MACHINING AND EROSION STUDIES

OF RED MUD AN INDUSTRIAL WASTE

BASED POLYMER MATRIX
COMPOSITE

Guide
Dr. M. UTHAYAKUMAR Ph.D.,
Professor,
Department of Automobile engineering.

Co-Guide Presented by,

Dr. V. ARUMUGA PRABU Ph.D., S.VIGNESHWARAN M.E.,
Associate Professor, 201617106 - Research Scholar / JRF
Department of Mechanical engineering. Department of Automobile Engineering.

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 ABOUT THE RESEARCH PROJECT

This Research Project is funded by Ministry of Forest, Environment

and climatic change, Government of India.

Title : MACHINING AND EROSION STUDIES OF RED MUD AN INDUSTRIAL

WASTE BASED POLYMER MATRIX COMPOSITE

MoFE Project number: 168/2016/RE (F No 19-20/2012-RE)

Principal Investigator : Dr. M. Uthayakumar (Professor)
Co Investigator : Dr .V. Arumuga prabu (Associate Professor)
Budget Sanctioned : RS. 2700000/-

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 INTRODUCTION
A Composite material is a material system composed of two or more materials that
differ in shape and chemical composition and which are insoluble in each other.

Composites are classified as follows:

 Metal Matrix Composites (MMC)
 Polymer Matrix Composite (PMC)
 Ceramic Matrix Composite (CMC)

According to the Reinforcement geometry

 Particles Reinforced composite
 Fibers Reinforced composite
 Hybrid Composite

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 HYBRID POLYMER COMPOSITES:

 Hybrid composite consists of two or more reinforcement in the matrix.

Reinforcement may be two different fibers or fiber with fillers.

 Hybridization concept produces different range of properties. The material

costs can be reduced to a great extent and also high performance can be
obtained by the effect of Hybridization.

 Filling composites with the fillers can reduce the initiation of crack in the
matrix phase and the debonding between fiber and the matrix. In addition
the mechanical properties of the composites will also increase with the
addition of filler material.

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 LITERATURE REVIEW

Literature review is carried out to understand the role of the filler on polymer
matrix, the machining performance and erosion characteristics of filled
composites and also to determine the research gap. The literature review is
discussed with the following classifications:

 Hybrid composites

 Solid particle Erosion test on Hybrid Composites

 Machining on Hybrid Composites

5 January 21, 2020

 Generally, fillers are solid particle reinforcing material which is added to change and
improve material properties more specifically for the improvement of mechanical
properties. Inorganic, organic and metallic particulate materials are taken as the filler
materials. The fillers at micro or nano sizes are used for reinforcement in the composite
[1].
 In general, addition of fiber in the matrix improves the mechanical characteristics of
polymer composites whereas the filler particles increases the modulus [2].
 Filler helps in restricting the melting of resin in the composite by absorbing the heat
induced during high working conditions [3].
 Reinforcing filler at higher percentage in composites affects uniformity of matrix and
filler distribution, which may lead to deterioration of composite properties [4][5].
 For the filled material, the efficiency of reinforcement depends on the interface of
several filler properties; comprises of particle size, particle shape, particle dispersion,
surface area, surface reactivity, structure of the filler and the bonding quality between
6 the fillers and the matrix [6]. 1/21/2020
  Omrani et al [7] reviewed the tribological characteristics of natural fiber
reinforced polymer composites and discussed in detail about the natural fiber
characteristics in erosion resistance of polymers.

 Addition of flyash filler in the hybrid composite having glass fiber and jute
fiber composite enhanced the erosion resistance. From experimental analysis it
was concluded that the filler reinforcement in the composite is highly
influencing factor in deciding the erosion rate [8].

 Using three different ceramic fillers (cement by-pass dust (CBPD), alumina
(Al2O3) and silicon carbide (SiC) hybrid composites was fabricated and
investigated for the solid state erosion performance. Compared to CBPD and
SiC, Al2O3 has showed improved erosion resistance. ANOVA analysis proved
the significance of the filler material in affecting the erosion rate [9].

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  In polymer composites machining performance depends on the reinforcement
characteristics like fiber orientation, fiber amount and fiber form [10].

 While fabricating of polymer composite it is more complex to form holes and slots
without affecting the reinforcement, in such cases, machining is the only preferred
technique to form complex shapes and needed requirements [11].

 Composite material because of their non-homogenous property shows significant

variation on machining when compared to conventional materials [12].

 Further, the cutting mechanism of composite material greatly varies with conventional
material cutting mechanism [13].

