Effect of processing conditions on warpage of film insert molded parts

In order to investigate effects of injection molding conditions on viscoelastic behavior and thermal deformation of film insert molded (FIM) parts, injection molding was performed with various conditions such as injection speed, melt temperature, and packing time. It was shown that variation of the warpage was decreased monotonically with increasing injection speed and exhibited a bell-shaped curve as a function of melt temperature. Warpage variation was not affected by the packing time significantly and the proportional relationship between warpage of the film insert molded part and shrinkage of the injection molded part without film was observed. The FIM specimens produced with unannealed films showed the warpage reversal phenomenon (WRP) during annealing and the magnitude of reversed warpage was affected significantly by the injection parameters and the extent of thermal shrinkage of the unannealed film. Warpage of the FIM specimen was predicted by three dimensional numerical flow and stress analyses and the predicted values showed a good agreement with the experimental results.     

Prediction and measurement of residual stresses in injection molded parts

Residual stresses were predicted by a flow analysis in the mold cavity and residual stress distribution in the injection molded product was measured. Flow field was analyzed by the hybrid FEM/FDM method, using the Hele Shaw approximation. The Modified Cross model was used to determine the dependence of the viscosity on the temperature and the shear rate. The specific volume of the polymer melt which varies with the pressure and temperature fields was calculated by the Tait’s state equation. Flow analysis results such as pressure, temperature, and the location of the liquid-solid interface were used as the input of the stress analysis. In order to calculate more accurate gap-wise temperature field, a coordinate transformation technique was used. The residual stress distribution in the gap-wise direction was predicted in two cases, the free quenching and the constrained quenching, under the assumption that the shrinkage of the injection molded product occurs within the mold cavity and that the solid polymer is elastic. Effects of the initial flow rate, packing pressure, and mold temperature on the residual stress distribution was discussed. Experimental results were also obtained by the layer removal method for molded polypropylene.     

Improvement in mechanical properties of aluminum polypropylene composite fiber

Aluminum particles (Al) were added to polypropylene (PP) in the presence of poly ethylene glycol (PEG) and polypropylene-graft-maleic anhydride to produce composites. The composites were then melt-spun into a mono filament and tested for tensile properties, diameter evenness and morphology. Melt rheological properties of Al/PP composites were studied in linear viscoelastic response regions. It was observed that level of dispersion of aluminum particles within a polypropylene composite fiber could be improved by incorporating polyethylene glycol. The improvement of dispersion led to an improvement in the fibers mechanical properties through a reduction of the coefficient of variation of fiber diameter.     

Comparative investigation of molded thickness and surface density on the structures and mechanical properties of lightweight reinforced thermoplastic composites

Lightweight reinforced thermoplastic (LWRT) is a newly developed porous material. The low density, high rigidity, design flexibility and sound absorption of LWRT facilitate its application in the automotive industry. Fibers are bonded with a matrix and air is imported by deconsolidation, which is not only economical but also environmentally friendly. In this work, film stacking and non-woven methods were employed as the impregnation techniques to manufacture LWRT. The molded thickness and surface density of LWRT were varied to study their influences on the structures and mechanical properties. Different lengths of fibers in LWRT were selected and 7 % PP-g-MAH was added to the matrix and compared with unmodified matrix. The mechanical properties decreased with the increase in molded thickness and the decrease in surface density. With higher fiber length, the strength and stiffness increased, while the toughness exhibited a maximum value at 80 mm fiber length. The strength and stiffness of LWRT were also enhanced when 7 % PP-g-MAH was added.     

Study on mechanical and thermal properties of fiber-reinforced Epoxy/Hybrid-silica composite

Recently, carbon fiber composites have been widely used as structural reinforcement materials of buildings, replacing reinforcing bars or concrete. And the increase in use of super fibers such as aramid and high strength PE, which is aimed at improving the reinforcement properties, has resulted in a demand for a resin system with excellent mechanical and thermal properties. In this research, a fiber-reinforced composite has been produced by using the super fibers such as carbon fiber or aramid fiber, reinforcement resin and the silica hybrid compound containing epoxy group. This study was carried out to confirm the effect of the silica hybrid on mechanical properties, heat resistance and adhesion strength of a fiber-reinforced epoxy composite, which was produced by blending silica or introducing silica hybrid through covalent bonds. And the silica hybrid containing epoxy group, which may be introduced to the structure of fiber-reinforced epoxy composite through covalent bonds caused by reaction with a hardener, has been used, so that the heat resistance and adhesion strength could be improved.     

