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CW3_1CW3_1 Characterization of Polymer Composite Material Coursework Title: Characterization of a Polymer Composite Material Module Name: Materials: Properties and Processing Module Code: 5065ENG Level: 5 Credit Rating: 20 Weighting: 20% Lecturer: Dr Ga...

CW3_1
CW3_1 Characterization of Polymer Composite Material Coursework Title: Characterization of a Polymer Composite Material Module Name: Materials: Properties and Processing Module Code: 5065ENG Level: 5 Credit Rating: 20 Weighting: 20% Lecturer: Dr Gareth Bradley Contact: If you have any issues with this coursework you may contact your lecturer. Contact details are: Email: g.r.bradley@ljmu.ac.uk Email: peter.claiden@sbc-usst.edu.cn Room: T 303 Tel: 021 64742195 Issue Date: March 2012. Hand-in Date: 3 weeks after the laboratory. To be submitted electronically via the Turnitin section of Blackboard. It is recommended that you submit your report as a pdf file (in MS Word: File – Save As – Save as type: select pdf) and that you check it prior to submission to ensure your document has converted correctly. Feedback: Feedback will be given when your coursework is returned to you. Feedback will be written and/or oral. Programmes: B.Eng (Hons) Manufacturing Systems Engineering. You are advised that the School of Engineering operates a zero tolerance approach to late submission of coursework. Any coursework submitted late will be awarded a zero mark unless there are valid mitigating circumstances supported with evidence of the mitigation claimed. Be advised that loss of computer data will not be accepted in mitigation; it is entirely your responsibility to ensure the secure backup of all electronic data. Please ensure that you submit your work by the deadline date and that you obtain an appropriate receipt. 1 Assessment The experimental procedure is to be undertaken as a small group, although the report is to be attempted individually. Marks will be awarded for the various sections (See Laboratory Report, page 5) as follows: i Description of the experimental technique 10% ii Tabulation of experimental data - 10%, iii Plotting of graphs - 10%, iv Discussion of the results and the methods of analysis- 40%, v Conclusions including the apparent advantage/disadvantage of thermo-set composite in this case - 20%, Presentation of the submitted work - 10%. 2 AIMS & OBJECTIVES , To assess the capacity of a composite to improve the mechanical properties of a polymeric fibrous mesh , To be able to undertake a compression test and understand the significance of the results with regards to the material properties , To assist the student in making informed choices with regards to material processing TRANSFERABLE SKILLS , Analysis of experimental data , Technical report writing MODULE LEARNING OBJECTIVES This assignment should assist the student in addressing the following learning objectives: , LO.1 Explain the micro-structural and macro-structural properties of composite and polymeric structural engineering materials , LO.2 Critically evaluate the typical mechanical properties of composite and polymeric structural engineering materials , LO.3 Understand the principles of monte-carlo modelling when analysing material properties RECOMMENDED TEXTS rdAshby, MF; Jones, DRH: Engineering Materials 1 – An introduction to properties, applications and design (3 edition), 2005, Elsevier Butterworth Heinemann. Ashby, MF; Jones, DRH: Engineering Materials 2 – An introduction to microstructures, processing and design rd(3 edition), 2006, Elsevier Butterworth Heinemann. Askeland, DR; Fulay, PP (2009): Essentials of Materials Science and Engineering (2nd edition), Cengage Learning, 978-0-495-43850-2. Callister, WD and Rethwisch, DG (2011): Materials Science and Engineering (8th edition), Wiley, 978-0-470- 50586-1. 3 INTRODUCTION The original fibrous mesh is cheap and easily cut to shape. But it has low strength and can be pulled apart with the fingers of the hand. The primary reason is that the fibres are not connected or interwoven. The sample-mesh has undergone a process which coats (surrounds) the fibres by a thermo-set epoxy-resin. This increases the stiffness of the individual fibre. Also, the resin joins groups of fibres at vertices thus providing continuous structural integrity to the mesh. The purpose of the experiment is to determine the Young’s Modulus (E) of the resin coating. This is complicated by the fact that the coating process is not perfect. As a result, there are clumps of resin that fill the space between the fibres. Also, where fibres are individually coated it is difficult to measure E-value directly. This is because the fibres are between 1mm and 3mm long, which is too short for conventional tensile testing machines. You will conduct a compression test on the sample mesh and analyse your results with the aid of a computer simulation. A statistical approach is necessary because the fibres have random length and orientation. During the computer simulations, mesh-geometry is represented as a network of four fibres joined at a vertex. The length and orientation of each fibre has a uniform random distribution within the following limits: length ooo between 1 and 3mm with 0.1mm interval, and orientation between 53 to 75 with 1interval. During each simulation, E-value of an individual fibre in the