 So that it becomes difficult in analyzing their machining performance. Machining

composite material can damage the material surface due to interlaminar and
intralaminar delamination, fiber exposure, fiber crack and matrix flow [14].

Since it become uneconomical to machine a composite

material through most of the conventional machining methods.
8 1/21/2020
 The present research work has been planned with an objective to
explore the potential of red mud as a filler material in polymer
composites and to investigate its effect on the erosion wear
performance of the resulting composites. Research work related to
red mud composite materials are as follows,

RED MUD
 Waste material formed during the production of Alumina from Bauxite by Bayer’s
process.

 Comprises of iron, titanium, aluminum and silica along with some other minor
constituents.

 Worldwide efforts have been taken for proper storage, utilization, and disposal of Red
mud.

 Though different approaches are for red-mud utilization few of them were proved to be
economical.
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  Johan [15] studied the physical (density) and thermal property (thermal
conductivity) of the red mud reinforced epoxy composites. Redmud filled
epoxy composites were fabricated by hand layup technique. Result shows the
increase in density with addition of red mud and also improved thermal
conductivity about 125% in 25% addition of red mud.

 Geetha and Ganesan [16] investigated the tensile behavior of metal matrix al
356 alloy reinforced red mud metal matrix composite. Results from the
experiment were analyzed through the variance analysis method. The analysis
result shows that the ultimate strength was achieved at 20% of volume
fraction of red mud.

 Red mud was used as filler in making natural fiber- polymer composite as
wood substitute products. The work results shows the red mud polymer
composites showed better physical, chemical, mechanical, weathering and
fire resistance properties than conventional materials including wood and
wood substitute. Their durability and strength make them a more promising
replacement to timber [17].
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 RESEARCH PROBLEM
From the literature, the following research gap is identified:

 Many researchers investigated the physical and mechanical properties of

composites developed by the added filler material. But very few have
investigated their erosion, machining and environmental characteristics.

 There is a need to produce a new composite material with the industrial waste
Redmud which can be used in structural applications. It should also have high
strength and high hardness as well as good erosion resistance and machining
characteristics.

 The fabricated hybrid composite need to undergo machining work to obtain a

near net shape product with better machining characteristics. In such a case, the
material should produce better surface finish with minimum delamination on
machining.

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  Few studies reported the use of Redmud (Industry waste) in composite
reinforcement. It is more essential to utilize these wastes potentially.
Though some research examine characteristics of red mud filled
composites, the results concludes with the limited examination. There is
a lack on erosion and machining studies of the redmud composite
materials.

 Thus from the thorough literature survey, it is understood the erosion

and machining studies are scarce. Hence the work is proposed to the to
study the erosion and machining property redmud filled composite
material having natural fiber reinforcement.

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 OBJECTIVES OF THE WORK
The intend of this project is to study and analyze the engineering properties of
natural fiber reinforced polymer composite formed using Red-mud as filler
material; thereby forming a low cost, light weight, high strength, and erosion
resistant composite material.
The objectives of study is
1. To fabricate natural fiber reinforced composites filled with red mud
particulate.

2. To investigate the reinforcement effect of natural fiber filled with red-

mud particulate.

3. To study the effects of surface modification of natural fiber filled with

red-mud particulate on mechanical properties and to carry out studies
on fiber matrix interaction.
13 Continues 1/21/2020
 OBJECTIVES OF THE WORK
4. The machining operation such as drilling and abrasive water jet
cutting will be conducted on the prepared specimen. In addition
erosion study will be done to observe the wear behavior of the
composite.

5. To compare the mechanical properties of different natural fiber

composites filled with red mud particulate.

6. To determine the environmental exposure on natural fiber

composites filled with red mud particulate.

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 METHODOLOGY

With respect to the objective stated, the research

methodology subdivided into four stages.
1. Specimen preparation
2. Mechanical testing on samples
3. Study on effect of erosion and machining
4. Environmental conditioning

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 Stage 1
Specimen preparation

 Specimens were planned to prepare by compression moulding and hand lay

up method.

 Needed material include Natural fiber, Filler material red mud, Resin – GP
and phenolic resin.

 Composites of three different compositions (10%, 20%, 30% of red mud) are
to be made.

 The casting are put under load for about 24 hours for proper curing at room
temperature.

 Specimens of required size are cut under AWJM for physical characterization.
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 Stage 2
Mechanical tests on samples

 As per the ASTM standard tension and compression will be

measured to provide elastic moduli, yield stress, ultimate
strength, strain to failure.

 Flexural and Impact tests will be done as per the ASTM

standard, to find the bending stiffness and strength.