Manufacturing technique and mechanical properties of polylactide acid net/chitosan composite membrane

Guided tissue regeneration is an important treatment for periodontal diseases, as it helps periodontal tissues to regenerate. This study aims to evaluate the influence of different procedures for gelation on the mechanical properties of low melting-point polylactic acid (LPLA) net/chitosan composite membranes. After immersion in a chitosan solution, LPLA nets undergo different steps of gelation and freeze-drying, forming the porous LPLA/Chitosan composite membranes. The tensile strength, swelling, degradation and water content of the resulting membranes are then evaluated. According to the experimental results, different sequences for gelation influence the tensile strength and swelling ratio, but do not significantly influence the water content ratio and contact angle.     

Enhanced mechanical properties of silk fibroin-based composite plates for fractured bone healing

We successfully fabricated bacterial cellulose/silk fibroin (BC/SF) composite plates having similar strength to that of human cortical bone (12.8–17.7 GPa). The mechanical properties of the BC/SF composite plates were investigated at various BC nanofiber contents. The BC nanofibers acted as good reinforcements for the stress transfer produced by the interactions between the BC nanofibers and the SF matrix, as confirmed by the molecular deformation of the BC nanofibers. The BC/SF composite plates have a promising potential as a replacement material for existing metal bone plate.     

Preparation and properties of polyvinyl alcohol/tannic acid composite film for topical treatment application

The purpose of this study was to develop an effective potential wound dressing material based on a polyvinyl alcohol (PVA) and tannic acid (TA) composite film. To prepare the PVA/TA films, PVA and TA blended aqueous solutions were cast into film form by spreading the solutions and drying them. Then the films were heat treated at 155 oC for 3 min to promote esterification between the PVA and TA. After removing un-crosslinked moieties from the films by rinsing and drying, the films were investigated by swelling behavior, FTIR spectroscopy, XRD and TGA. And, the antibacterial and antioxidant abilities of the films were also examined in this study. Through this investigation it was discovered that TA effectively acts as a functional antibacterial and antioxidant agent as well as crosslinker in the PVA/TA system. Thus, the PVA/TA composite films prepared by the casting and heat treatment method proposed in this study are expected to be used for topical medication, such as wound dressing material.     

Cellulose nanofiber-reinforced silk fibroin composite film with high transparency

We successfully prepared optically transparent silk fibroin-cellulose nanofiber (CN) composite films from solvent casting using a stable CN suspension in an aqueous silk fibroin solution. The transmittance of the silk fibroin composite films was observed by a UV-visible spectrophotometer. The secondary structural change of the silk fibroin caused by the incorporation of CNs was characterized using Fourier transform infrared spectroscopy. A tensile test was carried out to investigate the mechanical properties. The results showed that the composite film exhibited visible-light transmittance of 75 %, and its mechanical strength and Young’s modulus were increased by 44 % and 35 %, respectively, as compared to a neat silk fibroin film.     

Optimization of molecular structure of polythiophene-graft-PMMA for effective compatibilization of SAN/MWCNT composite with superior mechanical properties

A new compatibilizer, P3HT-g-PMMA with controlled graft density and degree of polymerization of PMMA graft, has been synthesized for preparation of poly(styrene-co-acrylonitrile) (SAN)/multi-walled carbon nanotube (MWCNT) composites with superior mechanical properties. Fluorescence emission and Raman spectra reveal that the π-π interaction between polythiophene backbone of the compatibilizer and the surface of MWCNT is more effective as the graft density of PMMA in the compatibilizer is decreased while the degree of polymerization of PMMA is increased. Since FE-SEM observation also shows that the use of compatibilizer with higher degree of polymerization of PMMA graft yields well-dispersed MWCNTs in composites, it is concluded that the compatibilizer with lower graft density and higher degree of polymerization of PMMA graft is the most effective for reinforcing SAN with MWCNT.     

