measured using dynolite and optical
microscope.
 Nylon-6 samples were tested using Instron machine
 Mathematical calculations have been done to find out the interfacial shear strength is
found.
 After the fracture has happened, the sample is then inspected using microscope
 Computational validation of Nylon 6 is done with ANSYS simulation.

METHODOLOGY:
• The fiber and matrix have been purchased and the fiber ropes have been extracted from
the fiber sheet.
• Matrix has been cut in a small square form of one square cm.
• Then the fabrication has been done by keeping a precise temperature window.
• We utilized 3 grids and single fiber for the creation of single fibre composite.
• We utilized 3 grids and single fiber for the creation of multifibre composite.
• After the temperature monitor reaches to 165C in the oven and it is left for 1 hour.
• The samples are taken from the oven after 12 hours and the dimensional measurements
will be measured under dynolite analyser and experimented on instron equipment.
• Meanwhile for each simulation, accurate soildworks model is made.

25
• All the models are saved under parasolid format to prevent object split by default in
ANSYS
• Standalone systems are created in static structural format. New material directory is
made in ANSYS for the required materials: Nylon6, Nylon 66, Polyethylene, LDPE &
UHMWP and polypropylene.
• The models are exported to the geometry and contact regions are marked for debonding
instead of CZM.
• Necessary constraints are marked for the parts of the bodies and solved
computationally.
• Required data collected and cross-checked for validation.
• Post fracture occurred on each sample is observed using scanning electron microscope.

EXPERIMENTAL WORK:
In microbond pullout method, the interfacial contact territory is kept at a little value so that
there is a high likelihood that debonding will happen before fiber break and before critical
matrix disfigurement. On the off chance that the force required in shearing the interfacial
bond is more noteworthy than that which the fiber can continue in strain, the fiber will burst
first prematurely and end the bond quality estimation. The microbond procedure begins
with embeddings strands through a little holes made on the tiny square PP sheet so that the
matrix shapes a concentric bead around the PP fiber pack after matrix (Fig.2.6). When the
matrix has hardened with a contact point, the fiber dia and the bead (i.e. the bolb)
measurements are estimated and used to decide the interfacial contact zone (Fig2.7). A
microvise grasps the bead on an Instron 8801 while the fiber group moves descending,
shearing the drop off the pack.

26
 2.1 Fibres and matrix of Nylon 6

Industrial oven consisting of composite materials

Figure 2.2

27
Fabricated single fiber sample Multi fiber sample
Figure 2.3

Image profiler
Figure 2.4

28
 Micro vise
Figure 2.5

Fig 2.6
Measurement of blob contact angles under dynolite analyzer

29
Testing of sample(Nylon6)
Fig 2.8

Scanning electron microscope

Fig 2.9

30
 Instron machine
Fig 2.10

Fig 2.11 Optical Microscope

31
32
Theoretical Calculations:

TABLE NO. 2.1 COMPOSITE MEASUREMENTS(SINGLE FIBER)

SERIAL EMBEDDED WETTING DIAMETER(mm)

NO LENGTH(mm) ANGLE(degree)
1 9.55 27.6 1.26
2 7.76 28.62 1.26
3 9.98 28.3 1.26
4 10.4 26.3 1.26
5 11.74 31.3 1.26
6 9.4 29.8 1.26
7 9.8 25.9 1.26
8 9.0 25.8 1.26
9 9.44 29.9 1.26
10 10.18 27.3 1.26
11 7.21 26.45 1.26
12 10.7 34.75 1.26
13 9.26 25 1.26
14 11.08 22.2 1.26
15 8.2 24.1 1.26

TABLE NO. 2.2 COMPOSITE MEASUREMENTS(MULTI FIBER)

SERIA EMBEDDED WETTING DIAMETE

L NO. LENGTH(mm ANGLE(degree R (mm)
) )
1 7.0 36.35 2.3
2 7.16 28.75 2.3
3 4.7 29.2 2.3
4 10.76 24.05 2.3
5 7.7 24.6 2.3
6 7.85 31.15 2.3
7 9.85 24.6 2.3
8 7.94 18.18 2.3
9 8.96 23.3 2.3
10 7.53 28.6 2.3
11 11.2 29.2 2.3
12 8.47 23.43 2.3
13 7.05 26.6 2.3
14 8.04 23.8 2.3
15 10.9 35 2.3

33
COMPUTATIONAL ANALYSIS
SOLIDWORKS MODEL
The specimen is modelled in soildworks with respected to approx. measurements as follows
1. Nylon 6 –1 & 3 fibres of 0.44mm dia.

