Vibration and tribological properties of epoxy-granite composites used as novel foundations for machine elements
-
Mohammed Y. Abdellah
,
Ahmed Abdelhaleem
Abstract
Composites have become attractive to many industries today and are a good alternative to many traditional materials. Epoxy granite (EG) is used as a competitive alternative to ground ceramics, especially as a foundation for machine tools. This is because of their high damping ratio compared to other traditional materials such as cast iron. In the present study, a lightweight and cost-effective EG composite material was developed as a new foundation for machine elements. The composite material EG was prepared by mixing epoxy resin (12 wt %) and granite particles by casting method. The crushed granite particles were sieved and separated into coarse particles ≤2.36 ≥ 1.18 mm, medium particles ≤1.18 ≥ 0.6 and fine particles ≤0.6 mm. Vibration modal analysis is performed using an impact hammer to measure the natural frequencies occurring at each material size and the damping ratios. Microbial and fungal resistance is tested to understand applicability in humid environments, and water absorption and soak resistance were also measured. Scratch tests are performed using a top scratch tester to measure scratch width for fine and coarse samples. The electrostatic discharges generated by friction on the rubber and granite-epoxy composite sole are measured. It was found that as the particle size decreases, the damping ratio increases and the damping capability is improved, both microbial and fungal resistance increases, the scratch width is small for fine particles, while it is difficult to achieve for other granite sizes. Electrostatic discharges show a better feel for the composite material, but it is better with fine particles.
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: The authors would like to thank the Deanship of Scientific Research at Umm Al-Qura University for supporting this work by grant code 22UQU4361171DSR01.
-
Conflict of interest statement: The authors declare that they have no conflicts of interest regarding this article.
References
1. Abdellah, M. Y., Abdelhaleem, A., Alnaser, I. A., Abdel-Jaber, G. T., Abdal-hay, A. Flexural, compression and fracture properties of epoxy granite as a cost-effective structure materials: new machine element foundation. AIMS Mater. Sci. 2021, 8, 82–98; https://doi.org/10.3934/matersci.2021006.Search in Google Scholar
2. Ramana, M. V., Thyla, P. R., Mahendrakumar, N., Praveena, K. Selection of resin and aggregates for particulate polymer concrete machine tool structures - a review. Mater. Today Proc. 2021, 46, 8621–8628; https://doi.org/10.1016/j.matpr.2021.03.595.Search in Google Scholar
3. Omar, M., Abdelrhman, Y., Hassab, M. I., Khierldeen, M. Experimental study on compressive strength and flexural rigidity of epoxy granite composite material. J. Eng. Sci. 2021, 49, 198–214; https://doi.org/10.21608/jesaun.2021.61303.1033.Search in Google Scholar
4. Do Suh, J., Kim, H. S., Kim, J. M. Design and manufacture of composite high speed machine tool structures. Compos. Sci. Technol. 2004, 64, 1523–1530.10.1016/j.compscitech.2003.10.021Search in Google Scholar
5. Suh, J. D., Lee, D. G. Design and manufacture of hybrid polymer concrete bed for high-speed CNC milling machine. Int. J. Mech. Mater. Des. 2008, 4, 113–121; https://doi.org/10.1007/s10999-007-9033-3.Search in Google Scholar
6. Kim, H. S., Park, K. Y. A study on the epoxy resin concrete for the ultra-precision machine tool bed. J. Mater. Process. Technol. 1995, 48, 649–655; https://doi.org/10.1016/0924-0136(94)01705-6.Search in Google Scholar