Comparative analysis of mechanical properties of size film. II. Effect of blend composition and lubricants

The advent of very high speed shuttleless looms has increased the importance of sizing. Starch has been the most popular and economic size material. Synthetic binders are also being blended with starch to improve weaving loom efficiency. Blending may lead to give different properties, which can be suited for particular application. In the present study effect of blend composition in modified starch and synthetic size blends have been evaluated and mechanical properties like cohesion power, adhesion power, abrasion resistance, bending rigidity etc were studied. In general, it is being observed that paste characteristics and film properties of polyester resin blends are better but because of economic reasons PVA and acrylic polymers are preferred. In this study the effect of lubricant is also observed. It is analyzed that lubricant improves the various mechanical properties and hence the weaving performance of the material.     

Flame retardancy,Thermal and mechanical properties of Kenaf fiber reinforced Unsaturated polyester/Phenolic composite

Unsaturated polyester (UP) resin has been blended with phenolic resin (PF) resole type at various ratios to obtain a homogeneous blend with improved flame resistance compared to its parent polymers. The polymer blend was reinforced with 20 wt% kenaf using hand lay out technique. Fourier transform infrared spectroscopy (FT-IR) was used to characterize changes in the chemical structure of the synthesized composites. The thermal properties of the composites were investigated using thermogravimetric analysis (TGA). The thermal stability of UP/PF kenaf composites co-varies with the PF content, as shown by the degradation temperature at 50 % weight loss. The char yield of the composites increases linearly with PF content as shown by the TGA results. The flammability properties of the composites were determined using the limiting oxygen index (LOI) and UL-94 fire tests. The LOI increased with the PF content while the composites exhibit improved flame retardancy as demonstrated by UL-94 test. The mechanical and morphological properties of the composites were determined by tensile test and scanning electron microscopy (SEM), respectively. The tensile strength and the Young’s modulus of the blend/composites slightly decreased with increasing PF content albeit higher than PF/kenaf fiber composites.     

Comparative analysis of mechanical properties of size film. I. Performance of individual size materials

Starch has been the most popular and economic size material. Synthetic binders have also been developed to be used as size material to improve weaving loom efficiency. Some synthetic size materials have got restrictions in use mainly because of ecological reasons. In the recent years, many modifications have come up in the starch as a sizing agent. Different modification can give different properties, which can be suited for a particular application. In the present study, for comparative analysis of different varieties of natural starch, modified starch and synthetic size material have been evaluated and mechanical properties like cohesion power, adhesion power, abrasion resistance, bending rigidity etc. were studied. PVA shows best properties among all size material. Among modified starch, starch ester shows better properties.     

Protective rigid fiber-reinforced polyurethane foam composite boards: Sound absorption,drop-weight impact and mechanical properties

Polyurethane foam has been develocped for years. In the past, the most study is focused on one function of Polyurethane foam including noise absorption, thermal protection, and mechanical impact as well as cushioning properties, and thus interdisciplinary functions of these foam boards become an innovation research. Therefore, the objective of study is to develop the multifunctional protective composite boards which are suitable for diversified environments. In this study, the carbon fibers (CF) and glass fibers (GF) are used as reinforcements for PU composite boards which are denoted as CFR-PU and GFR-PU respectively. The composite boards are made with different thickness and different contents of reinforcing fibers. The drop-weight impact test adopts a circular drop weight that falls from a certain height in order to observe the deformation mechanism of the boards. Different fracture modes that are caused by the bursting, compression, drop-weight impact, and puncture resistance tests are then examined. The test results indicate that the CFR-PU and GFR-PU fiberreinforced composite boards have a satisfactory impact load of 90 % and a favorable absorption coefficient at a certain frequency, and also have improved mechanical properties.     

Effects of wet-spinning conditions on structures,mechanical and electrical properties of multi-walled carbon nanotube composite fibers

A series of composite fibers composed of multi-walled carbon nanotube (MWCNT) and poly(vinyl alcohol) (PVA) are prepared by varying co-flowing wet-spinning conditions such as spinning geometry and PVA concentration, which affect aligning shear stress for MWCNTs during the wet-spinning. Then, structural features, mechanical and electrical performances of MWCNT/PVA composite fibers are investigated as a function of the aligning shear stress of the wet-spinning process. SEM images of the composite fibers exhibit that MWCNTs are wetted effectively with PVA chains. Polarized Raman spectra confirm that the alignment of MWCNTs is enhanced along the composite fiber axis with increasing the aligning shear stress of the spinning process. Accordingly, initial moduli and tensile strengths of the composite fibers are significantly increased with the increment of the aligning shear stress. In addition, it is found that electrical conductivities of MWCNT/PVA composite fibers increase slightly with the aligning shear stress, which is associated with the formation of efficient electrical conduction paths caused by well-aligned MWCNTs along the composite fiber axis.     

