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Self-Sensing, Lightweight and High Modulus Carbon Nanotube Composites for Improved Efficiency and Safety of Electric Vehicles

NoPo Nanotechnologies India Pvt Ltd-Aparna Allannavar
NoPo Nanotechnologies India Pvt, Ltd.-Gadhadar Changalaraya Reddy
  • Technical Paper
  • 2019-28-2532
To be published on 2019-11-21 by SAE International in United States
Carbon Composites (CFRP) have been touted to be an essential component of future automobiles due to their mechanical properties and lightweight. CFRP has been adopted successfully for secondary and primary structures in Aerospace industry. In Automobiles, they are incorporated in models like the BMW i-series. CFRP suffers from 2 major problems. Delamination of Composites leads to catastrophic and rapid failure which could be dangerous in passenger vehicles. Delamination occurs whenever there is a shock on the composite. Secondly, Composites need regular expensive maintenance to ensure that the material is intact and will not compromise passenger safety. Carbon Nanotubes in composites have shown a substantial increase in delamination resistance. A 0.1wt% addition of HiPCO® Single-walled Carbon Nanotube provides both self-sensing and improved fracture resistance. Here we report results of our work with NoPo HiPCO® Nanotubes with small amounts of Iron. 6K Carbon fiber was used as the fiber reinforcement. NoPo HiPCO® Nanotubes were reinforced in the Epoxy system by sonication. HiPCO® Nanotubes were produced using standard parameters. The coupons of CENCE composite were made using VARTM…
 

Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

Hyundai Motor India Engineering PVT LTD-Vignesh balaji S G, Pradeep S, Aakash S K
  • Technical Paper
  • 2019-28-2538
To be published on 2019-11-21 by SAE International in United States
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts. Methodology: Before beginning the tests, the specimens should be prepared and the steps for the preparation of paper honeycomb reinforced epoxy composites are shown below: 1. Mould Preparation 2. Mixing of Epoxy and Hardener with a ratio of 10:1 3.…
 

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

Dhanalakshmi Srinivasan Institute of Tec-Thirugnana Sambandha T, Arun R
Dhanalakshmi Srinivasan institute of tec-Krishnaraj M
  • Technical Paper
  • 2019-28-2570
To be published on 2019-11-21 by SAE International in United States
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
 

A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle

FORCE MOTORS, Pune , India.-Pradeep C
Sri Krishna College of Engg and Tech-Soundararajan R, Sathish Kumar K, Shanthosh G
  • Technical Paper
  • 2019-28-2572
To be published on 2019-11-21 by SAE International in United States
A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle Research Objective This paper presents a hybrid composite brake disc with reduced Un Sprung Weight clearing thermal and structural analysis in a formula vehicle.Main purpose of this study is to analyse thermomechanical behaviour of composite brake disc for a formula vehicle under severe braking conditions. Methodology In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodelled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of Silicon carbide (SiC) and Graphite (Gr) as a hybrid composite material for this proposed work. In First Phase of this Project work, By varying slotting pattern and groove angles the transient thermal and structural analysis using ANSYS workbench ,the hybrid composite disc plate of disk brake is done.The…
 

Design and Analysis of Natural Fibre Reinforced Epoxy Composites for Automobile Hood

SRM Institute Of Science And Technology-Akhil Kumar Guduru, V N B Prasad Sodisetty, Vidya Prudhvi Sai Katari
  • Technical Paper
  • 2019-28-0086
To be published on 2019-10-11 by SAE International in United States
The need for eco-friendly materials is recently increasing in the automobile and aerospace sectors. Material selection for automobile components is influenced by various factors such as cost, weight and strength. Natural fibers offers various advantages over conventional materials such as environmental friendly, easily available, recyclable and higher specific strength. Among the natural fibers Sisal and Kenaf fibers are selected for present study due to their good mechanical properties and availability. Kenaf fibers have great potential to be used as construction and automotive materials due to their long fibers which are derived from the bast. Sisal fibers do not absorb moisture and posses good impact, sound absorbing properties and high fire resistance properties. Epoxy LY556 is selected as matrix material to bind the combination of these two natural fibers due to its high temperature resistance and adherence to reinforcements. Alkaline treatment was carried out to remove the moisture from the natural fibers. Fabrication of epoxy/Kenaf fibre/Sisal Fibre composite materials of different stacking sequence was carried out by Vacuum Assisted Resin Transfer Molding (VARTM) method. These composites…
 

Mechanical and corrosion behaviour of 7075 aluminium matrix composite reinforced with TiC and Al2O3

Vellore Institute of Technology-Subham Jaiswal, Govindasamy Rajamurugan, Prabu Krishnasamy, Yashwardhan Shaswat, Mishra Kaushik
  • Technical Paper
  • 2019-28-0094
To be published on 2019-10-11 by SAE International in United States
Various research regarding new methods of fabrication and modifications of Aluminium alloy to improve the existing properties are going on. The wide application of aluminium in aerospace and automobile Industry, demands improved mechanical properties with little to zero increment in weight. This work is based on the fabrication of hybrid metal matrix composites of 7075 aluminium alloy with the addition of TiC (Titanium Carbide) and Al2O3(Aluminium Oxide) reinforcements is fabricated using stir casting technique. Weight percentage of 5%, Al2O3 8% and Tic 12%, Tic 15% and Al2O3 10%. Samples are prepared for each mass distribution . Varying weight fraction samples are prepared to have a proper comparative study of the mechanical properties. In the fabrication we gradually increased the weight of TiC and Al2O3 as we progressed with the experiment.. The objective is to have a clear idea of mechanical properties variation with variation in reinforcement. Hardness tests is done using optical Brinell Hardness Testing machine . A proper characterisation of the samples was attained by using advanced electron microscopes. Tensile properties of the samples…
 