group is calculated. Also, vertical load on the fibre is calculated, by considering equilibrium conditions such as net zero-moment. After approximately 1000 simulations the average calculated load converges to the value derived from experimental procedure i.e. estimated fibre density and compressive load. In a separate experiment the hardness of the resin material will be estimated. Hence the derived yield stress will indicate whether results are approximately correct or not. PROCEDURE A sample mesh is placed in the compression test machine and loaded until the thickness of the mesh is approximately 25% of original thickness. The load is then removed. During all this time, stress and strain data is collected. Part 1: Prior to commencing the experiment, measure the initial thickness and diameter of the sample using a micrometer. Conduct the compression test on the sample, and download load and displacement data. After the test, re-measure the thickness and diameter of the sample. In addition, estimate the fibre density of the original mesh using a magnifying glass Part 2: By carefully examining the surface of another sample of composite mesh, select an area which is suitable for hardness testing. Conduct the hardness test on the surface, while noting that only a relatively small force will be required to indent the material. 4 LABORATORY REPORT The report will have a title page, an abstract, introduction, discussion, conclusion and bibliography: 1. Describe the experimental technique in your own words 2. Tabulate the following: Load/Displacement Data, Hardness and Yield Stress and Input Parameters for Computer Simulations 3. Plot graph of Load versus Displacement Curve 4. Explain the curve(s) of the graph. Using the computer simulation, calculate E-value of individually coated fibres. Identify the parts of the computer program which is able to represent the random structure of the mesh. How these might be changed, and what would be their effect. 5. From the hardness test results estimate the yield strength of the bulk material i.e. clumps of resin that fills the space between the fibres. Compare the yield stress value with maximum stress value obtained from compression testing 6. Compare results from experiments and simulation with typical values obtained from the literature 5 Guide to Performance Criteria 70% and above: Your work must be of outstanding quality and fully meet the requirements of the coursework specification and learning outcomes stated. You must show independent thinking and apply this to your work showing originality and consideration of key issues. There must be evidence of wider reading on the subject. 60% - 70%: Your work must be of good quality and meet the requirements of the coursework specification and learning outcomes stated. You must demonstrate some originality in your work and show this by applying new learning to the key issues of the coursework. There must be evidence of wider reading on the subject. 50% - 60%: Your work must be comprehensive and meet all of the requirements stated by the coursework specification and learning outcomes. You must show a good understanding of the key concepts and be able to apply them to solve the problem set by the coursework. There must be enough depth to your work to provide evidence of wider reading. 40% - 50%: Your work must be of a standard that meets the requirements stated by the coursework specification and learning outcomes. You must show a reasonable level of understanding of the key concepts and principles and you must have applied this knowledge to the coursework problem. There should be some evidence of wider reading. Below 40%: Your work is of poor quality and does not meet the requirements stated by the coursework specification and learning outcomes. There is a lack of understanding of key concepts and knowledge and no evidence of wider reading. 6 Plagiarism Plagiarism is considered as academic misconduct. The University takes cases of plagiarism very seriously and all alleged cases of academic misconduct will be investigated thoroughly by a School Investigatory Panel. Students are advised to ensure that any coursework submitted is their own work or, where the work of others is referred to (this includes any third-part material e.g. text, images, diagrams, drawings), it is correctly referenced. The University defines plagiarism in the following way: The representation of the work, written or otherwise, of any other person, from any source whatsoever, as the candidate's own. Examples of plagiarism may be as follows: The verbatim copying of another's work without clear identification and acknowledgement – including the downloading of materials from the internet without proper referencing and acknowledgement. The close paraphrasing of another's work by simply changing a few words or altering the order of presentation, without clear identification and acknowledgement. Unidentified and unacknowledged quotation of phrases from another's work. The deliberate and detailed presentation of another's concept as one's own. For more information you are directed to following the university websites: Academic misconduct (including plagiarism): www.ljmu.ac.uk/corporate/SPR/89510.htm Study skills: www.ljmu.ac.uk/lea/78126.htm Referencing: www.ljmu.ac.uk/lea/78127.htm 7
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