2. Polypropylene – 4 fibres of 0.20mm dia.

3. Polyethylene (General material listed in ansys) - 1,2 & 3 fibres of 0.86mm dia.

34
 4. Polyethylene LDPE sheet/ UHWMP fibre 2 fibres of 0.7mm dia.

Solidworks model has been made using the feature extrude cut and boss extrude.

ANSYS SIMULATION
 The soildworks model that has been crafted is exported into ansys software. Since
all the materials required aren’t available in the software, material directory is
amended.
 The new four materials have been made and imported to the filtered geometry
section. Static structural analysis is required for the samples and therefore,
standalone system.

35
 Then the geometry is the imported, material data is assigned. Further after that mesh
is created.
 Refinement is made to the necessary parts.

 Contact regions are specified for debonding simulations.

 Static structural constraints are specified and displacement is marked.

36
 Further once the constraints are marked, the solve button is clicked for simulation.
The required analysis data is obtained through the simulation.

ANSYS SIMULATION RESULTS

Ansys simulation of the solid works model is done using its parasolid format. Total
deformation and max Principal stress is used for this purpose. The following results
are given below.

1. Nylon 6 –1 & 3 fibres of 0.44mm dia

37
2. Polypropylene – 4 fibres of 0.20mm dia

3. Polyethylene (General material listed in ansys) - 1,2 & 3 fibres of 0.86mm dia

38
4. Polyethylene LDPE sheet/ UHWMP fibre 2 fibres of 0.7mm dia

39
2.4 Realistic and Design constraints addressed:
Design Elements included
 Engineering Standards

 Experimentation

 Fabrication

Realistic Constraints to be addressed

 Economic

 Manufacturability &Sustainability
 Health and safety
2.5 Codes and Standards:
Tensile Test -ASTM D368
Instron -8801

40
 CHAPTER 3
3.RESULTS AND DISCUSSION:

Fig 3.1 Direction of the forces Fig3.2 Load vs extension curve (Multi
fiber)

Fig 3.3 Load vs Extension curve(Multi fiber)

The interfacial properties of the self-reinforced Nylon 6 composite, like the interfacial shear
strength, the coefficient of friction between the fibre and the matrix, interfacial frictional stress
and intrinsic bond strength were predicted and evaluated with the aid of the mesomechanical
method (Table 1) . In the microbundle pullout test, a maximum pullout force in between 49N
and 250 N was observed for the single fibres and a maximum pullout force in between 46N to
126N. The frictional stress at peak load was in the range of 1 and 7 MPa for single fibers and
for multi fibers in between 0.5 and 2 MPa. The interfacial shear strength was between 1 and 8
MPa for the Nylon6 SRPC in comparison to a value of 35-50 MPa for a glass/epoxy specimen.

41
 Table 3.1: Interfacial Properties of the Nylon-6 SRPC
Sample Max Bundle Drop Contact Area, Coeffi Intrinsic Peak Interfacia Frictional
lengt angle A Bond pullout l Shear stress at
load[F avg dia cient
hl (θ) (mm
2
strength force Stress peak load
]  in of , (MPa) (N) (MPa) (MPa)
(mm) )
(N) (mm) degrees frictio
n
1 12.5 1.26 9.56 15.45 37.8 1.81 0.33 94.5 2.5 2.16
2 11.0 1.26 7.76 20.75 30.7 1.32 0.36 49.1 1.6 1.25
3 13.0 1.26 9.99 11.0 42.9 2.57 0.33 197.3 4.6 4.37
4 13.0 1.26 10.5 15.0 41.6 1.86 0.32 104 2.5 2.23
5 14.0 1.26 11.7 12.3 46.3 2.29 0.31 162 3.5 3.26
6 9.0 1.26 9.5 18.0 37.3 1.54 0.24 52.2 1.4 1.14
7 11.35 1.26 9.88 8.75 39.1 3.25 0.29 250.2 6.4 6.12
8 13.55 1.26 9.0 16.5 35.7 1.69 0.38 89.25 2.5 2.16
9 12.6 1.26 9.44 14.75 37.4 1.9 0.34 103.2 2.8 2.45
10 13.2 1.26 10.2 12.15 40.1 2.3 0.33 156.4 3.9 3.56
11 11.6 1.26 7.2 9.5 27.6 2.98 0.42 218.0 7.9 7.5