7. Orak, S. Investigation of vibration damping on polymer concrete with polyester resin. Cem. Concr. Res. 2000, 30, 171–174; https://doi.org/10.1016/s0008-8846(99)00225-2.Search in Google Scholar
8. Piratelli-Filho, A., Levy-Neto, F. BehaviourBehaviour of granite-epoxy composite beams subjected to mechanical vibrations. Mater. Res. 2010, 13, 497–503; https://doi.org/10.1590/s1516-14392010000400012.Search in Google Scholar
9. Swamy, S., Sreedhar, B. R., Kalas, V. J., Chandan, K. M . Experimental studies on compression and vibration characteristics of granite epoxy - an alternative material for precision machine tool beds. Int. J. Pure Appl. Sci. Technol. 2014, 2, 120–135.Search in Google Scholar
10. Mahendrakumar, N., Syathabuthakeer, S., Mohanram, P. Study of alternative structural materials for machine tools. In 5th International & 25th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), Assam, India, IIT Guwahati, December 12–14, 2014.Search in Google Scholar
11. Selvakumar, A., Ganesan, K., Mohanram, P. V. Dynamic analysis on fabricated mineral cast lathe bed. Proc. Inst. Mech. Eng. B. J. Eng. Manuf. 2013, 227, 261–266; https://doi.org/10.1177/0954405412467141.Search in Google Scholar
12. Selvakumar, A., Mohanram, P. V. Analysis of alternative composite material for high speed precision machine tool structures. Ann. Fac. Eng. Hunedoara. 2012, 10, 95.Search in Google Scholar
13. Kareem, A. A. Mechanical properties of granite powder as a filler for polycarbonate toughened epoxy resin. Int. J. Pharma Sci. 2013, 3, 254–257.Search in Google Scholar
14. Venugopal, P. R., Dhanabal, P., Thyla, P. R., Mohanraj, S., Nataraj, M., Ramu, M., Sonawane, H. Design and analysis of epoxy granite vertical machining centre base for improved static and dynamic characteristics. Proc. Inst. Mech. Eng. L. 2020, 234, 481–495; https://doi.org/10.1177/1464420719890892.Search in Google Scholar
15. Venugopal, P. R., Kalayarasan, M., Thyla, P. R., Mohanram, P. V., Nataraj, M., Mohanraj, S., Sonawane, H. Structural investigation of steel-reinforced epoxy granite machine tool column by finite element analysis. Proc. Inst. Mech. Eng. L. 2019, 233, 2267–2279; https://doi.org/10.1177/1464420719840592.Search in Google Scholar
16. Hinnuraj, S., Thyla, P. R., Elango, S., Venugopal, P. R., Mohanram, P. V., Nataraj, M., Ayyasamy, S. Static and dynamic behaviourbehaviour of steel-reinforced epoxy granite CNC lathe bed using finite element analysis. Proc. Inst. Mech. Eng. L. 2020, 234, 595–609; https://doi.org/10.1177/1464420720904606.Search in Google Scholar
17. Do Suh, J., Chang, S. H., Choi, J. K., Park, B. S. Damping characteristics of composite hybrid spindle covers for high speed machine tools. J. Mater. Process. Technol. 2001, 113, 178–183; https://doi.org/10.1016/s0924-0136(01)00699-9.Search in Google Scholar
18. Choi, J. K. Manufacture of a carbon fibre-epoxy composite spindle-bearing system for a machine tool. Compos. Struct. 1997, 37, 241–251; https://doi.org/10.1016/s0263-8223(97)80016-5.Search in Google Scholar
19. Cho, S. K., Kim, H. J., Chang, S. H. The application of polymer composites to the table-top machine tool components for higher stiffness and reduced weight. Compos. Struct. 2011, 93, 492–501; https://doi.org/10.1016/j.compstruct.2010.08.030.Search in Google Scholar
20. Wang, T., Zhang, J., Bai, W., Hao, S. Forming process and mechanical properties of fibers-reinforced polymer concrete. J. Reinf. Plast. Compos. 2013, 32, 907–911; https://doi.org/10.1177/0731684413478476.Search in Google Scholar
21. Gomes, M. L. P., Carvalho, E. A., Demartini, T. J., de Carvalho, E. A., Colorado, H. A., Vieira, C. M. F. Mechanical and physical investigation of an artificial stone produced with granite residue and epoxy resin. J. Compos. Mater. 2021, 55, 1247–1254; https://doi.org/10.1177/0021998320968137.Search in Google Scholar