 Micro hardness test is also to be carried out to find the hardness

characteristics of the composite.

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 Stage 3
Study on effect of erosion and machining

 Drilling operation is performed to find the optimum cutting

condition with the objective of reduced cutting force.

 By abrasive water jet machining process, kerf width and kerf

angle will be found at different water pressure, stand off distance
and transverse speed .

 In addition erosion test will also be done by using Erosion test

ring at different conditions.

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 Stage 4
Environmental conditioning

 The main idea of this stage is to study the durability of the

composite to environmental exposure.

 Factors that are considered for the environmental exposure are

temperature, time, moisture and salinity.

 Samples are exposed to the elevated temperature during

environmental exposure will be tested at ambient temperature.

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 M Primary Reinforcement
Natural Fibers
(20%, 30% & 40%)
Secondary Reinforcement
Redmud particulate
(0wt %, 10wt %, 20wt % & 30wt
Matrix material
Resin
(GP & Phenolic)

E %)

T
Fabrication of composites
H (Press moulding & Hand
Layup technique)

O
D Erosion wear Testing
Mechanical testing (ASTM std.) (ASTM Std.) Machining
O (Tension, Compression, Flexural,
Impact, Micro-hardness &
(Experimentation through
Taguchi
(Abrasive water jet machining
& Drilling)

L Environmental test) Experimental design)

AWJM:

O 

Tensile strength
Compression strength  Taguchi analysis
 Kerf
 MRR
 Surface Roughness
 Flexural strength  SEM analysis DRILLING:
G 

Hardness
Failure analysis (SEM)
 MRR, Delamination
 Temperature , Trust force
 Tool wear

Y
Analysis of Results

20 Conclusion and Publications

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 COURSE WORK RESULT

Sub Code Name of the subject Marks

MEC6005 Research Methodology 77

MFE6614 Composite Materials 66

MEC6705 Surface Engineering 74

MEC6031 Analysis and characterization of Polymers 65

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 WORK PLAN

Time schedule
Stage Activity
(months)

1 Literature survey 0-3

2 Fabrication and testing of natural fiber composites 4-8

Fabrication and testing of natural fiber filled with red mud in

3 9-11
thermo setting resin matrix
4 Studies on fiber matrix interaction 12-14
5 Studies on effect of fiber surface modification 15-18
Fabrication and testing of short fiber hybrid composites in
6 19-22
thermo sets
7 Machining studies 23-25

Environmental conditioning and mechanical tests on conditioned

8 26-29
samples & erosion test on samples

9 Workshop/ seminar / conferences 30-33

10 Preparation of final report 34-36

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 WORK PROGRESS
 Thorough literatures studies have been made.

 Course work is completed.

 Problem for the research work is identified based on the Literature Survey.

 Material purchase was done.

 Hybrid composites have been fabricated with varying percentage of redmud

and sisal fiber to study the effect on the mechanical properties and erosion
properties

 Mechanical properties (Tensile and Hardness strength) of composites have

been studied.

 Erosion study is under processing for fabricated composites.

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 Figure 1 provides the image of redmud secondary reinforcement material
used in this work.

Fig 1. Collected Redmud powder and SEM image of sieved redmud

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 Figure 2 shows the average particle size of the redmud reinforcement
material.

Fig. 2. Average particle of the red mud reinforcement material.

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  Fabricated Redmud and sisal fiber reinforced polyester
composite

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Fig 3. Fabricated composite plate 1/21/2020
Composites tensile strength was found as per ASTM standard ASTM D-3039. Hardness of
the composite samples were found using durometer as per ASTM D-2240. Five specimens
from each composition were tested and average value was taken for finding strength.

Fig 4. Tensile tested specimen

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 As per ASTM G76-13 solid particle erosion test was conducted on Air jet erosion
tester. The size of the sample is 25 × 25 × 5mm. Figure 5 shows the equipment
used for conducting the solid particle erosion test.

Fig. 5. (a) Solid particle erosion tester, (b, c) Position of sample at 45° and 60°
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 Figure 6 shows the shape of the erodent particles. It is observed from the SEM
image that the erodent particles are in the shape of spherical, and sharp edged.

Fig. 6. SEM image of Erodent particles Fig 7. Erosion tested specimen

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 SEM Analysis

Figure 8. SEM image of tensile tested specimens

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 Fig 9. SEM image of erosion tested samples
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 PROPOSED WORK
From result analysis a new set of specimen is planned to fabricate for
conducting drilling and water jet cutting study.

As the outcome from drilling the material removal rate tool wear rate
temperature rise and surface roughness will be measured and reported on all
kind of specimens fabricated.

