MECHANICAL BEHAVIOUR OF ALUMINIUM BASED
METAL MATRIX COMPOSITES REINFORCED WITH SiC
AND AFOR SHAFT
PRESENT BY:A.Kalaiyarasan & Ragupathi.PAssistant Professor, Department of mechanical Engineering ,Muthayammal Engineering college Rasipuram.
PRESENTATION TOPICS Objective
Introduction
Literature Survey
Methodology
Identification of problem
Material Selection
Aluminum Series
Properties of reinforcement
Core Materials
Parameter selection
Testing
Type of analysis
Static Analysis
Modal Analysis
Analysis Results
Application
Work in progress
Future work
References
OBJECTIVE
The main objective of project to avoid whirling vibration. The operating parameter of the composite as its control the properties of the composite material.
These is focus on the study of mechanical behavior of Aluminum metal matrix composite with varies composition of reinforcement particles of graphite or nanoparticles, Sic and Al2O3 composite produced by the stir casting technique. Different percentage of reinforcement is used. Tensile test, Hardness test and torsional test.
INTRODUCTION
A composite material is defined as a material system which consist of a
mixture or a combination of two or more different materials which are
insoluble in each other and differ in form or chemical composition.
Composite materials should comprise component materials that are congenital
with each other. In the field of high modulus composites, resin-matrix
composites find considerable interest is easy to fabricate into engineering
structures.
Two Phase of Composite materials.(i)Matrix (ii)Reinforcement.
Classification of composite materials:
1. Based on matrix material.
2. Based on material structure.
INTRODUCTION (Cont.…)
The major composite classes based on structural composition of the matrix are:
Polymer-matrix composites Metal- matrix composites Ceramic- matrix composites Carbon- carbon composites The composite gives indication of the combinations of two or more
materials in order to improve the properties of monolithic material for adjusting to global need for reduced weight, low cost,quality,and high performance in structural materials.
LITERATURE SURVEYSI.No
TITLE AUTHOR YEAR INFERENCE
1. Preparation of Aluminum matrix composite by using stir casting method
Rajesh Kumar Gang Aram Bhandare
2013 Stir casting process, Aluminum Matrix reinforcement, mixing and agitation.
2.A review of friction stir welding of aluminum matrix composite
Umar S.Salih, Hengan
2015 Friction stir welding, Al- Matrix ,microstructural and mechanical properties.
3. Characterization of Silicon Carbide reinforced Aluminum matrix composite
M.D.Habibur Rahman,H.M.
Mamunal Rashed
2013 MMCs,stir casting,Hardness,Micro Structure, wear resistance.
LITERATURE SURVEY(Cont...)SI.No
TITLE AUTHOR YEAR INFERENCE
4. Fabrication of Al-Sic composite through power metallurgy process and testing properties.
C.S.Verma RajeshPurohit,
R. S.Rana
2012 MMCs,mechanical alloying, micro-structural analysis.
5.Effects of process parameter of stir casting on metal matrix composite.
Alok Barnwal Shubham Mathur
2013 Silicon carbide, Stir pouring temperature,UTM,Hardness.
6. A study on microstructure of Al matrix composite.
Pardeep shrma,Dinesh
khanduja
2015 Al –MMC graphite, Microstructure scanning.
7. Experimental investigation on machining characteristics of Al6061 hybrid metal matrix composite processed by EDM
C.Velmuruga Subramanian
2011 Aluminum composite, stir casting, Hybrid composite.
LITERATURE SURVEY(Cont...)SI.No
TITLE AUTHOR YEAR INFERENCE
8. Characterization of SiC particulate reinforced AA6061 Aluminium alloy composite produced via stir casting.
N. Chawla, J.J. Williams, G. Piotrowski, and R. Saha
2014 Tensile strength, microstructure,
stir casting, MMCs.
9.Material optimization and weight reduction of drive shaft using composite material.
G. B. Veeresh Kumar, C. S.
P. Rao, N. Selvaraj, M.
S. Bhagyashekar
2013 Composite, propeller shaft, transmission,
universal joint.
10. Experimental investigation to study tool wear during turning of alumina reinforced Aluminium.
Balasivanandha Prabu,L.
Karunamoorthy, S.
Kathiresan, B. Mohan
2013 MMC graphite, Harness
toughness, Microstructure
scanning.