22. Rama, S. R., Rai, S. Mechanical and fractrographic studies on fly ash-filled hydroxyl-terminated polyurethane-toughened epoxy composites. J. Compos. Mater. 2009, 43, 3231–3238; https://doi.org/10.1177/0021998309345331.Search in Google Scholar
23. Gangwar, S., Pathak, V. K. A critical review on tribological properties, thermal behaviourbehaviour, and different applications of industrial waste reinforcement for composites. Proc. Inst. Mech. Eng. L. 2021, 235, 684–706; https://doi.org/10.1177/1464420720972434.Search in Google Scholar
24. Rout, A. K., Satapathy, A. Study on mechanical and erosion wear performance of granite filled glass-epoxy hybrid composites. Proc. Inst. Mech. Eng. L. 2015, 229, 38–50; https://doi.org/10.1177/1464420713499483.Search in Google Scholar
25. Miyazaki, N. Solid particle erosion of composite materials: a critical review. J. Compos. Mater. 2016, 50, 3175–3217; https://doi.org/10.1177/0021998315617818.Search in Google Scholar
26. Srivastava, V. K., Pawar, A. G. Solid particle erosion of glass fibre reinforced flyash filled epoxy resin composites. Compos. Sci. Technol. 2006, 66, 3021–3028; https://doi.org/10.1016/j.compscitech.2006.02.004.Search in Google Scholar
27. atnaik, P. A., Satapathy, A., Mahapatra, S. S. Study on erosion response of hybrid composites using Taguchi experimental design. J. Eng. Mater. Technol. 2009, 131, 031011; https://doi.org/10.1115/1.3086334.Search in Google Scholar
28. Biswas, S., Satapathy, A. A comparative study on erosion characteristics of red mud filled bamboo–epoxy and glass–epoxy composites. Mater. Des. 2010, 31, 1752–1767; https://doi.org/10.1016/j.matdes.2009.11.021.Search in Google Scholar
29. Rout, A. K., Satapathy, A. Study on mechanical and tribo-performance of rice-husk filled glass–epoxy hybrid composites. Mater. Des. 2012, 41, 131–141; https://doi.org/10.1016/j.matdes.2012.05.002.Search in Google Scholar
30. Gunes, I., Uygunoglu, T., Çelik, A. G. Tribological properties of fly ash blended polymer composites. Materia 2021, 26, 12929; https://doi.org/10.1590/s1517-707620210001.1229.Search in Google Scholar
31. Xu, W., Ma, X., Tang, N., Zhu, L., Li, W., Ding, Y. Effect of post-welding heat treatment on wear resistance of cast-steel die with surfacing layer. Manuf. Rev. 2015, 2, 25; https://doi.org/10.1051/mfreview/2015027.Search in Google Scholar
32. Chauhan, S. R., Kumar, A., Singh, I., Kumar, P. Effect of fly ash content on friction and dry sliding wear behaviourbehaviour of glass fiber reinforced polymer composites-a taguchi approach. JMMCE 2010, 9, 365–387; https://doi.org/10.4236/jmmce.2010.94027.Search in Google Scholar
33. Kulkarni, S. Effects of surface treatments and size of fly ash particles on the compressive properties of epoxy based particulate composites. J. Mater. Sci. 2002, 37, 4321–4326.10.1023/A:1020648418233Search in Google Scholar
34. Nallusamy, S., Karthikeyan, A. Synthesis and wear characterization of reinforced glass fiber polymer composites with epoxy resin using granite powder. J. Nano Res. 2017, 49, 1–9; https://doi.org/10.4028/www.scientific.net/jnanor.49.1.Search in Google Scholar
35. Fathy, A., Zhu, H., Kohail, M. Factors affecting the fresh-to-hardened concrete repair system. Constr. Build. Mater. 2022, 320, 126279; https://doi.org/10.1016/j.conbuildmat.2021.126279.Search in Google Scholar
36. McKeown, P. A., Morgan, G. H. Epoxy granite: a structural material for precision machines. Precis. Eng. 1979, 1, 227–229; https://doi.org/10.1016/0141-6359(79)90104-1.Search in Google Scholar