12 11.6 1.26 10.7 13.0 42.9 2.17 0.27 120.1 2.8 2.53

13 15.0 1.26 9.3 17.9 36.6 1.55 0.41 87.8 2.4 1.97

14 16.5 1.26 11.1 11.35 43.5 2.49 0.38 221.8 5.1 4.72

15 12.1 1.26 8.3 18.1 32.7 1.53 0.37 68.7 2.1 1.73

42
Sample Max Bundle Drop Contact Area, Coefficient Intrinsic Peak Interfacial Frictional
length angle A Bond pullout Shear stress at
load[F] avg of friction
l (θ) 2
(mm ) strength, force Stress peak load
(N) dia  in (MPa) (N) (MPa) (MPa)
(mm)
(mm) degrees

1 14.1 2.3 7.0 21.2 50.43 1.29 0.28 60.52 1.2 0.93
2 16.8 2.3 7.2 18.5 51.03 1.49 0.33 91.85 1.8 1.47
3 12.2 2.3 4.7 23.0 35.91 1.18 0.34 46.68 1.3 0.94
4 14.1 2.3 10.7 14.25 78.55 1.97 0.18 125.7 1.6 1.4
5 14.3 2.3 7.7 24.0 55.15 1.12 0.26 49.6 0.9 0.66
6 13.8 2.3 7.8 17.5 57.5 1.59 0.24 83.4 1.45 1.21
7 13.9 2.3 9.8 14.6 69.35 1.92 0.2 117.9 1.7 1.47
8 13.9 2.3 7.9 15.5 57.75 1.8 0.24 103.9 1.8 1.56
9 13.3 2.3 8.9 23.0 63.19 1.18 0.21 50.55 0.8 0.58
10 14.65 2.3 7.5 18.8 54.26 1.47 0.27 75.96 1.4 1.16
11 16.55 2.3 11.2 19.5 78.81 1.41 0.21 82.75 1.05 0.84
12 13.95 2.3 8.5 23.0 60.65 1.18 0.23 54.58 0.9 0.64
13 16.5 2.3 7.1 25.0 49.88 1.07 0.33 54.87 1.1 0.76
14 15.6 2.3 8.05 18.8 57.67 1.47 0.27 80.74 1.4 1.16
15 15.25 2.3 10.9 15.0 80.26 1.86 0.19 120.4 1.5 1.32
Table 3.2: interfacial properties of multi-fiber Nylon-6 SRPC

43
 CHAPTER 4

4.CONCLUSIONS:
4.1 Contributions to the literature:
A strategy has been effectively created and illustrated, to assess the fiber-network
interfacial properties of self-reinforced composites like Nylon6. Validation of
computational analysis is made with the help of SOLIDWORKS and ANSYS.

44
REFERENCES:
1.Sharan Chandran M , Padmanabhan K: Processing and Mechanical Characterization of Self
Reinforced Polymer Composite System

2. Subramani Sockalingam: Fiber-Matrix Interface Characterization through the Microbond

Test

3. L. M. Morgan, B. M. Weager, C. M. Hare and G. R. Bishop: The Path to Maturity for Self
Reinforced Polymer Composites.

4.A new method of evaluating the interfacial properties of composites by means of the
gradual multi-fiber fragmentation test
Joung-Man Parka,*, Jin-Won Kima, Koichi Godab

5.Micromechanical modeling of the microbond test to quantify the interfacial properties of

fiber-reinforced composite.
M. Nishikawa a, T. Okabe b,*, K. Hemmi a, N. Takeda c

6. B. Miller, P. Muri and L. Rebenfeld, Comp. Sci & Tech. 28, 17 (1987).
G. C. Tesoro, R. Benrashid, L. Rebenfeld and U. Gaur, International
Symposium on Polymers for
Advanced Technologies, 773, Jeiusalem, Israel, August 17-21, 1987.

7.Alfano, M., Furgiuele, F., Leonardi, L., Maletta, C., Paulino, G.H., 2007. Fracture analysis
of adhesive joints using intrinsic cohesive zone model. Key Eng. Mater 348, 13–16.
Alfano, M., Furgiuele, F., Leonardi, L., Maletta, C., Paulino, G.H., 2009.
Mode I fracture of adhesive joints using tailored cohesive zone models. Int. J.
Fract. 157, 193–
204.
8. Griffith AA. The phenomena of rupture and flow in solids. Philos Trans Roy
Soc Lond Ser A, Containing Papers of a Mathematical or Physical Character
221.

45
9. Shiriajeva GV, Andreevskaya GD. Method of
determination of the adhesion of resins to the surface of
glass fibers. Plast Massy (Polymer Compounds USSR)
1962(4):43–6 [in Russian].

10. Penn LS, Bowler ER. A new approach to surface energy

characterization for adhesive performance prediction.
1981;3:161–4.

46