The kerf, material removal rate and surface roughness will be measured on
Waterjet machining experiment and a detail report will be submitted as soon
as the experiments are finished.

Further specimens will be prepared on different natural fibres and with

varying redmud particle percentage. Same tests and machining methods will
be carried out and to explore the better performing composite for the specific
application.

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 PUBLICATIONS

 S. Vigneshwaran, M. Uthayakumar, V. Arumugaprabu. A review on erosion

studies of fiber-reinforced polymer composites, Journal of Reinforced Plastics
and Composites, 36 (2017) 1019–1027.

 S. Vigneshwaran, M. Uthayakumar, V. Arumugaprabu. Abrasive water jet

machining of fiber-reinforced composite materials, Journal of Reinforced
Plastics and Composites, (2017) , https://doi.org/10.1177/0731684417740771.

 S. Vigneshwaran, M. Uthayakumar, V. Arumugaprabu. Review on

machinability of fiber reinforced polymers: A drilling approach, Silicon,
accepted.

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 REFERENCE:
1. Daniel Gay, Composite Materials: Design and Applications, Third Edition, CRC Press, 2014,
ISBN 9781420031683.
2. Nassar MMA, Arunachalam R, Alzebdeh KI (2016) Machinability of natural fiber reinforced
composites: a review. The International Journal of Advanced Manufacturing Technology 88:
2985- 3005.
3. Ismail SO, Dhakal HN, Dimla E, et al (2016) Comprehensive study on machinability of
sustainable and conventional fibre reinforced polymer composites. Engineering Science and
Technology, an International Journal 19: 2043-2052.
4. Hejjaji A, Singh D, Kubher S, et al (2016) Machining damage in FRPs: Laser versus
conventional drilling. Composites Part A: Applied Science and Manufacturing 82: 42–52.
5. Lopresto V, Caggiano A, Teti R, et al, (2016) High Performance Cutting of Fibre Reinforced
Plastic Composite Materials. 7th HPC – CIRP Conference on High Performance Cutting,
Chemnitz, Germany, In: Procedia CIRP.
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International Journal of Machine Tools & Manufacture 51: 937–946
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matrix composites reinforced with natural fibers in the green materials world, Eng. Sci.
Technol. an Int. J. 19 (2016) 717–736. doi:10.1016/j.jestch.2015.10.007.
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reinforced composite using taguchi experimental design, Mater. Today Proc. 2 (2015) 2389 –
2398 4th. doi:10.1016/j.matpr.2015.07.176.
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composites using Taguchi experimental design, Mater. Des. 30 (2009) 2791–2801.
34 doi:10.1016/j.matdes.2009.01.037. 1/21/2020
 REFERENCE:
10. Nassar MMA, Arunachalam R, Alzebdeh KI (2016) Machinability of natural fiber reinforced
composites: a review. The International Journal of Advanced Manufacturing Technology 88: 2985-
3005.
11. Ismail SO, Dhakal HN, Dimla E, et al (2016) Comprehensive study on machinability of
sustainable and conventional fibre reinforced polymer composites. Engineering Science and
Technology, an International Journal 19: 2043-2052.
12. Hejjaji A, Singh D, Kubher S, et al (2016) Machining damage in FRPs: Laser versus conventional
drilling. Composites Part A: Applied Science and Manufacturing 82: 42–52.
13. Lopresto V, Caggiano A, Teti R, et al, (2016) High Performance Cutting of Fibre Reinforced
Plastic Composite Materials. 7th HPC – CIRP Conference on High Performance Cutting,
Chemnitz, Germany, In: Procedia CIRP.
14. Lazar MB, Xirouchakis P (2011) Experimental analysis of drilling fiber reinforced composites.
International Journal of Machine Tools & Manufacture 51: 937–946.
15. Johan Banjari, Yagya Kumar Sahu, Alok Agrawal, Alok Satapathy, Physical and thermal
characterization of red mud reinforced epoxy composites; An experiment investigation.
International conferences on advances in manufacturing and materials engineering, Procedia
materials, issue 5, pp. 755–763 (2014).
16. B.Geetha, K.Ganesan, Optimization of tensile characteristics of al 356 alloy reinforced with
volume fraction of red mud metal matrix composite. 12th Global congress on manufacturing and
management, GCMM 2014, procedia engineering, vol 97, pp. 614–624 (2014).
17. Mohini Saxena and P. Asokan, Utilisation of bauxite redmud in wood substitute composites. The
35 International Committee for the Study of Bauxite, Alumina and Aluminium (ICSOBA), Volume 3,
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June 2010.
 Thank you

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