37. Standard, A. D3171-99. Standard Test Methods for Constituent Content of Composite Materials; ASTM international: West Conshohocken, PA, 1999.Search in Google Scholar
38. Fairchild, A. L., Rosner, D., Colgrove, J., Bayer, R., Fried, L. P. The exodus of public health - what history can tell us about the future. APHA 2010, 100, 54–63; https://doi.org/10.2105/ajph.2009.163956.Search in Google Scholar
39. Kämpfer, P. Detection and cultivation of filamentous bacteria from activated sludge. FEMS Microbiol. Ecol. 1997, 23, 169–181.10.1016/S0168-6496(97)00030-5Search in Google Scholar
40. Alamri, H., Low, I. M. Mechanical properties and water absorption behaviour of recycled cellulose fibre reinforced epoxy composites. Polym. Test. 2012, 31, 620–628; https://doi.org/10.1016/j.polymertesting.2012.04.002.Search in Google Scholar
41. Thirunavukkarasu, J., Poulet, M., Turner, T., Pickering, S. Separation of composites for recycling: measurement of electrostatic charge of carbon and glass fiber particles. J. Electr. Comput. 2021, 15, 366–371.Search in Google Scholar
© 2022 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Material properties
- Effect of nanodiamond particles on the structure, mechanical, and thermal properties of polymer embedded ND/PMMA composites
- A comparative investigation on wear characteristics of polymer and biopolymer gears
- Unsaturated polyester resin modified with a novel reactive flame retardant: effects on thermal stability and flammability
- Recent progress on the morphology and thermal cycle of phase change materials (PCMs)/conductive filler composites: a mini review
- Effect of tiny amount of DMC on thermal, mechanical, optical, and water resistance properties of poly(vinyl alcohol)
- Vibration and tribological properties of epoxy-granite composites used as novel foundations for machine elements
- Effect of lyocell fiber cross-sectional shape on structure and properties of lyocell/PLA composites
- Engineering and processing
- Quality prediction and control of thin-walled shell injection molding based on GWO-PSO, ACO-BP, and NSGA-II
- Doubly modified MWCNTs embedded in polyethersulfone (PES) ultrafiltration membrane and its anti-fouling performance
- Solid-state extrusion of polymers using simple shear deformation
- Molding process and properties of polyimide-fiber-fabric-reinforced polyether ether ketone composites
Articles in the same Issue
- Frontmatter
- Material properties
- Effect of nanodiamond particles on the structure, mechanical, and thermal properties of polymer embedded ND/PMMA composites
- A comparative investigation on wear characteristics of polymer and biopolymer gears
- Unsaturated polyester resin modified with a novel reactive flame retardant: effects on thermal stability and flammability
- Recent progress on the morphology and thermal cycle of phase change materials (PCMs)/conductive filler composites: a mini review
- Effect of tiny amount of DMC on thermal, mechanical, optical, and water resistance properties of poly(vinyl alcohol)
- Vibration and tribological properties of epoxy-granite composites used as novel foundations for machine elements
- Effect of lyocell fiber cross-sectional shape on structure and properties of lyocell/PLA composites
- Engineering and processing
- Quality prediction and control of thin-walled shell injection molding based on GWO-PSO, ACO-BP, and NSGA-II
- Doubly modified MWCNTs embedded in polyethersulfone (PES) ultrafiltration membrane and its anti-fouling performance
- Solid-state extrusion of polymers using simple shear deformation
- Molding process and properties of polyimide-fiber-fabric-reinforced polyether ether ketone composites