Chitosan–starch composite film: preparation and characterization

Chitosan film has potential applications in agriculture, food, and pharmacy. However, films made only from chitosan lack water resistance and have poor mechanical properties. Forming miscible, biodegradable composite film from chitosan with other hydrophilic biopolymers is an alternative. The objective of this study was to prepare chitosan/starch composite films by combining chitosan (deacetylated degree, 90%) solution and two thermally gelatinized cornstarches (waxy starch and regular starch with 25% amylose). The film’s tensile strength (TS), elongation-at-break (E), and water vapor transmission rate (WVTR) were investigated. The possible interactions between the two major components were evaluated by X-ray diffraction and Fourier-transform infrared spectroscopy (FTIR). Regardless of starch type, both the TS and E of the composite films first increased and then decreased with starch addition. Composite film made with regular starch showed higher TS and E than those with waxy starch. The addition of starch decreased WVTRs of the composite films. The introduction of gelatinized starch suppressed the crystalline peaks of chitosan film. The amino group band of chitosan molecule in the FTIR spectrum shifted from 1578 cm⁻¹ in the chitosan film to 1584 cm⁻¹ in composite films. These results indicated that there was a molecular miscibility between these two components.     

Interaction of textile parameters,wash-ageing and fabric conditioner with mechanical properties and correlation with textile-hand. II. Relationship between mechanical properties and textile-hand

In first part of this study, influences of wash-ageing and the use of fabric softener on the different mechanical parameters of textiles were examined. This paper deals with correlation of those mechanical parameters with sensory attributes. We defined the tracking criterion to investigate the relevancy of mechanical parameters with different sensory attributes. An intelligent system based on Fuzzy-Logic was developed in order to predict the sensory attribute score using two most relevant mechanical parameters.     

Hand and mechanical properties of stretch fabrics

This paper discusses the hand and preference of stretch fabrics for sportswear through subjective and objective hand evaluations. Twenty-two varieties of stretch fabrics for fall/winter sportswear fabrics were used. Seven main factors were classified through subjective evaluation and total cumulative variance value was 68.28 %. According to correlations between objective hand and preference, there are differences in preferences for pants and shirts, and in response to preference for shirts, no gender differences are observed. Correlations between subjective hand and preference show that there is a similar tendency in preferences for pants and shirts regardless of usage by different genders.     

Enhancement of thermal and physical properties of epoxy composite reinforced with basalt fiber

The basalt chopped fiber reinforced epoxy composites using different curing systems were prepared in order to investigate the thermal characteristics of the composites. 2 different curing systems for bisphenol F type epoxy resin — an epoxy-amine curing system and an epoxy-anhydride curing system — were selected and used to investigate the interaction between matrix resin and basalt fiber in the means of thermal properties and physical properties. Through the evaluation of T _g and thermal degradation behavior of both systems, it was deduced that the type of curing system as well as basalt fiber reinforcement have a great role in determining thermal properties of the composites. Also, the tensile and flexural properties of the composites were systematically evaluated in order to further understand the effect of curing agents on the interaction with basalt fiber.     

Effect of the low and radio frequency oxygen plasma treatment of jute fiber on mechanical properties of jute fiber/polyester composite

We investigated the surface modification of jute fiber by oxygen plasma treatments. Jute fibers were treated in different plasma reactors (radio frequency “RF” and low frequency “LF” plasma reactors) using O₂ for different plasma powers to increase the interface adhesion between jute fiber and polyester matrix. The influence of various plasma reactors on mechanical properties of jute fiber-reinforced polyester composites was reported. Tensile, flexure, short beam shear tests were used to determine the mechanical properties of the composites. The interlaminar shear strength increased from 11.5 MPa for the untreated jute fiber/polyester composite to 19.8 and 26.3 MPa for LF and RF oxygen plasma treated jute fiber/polyester composites, respectively. O₂ plasma treatment also improved the tensile and flexural strengths of jute fiber/ polyester composites for both plasma systems. It is clear that O₂ plasma treatment of jute fibers by using RF plasma system instead of using LF plasma system brings about greater improvement on the mechanical properties of jute/polyester composites.