METHODOLOGY
OBJECTIVE
SELECTION OF MATERIAL
STARTING ALUMINUM ALLOY LM6 WITH REINFORCEMENT SiC AND Al2O3
PROBLEM DEFINITION
DATA COLLECTION
PRODUCTION OF COMPOSITE BY STIR CASTING
TENSILE TEST HARDNESS TEST TORSIONAL TEST
STATIC AND MODAL ANALYSIS OF SHAFT
RESULT AND CONCLUSION
Characterization (SEM,XRD)
FINISH
PHA
SE-I
PHA
SE-I
I
IDENTIFICATION OF PROBLEM
The passenger cars, trucks and vans should have the torque transmission capacity more than 3500Nm and the natural frequency must be higher than 6500 rpm to avoid whirling vibration.
In that the critical speed of shaft is inversely proportional to the square of the length.so that the vibration problem could be solve by increasing the length of shaft but its not permitted due to space limitations.
So that its only for manufacturers and manufacture the shaft in two pieces.
SCHEMATIC ARRANGEMENT OF UNDERBODY OF AN AUTOMOBILE
MATERIAL SELECTION
Aluminum alloy Silicon carbide and alumina (Reinforcement Particles) Graphite particles
ALUMINUM SERIES
ALLOY SERIES FEATURES APPLICATION
Al2024 Good corrosion resistance & High
strength
High strength structural(aircraft),
automotive parts, screws and rivets.
Al6061 Good formability, weld ability, corrosion
resistance and strength.
Automobile parts, Marine, aircraft's
Al7079 High strength alloy Aircraft and structure, recreation equipment's.
PROPERTIES OF REINFORCEMENT MATRIXPROPERTY Al2O3 SiC GRAPHITE
Density(at 20) g/c 3.97 3.22 2.09-2.23
Melting point 2288 2973 3915
Thermal expansion )
7.1 4 2.6
Thermal conductivity
(W/m K)
35.6 126 85
Young's modulus GPa
370 410 10
CORE MATERIALS
PROPERTIES/ MATERIALS
ALUMINUM STEEL
Stiffness(N/m) 22.9 22.65
Density(Kg/) 2700 7800
Weight Low High
Young's modulus(GPa)70 21
Poisson ratio 0.33 0.3
Co.eff of Thermal expansion ()
23.4 12
Correction resistance High Low
VOLUME FRACTIONS
Fiber and Matrix volume fraction is,
Sum of volume fraction is
volume of composite, fiber, and matrix
density of composite, fiber, and matrix
MASS FRACTIONS
Fiber and Matrix mass fraction is
mass of composite, fiber, and matrix
Sum of volume fraction is
DENSITY of the composite
PARAMETER SELECTION
PARAMETERS NEW MATERIAL OLD MATERIAL
Density(Kg/) 2810 2700
Poisson ratio 0.31 0.33
Young modulus(Pa) 1.21e11 7.0e10
TESTING
Tensile test Hardness test Torsional test Characterization (SEM,XRD)
TYPE OF ANALYSIS
Static analysis of composite shaft Torsional analysis Dynamic analysis (modal)
STATIC ANALYSIS
A static analysis is used to determine the displacements, stresses, strains and forces in structures or components caused by loads that do not induce significant inertia and damping effects.
In static analysis loading and response conditions are assumed, that is the loads and the structure responses are assumed to vary slowly with respect to time.
BOUNDARY CONDITION
DEFORMATION,VON MISES STRESS & EQUIVALENT ELASTIC STRAIN
STATIC ANALYSIS RESULTS
Al-SiC Aluminium Steel
Total Deformation
[m]6.893 1.1927 4.147
Equivalent (von-
miss)stress[Pa]
1.39851.3985
1.4634
Equivalent Elastic
Strain[No Unit]
1.1604 2.0716 7.3721
TOTA
L DEF
ORMATION
EQUIVALEN
T(VON-M
ISS)ST
RESS
EQUIVALEN
T ELA
STIC ST
RAIN
0.00E+00
2.00E+05
4.00E+05
6.00E+05
8.00E+05
1.00E+06
1.20E+06
1.40E+06
1.60E+06
STEELAl
Al -SiC
STEELAlAl -SiC
MODAL ANALYSIS
The natural frequencies and the mode shapes are important parameters in the design of a structure for dynamic loading conditions. Modal analysis is used to determine the vibration characteristics such as natural frequencies and mode shapes of a structure or a machine component while it is being designed.
