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(FRP)
They possess
➲ good resistance to wide range of different chemicals at
room and elevated temperatures.
Surface tissue:
➲ consists of a thin randomly distributed fibrous mat. They
are available in different thickness ranging from 0.08 to
0.34 mm manufactured from C- glass or synthetic fibre
such as PAN or PET.
➲ Catalyst
sometimes called as initiator or hardener is
thoroughly dispersed in the resin to ensure uniform cure.
➲ Accelerators or promoters
are used in conjugation with a catalyst to increase the rate of
reaction.
➲ Inhibitors
are added to the resinCORPORATE
to ensure adequate
TRAINING AND shelf life.
PLANNING
➲ Curing agents
produce a cross linked thermosetting polymer from
an initially linear or branched polymer
➲ Fillers
are used to reduce cost of the system.
Lubricants
Prevents use of release agents. E.g. Zinc stearate
Light stabilizer
FRP laminates can be protected from UV light by mixing the
resin with light stabilizer such as phenyl salicylate.
Other ingredients which are used in FRP are Coupling agents, flame
retardants, thixotropic additives, skin former etc.
CORPORATE TRAINING AND
PLANNING
Moulding Materials
➲ With hot press moulding, injection and transfer moulding,
the most convenient procedure is to use a pre-formed
moulding compound to which all necessary ingredients have
been added.
Mechanical properties
Strength/weight ratio
Specific gravity
Stiffness and impact strength
Fatigue life
Thermal properties
Heat Distortion Temperature
Operating temperature
Coefficient of expansion
Humidity conditions
Fire resistance
CORPORATE TRAINING AND
PLANNING
Chemical resistance
Resistance to liquid, gases or solvent solutions.
Whether exposed to continuous / intermittent
operating temperature.
Biological
Is food contact involved?
Problems due to bacteria, microbes and termites.
Electrical Properties
Dielectric strength and Dielectric constant
Surface and volume resistivity
Crystalline
Nylon 66 248 +153 180 +100
PEEK 300 +145 175 +75
PBT 210 +145 135 +75
Nylon 6 212 +137 160 +100
Polypropylene 148 +83 86 +51
Acetal 164 +54 140 +75
Amorphous
PES 216 +15 145 +55
Modified PPO 145 +15 125 +59
Polycarbonate 140 +10 120 +56
ABS 100 +10 90 +40
➲ Flanges
provide adequate stiffness on small moulding.
➲ Inserts
Can be incorporated with little difficulty, particularly
with hand or spray- up technique.
➲ GRP moulds
Made from glass reinforced polyester resin by hand or
spray-up techniques. FRP mould can give excellent
service.
➲ When not in use, mould should be stored flat to prevent
distortion and protected from dust and moisture.
➲ Adequate taper
Incorporated to permit easy removal of the moulding
Other processes
1. Filament Winding
2. Centrifugal Casting
3. Sandwich construction
Consolidation
By hand rolling as in hand laminating,
Advantages Disadvantages
Low material cost,comparatively high Very Operator dependent, very
production rate, large parts. poor thickness control, only one
molded face
CORPORATE TRAINING AND
PLANNING
9.5.2 VACUUM AND PRESSURE BAG
MOULDING.
1. Vacuum bag
Advantages Disadvantages
➲ Bleed cloth, release film and vacuum bag are placed over the
prepreg.
➲ Laminate subjected to vacuum pressure and heat simultaneously.
➲ This ensures that all air is extracted from the laminate and full
consolidation and cure is achieved.
➲ Advantage-Moulds are not subjected to large force and can
therefore be of reasonably light construction.
➲ Release agent and gelcoat are applied to the mould surface and
a glass mat is laid into the lower part of the open mould.
➲ The activated resin is then poured on top of the mat and when
the mould is closed the resin spreads throughout the reinforcement.
(See fig.25)
1.Injection Moulding
➲ Fibre emerges from the bath via nip rollers (to remove
excess resin) pass through a vertical comb before being
wrapped around the rotating former (mandrel).
Advantages Disadvantages
High production rate, close tolerance Shape limitation and limited
and high mechanical properties transverse
CORPORATE TRAINING AND properties
PLANNING
9.5.11 CONTINUOUS LAMINATING OR SHEET
MANUFACTURE
Advantages Disadvantages
Very high production rate, low
cost, consistency and good Shape limitation
mechanical properties CORPORATE TRAINING AND
PLANNING
9.5.12 SANDWICH CONSTRUCTION
Moulding Too soft or damp Dry and pre- heat the compounds
stick to compounds Increase taper
mould Insufficient taper Provide split mold
Under cuts
CORPORATE TRAINING AND
PLANNING
APPLICATION
TRANSPORTATION : 1.Land
➲ Automotive components
Automotive trunk lids and hoods
Flat sheet for vehicle bodies
External body panel
Head lamp housing
Bumper beams
Glove box doors
Instrument panels
Battery trays
Seat back
Sun roof frame
Heat shields,
Radiator support
Roofing
CORPORATE TRAINING AND
PLANNING
Engineering parts
Leaf for trucks
Bumper fascia
Front grill
Acoustic shields.
Special applications
Lightweight armour for police protection
Special vehicle body
Tanks for oil
Gasoline
Railway
Housing and covers
Aerodynamic front ends of the High-speed trains.
Wings
Fin
Control devices
Doors
Engine covers
Helicopter interior
➲ Roofing lights
Electrical insulator
Encapsulating electronic components
Switchgear sky lighting
Printed circuit Board
Switch gears
Tie bar
Brush holder
Motor housing
Bushing
Circuit breakers
Bobbins
Compressor bases
Power tool housing
CORPORATE TRAINING AND
PLANNING
Stand off rods
Electrical Junction boxes
Cherry picker buckets
Electrical trucking conduit
Electrical housing etc.
Frames
Bases
Fan in the manufacture of computers
Vacuum cleaners
Air conditioner
Refrigerators
Protection boxes
Corrugated sheeting
Composite bridge
Fire doors
Door component
Fig.62 Floating roof crude oil storage tank Fig.63 Post office building panel moulded from GRP
Beams
Outdoor structural panel
Roofing
Corrugated panels
Office furniture
Chairs
Tables and other modern furniture design
Floorings
Road surfaces
Radiator supporter
Fishing rods
Golf crates
General Precautions