Investigation of Dry sliding Wear behavior of AA8011 reinforced with Zirconium Oxide and Aluminium Oxide Hybrid Composites processed through Multi direction forging

Sri Krishna College of Engg. and Tech.-Sathishkumar Kuppuraj, Soundararajan Ranganathan, Sathishkumar Aruchamy, Shanthosh Gopal
  • Technical Paper
  • 2019-28-0057
To be published on 2019-10-11 by SAE International in United States
The present work focused on fabricating hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 was taken equal (5wt%) weight percentage respectively. The hybrid composites were casted in square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further it was taken for forging process. The prepared three samples were induced for uni-direction (x), bi- direction (x and y) and multi direction (x,y and z) forging route and the response of micro hardness of 68,81 and 96 VHN were obtained due to microstructural phase changes with uniform distribution of particles in the matrix. Further the forged hybrid composites were investigated for tribological tests under dry sliding condition in a Pin-on-Disc tribometer apparatus by varying the load of 5,10,15,20 N and by adjusting the sliding speed as 200, 450 and 800 rpm respectively. The outcomes uncovered all the samples that the wear rate increments with increase in load and coefficient of friction shows decrement at most extreme load conditions. Wear rate increases with increase in sliding speed and coefficient of friction…
 

Damage Analysis of Composite Laminates

GITAM School of Technology-Palaniammal Rajamani, Nathi Venu Kumar
  • Technical Paper
  • 2019-28-0092
To be published on 2019-10-11 by SAE International in United States
The favourable mechanical properties of Composite materials are excellent stiffness/weight and strength/weight ratios, easy formability and corrosion resistance. The application of composites in structural components is still limited by the difficulty in predicting their service lives. The objective of this research paper is to develop and evaluate damage initiation or delamination onset and growth in a C-C composite 8 layered pre-preg material 3D laminate model (dimension 25x3.4x85mm and ply thickness 1mm) under various loading conditions for two cases, one without crack and another with crack using ANSYS Autodyne tool subjected to a uni-axial load of 40N at the free end. Mapped quadrilaterals mesh is generated with 2610 nodes and 1792 elements. Cohesive Zone Model (CZM) formulations are more powerful than Fracture Mechanics approaches because they allow the prediction of both initiation and crack propagation. The composite laminate plate is thus bent due to Poisson effect, and crack opens up due to the heavy normal stress at the crack interface and the strain energy variation is uniform in length direction for pre-preg model. The bonding ply…
 

Critical wear assessment of AA8011/Hybrid metal matrix composites with surface amendment using Friction Stir process

Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Shri Vignesh Ramachandran, Ramprakash Palanivelu, Saravanakumar Ramasamy
  • Technical Paper
  • 2019-28-0096
To be published on 2019-10-11 by SAE International in United States
Friction Stir Process (FSP) was used for surface modification of steel, titanium, aluminum and magnesium based alloy has been considerably reviewed during the last decade. FSP can improve surface properties such as abrasion resistance, hardness, strength, ductility, corrosion resistance, fatigue life and formability without affecting the bulk properties of the material. The aluminum alloy having low ductility and softness characteristics are restricted because of their poor tribological properties. Preliminary studies reveal that, an ideal circumstance is to improve the aluminum alloy material life cycles by the way of strengthening the surface layer which can be modified through reinforcing nano particles through FSP. By the way, this experiment was carried out to obtain three set of samples like virgin AA8011, AA8011 with shape memory alloy and AA8011 along with shape memory alloy and silicon nitride during FSP under optimal process parametric condition. The improved distributions of nanoparticles were obtained after each FSP pass and progress in mechanical properties was observed. On the other hand to assess the tribological performance of prepared hard surface, three samples were…
 

Design and Analysis of Aluminium-Flyash Composite for Connecting Rod

Geethanjali College of Engg. and Tech.-Suresh Nuthalapati, Devaiah Malkapuram
  • Technical Paper
  • 2019-28-0166
To be published on 2019-10-11 by SAE International in United States
In this modern era of rapid growth of technology and need of economical machining processes and materials, there is an increasing demand for new materials for different mechanical applications. Composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications. To improve wettability, elements such as Mg and Si are added into Al melt to incorporate the ceramic particles. The chemical composition and engineering properties of fly ash, its physical and chemical properties make it an ideal raw material for producing various application based composites. The main objective this paper is to fabricate an aluminium- fly ash composite material suitable for parts like engine connecting rod which demand high strength and temperature sustainability at comparatively less weight. The composite will be made using casting process and Engine connecting rod will be designed in AutoCAD software. The design will be analyzed with the help of ANSYS with aluminium and aluminium- fly ash composite (at different compositions).