The natural frequency depends on the diameter of the shaft, thickness of the hollow shaft, specific stiffness and the length.
MODE 1 & 2
MODE 3 & 4
MODE 5 & 6
MODE 7
MODAL ANALYSIS RESULTS
Mode 1 mode 2 mode 3 mode 4 mode 5 mode 6 mode 70
100
200
300
400
500
600
700
800
900
1000
Al-SiC
Al-SiC
APPLICATIONS
Aircrafts structures Automotive parts Aerospace Marine
WORK IN PROGRESS
FIRST REVIEW
• Field Research• Literature Survey
SECOND REVIEW
• Problem Identification • Material selection
THIRD REIVEW
• Design and Analysis of shaft• Static and Dynamic Analysis is done using ANSYS Workbench
15.0
PRESENT CONCLUSION
The behaviour of Aluminium alloy (LM6) and Silicon carbide literature was collected and studied.
The finite element analysis is used in this work to predict the deformation of shaft.
The fabrication of the section will be done in the next phase. Fabrication of section will be based on the design created in the first phase.
The modeling and analysis of shaft is done by using ANSYS Workbench.
FUTURE WORK
The volume fraction (5%,10%,15%,20%) of aluminum alloy(LM6) and SiC with Alumina will be fabricate through stir casting technique.
The specimen will be evaluated by using Hardness test, tensile test, Torsional test and SEM/XRD.
The specimens are going to be prepared by liquid metallurgy method, the Anna University CEG campus, Chennai was identified to prepare casting of composite materials by stir casting method.
The testing is identified at Root India Pvt ltd, Ganapathi Coimbatore.
Material purchase
Specimen preparation
Submission Project PhaseII Report
Mechanical testing and
Result analysis
REFERENCES Manoj,S. Dwivedi,D.D., Lakhvir,S.andVikas,C.(2009):”Development of Aluminum
Based Silicon Carbide Particulate Metal Matrix Composite". Journal of Minerals and Materials Characterization and engineering, Vol.8,No.6,pp455-467.
Dunia Abdul Sahib, Aluminum silicon carbide and aluminum graphite particulate composites,ARPN J.Engg Appl. Sci.6(2011)41-46.
Muhammad Hayat Jokhio,Muhammad Ibrahim Pan war, and Mukhtiar Ali Unar “Manufacturing of aluminum composite material using stir casting process”. Mehran University Research Journal of Engineering and Technology, volume 30,NO.1, January,2011[ Issan 0254-7821].
Hashmi Looney L, Hashmi MSJ(1996).MMCs: Production by stir casting method. Journal of Materials Processing Technology,92-93pp1-7
Lilholt H , Aspects of Deformation of Metal Matrix Composites, Materials. Kurt A, Uygur I, Cete E. Surface modification of aluminum by friction stir
processing. J Mater Process Techno 2011;211:313–7. Mostafapour Asl A, Khandani ST. Role of hybrid ratio in microstructural,
mechanical and sliding wear properties of the Al5083/Graphite /Al2O3p a surface hybrid Nano composite fabricated via friction stir processing method. Mater Sic Eng. A 2013;559:549–57.
REFERENCES(Cont...)
Vijayarangan.S., Rajendran.I,Optimal design of a composite leaf spring using Genetic algorithm computers and Structure 79 2001:pp.1121-1129.
T.Rangaswamy “Optimal design and analysis of Automotive Composite Drive Shaft” International symposium of research students on materials science and engineering December 2002-004 Chennai India.
Kim C.D 1992”Critical speed analysis of laminated shafts". Composite engg.vol.3,pp.633-643.
J.H.Park,J.H.Wang 2001.”Stacking sequences design of Composite laminates for maximum strength using Genetic Algorithm". Journal of Composite Structure,Vol.52.pp.217-231.
Mr.V.I.Narayana, Mr.D.Mojeswararao and Mr. Kumar. ”Optimization of composite drive shaft assembly and comparison with conventional steel drive shaft,vol.I issues 6 august 2012.
https://www.google.co.in/properties of aluminum https://www.google.co.in/properties of steel https://www.google.co.in/properties of stainless steel pdf https://www.google.co.in/properties of silicon carbide
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