The potential of metal epoxy composite (MEC) as hybrid mold inserts in rapid tooling application: a review

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Radhwan Bin Hussin ◽  
Safian Bin Sharif ◽  
Shayfull Zamree Bin Abd Rahim ◽  
Mohd Azlan Bin Suhaimi ◽  
Mohd Tanwyn Bin Mohd Khushairi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Epoxy Composite ◽  
Mold Insert ◽  
Physical And Mechanical Properties ◽  
Rapid Tooling ◽  
Current Application ◽  
Content Type ◽  
Manufacturing Technologies ◽  
New Formulation ◽  
Research Studies

Purpose Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts. Design/methodology/approach The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted. Findings Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles). Research limitations/implications The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available. Originality/value This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.

scholarly journals Effect of Filler Nature on Chemical Resistance and Microhardness of Epoxy Composite Films

2015 ◽  
Vol 16 (3) ◽  
pp. 528-533
Author(s):  
G. Martinyuk ◽  
O. Aksimentyeva ◽  
N. Skoreiko ◽  
V. Zakordonskyi
Keyword(s):  
Mechanical Properties ◽  
Chemical Resistance ◽  
Filler Content ◽  
Epoxy Composite ◽  
Composite Films ◽  
Physical And Mechanical Properties ◽  
Epoxy Composites ◽  
Mineral Filler ◽  
Operating Characteristics ◽  
Mineral Fillers

We investigated the processes of water absorption, chemical stability and microhardness of films of epoxy composites that contained as the polymer matrix the epoxy resin UP-655 and mineral fillers: graphite, mica, aluminum oxide at their content (0 - 30 % mass). It found that introduction of mineral fillers significantly affects on all complex of operating characteristics of the films. Increase of filler content, especially mica, to 20 %, resulting in slower process and reducing the quantity of absorbed moisture by films. In the study of physical and mechanical properties of filled epoxy composites was established that the introduction of mineral filler significantly affects their microhardness, and the nature of the exposure is determined by the type and filler content.

Experimental study on effect of fiber length and fiber content on tensile and flexural properties of bamboo fiber/epoxy composite

2019 ◽  
Vol 15 (5) ◽  
pp. 947-957 ◽  
Author(s):  
Giridharan R. ◽  
Raatan V.S. ◽  
Jenarthanan M.P.
Keyword(s):  
Mechanical Properties ◽  
Fiber Length ◽  
Epoxy Composite ◽  
Natural Fibers ◽  
Weight Ratio ◽  
Fiber Content ◽  
Bamboo Fiber ◽  
Flexural Properties ◽  
Fiber Reinforced ◽  
Content Type

Purpose The purpose of this paper is to study the effects of fiber length and content on properties of E-glass and bamboo fiber reinforced epoxy resin matrices. Experiments are carried out as per ASTM standards to find the mechanical properties. Further, fractured surface of the specimen is subjected to morphological study. Design/methodology/approach Composite samples were prepared according to ASTM standards and were subjected to tensile and flexural loads. The fractured surfaces of the specimens were examined directly under scanning electron microscope. Findings From the experiment, it was found that the main factors that influence the properties of composite are fiber length and content. The optimum fiber length and weight ratio are 15 mm and 16 percent, respectively, for bamboo fiber/epoxy composite. Hence, the prediction of optimum fiber length and content becomes important, so that composite can be prepared with best mechanical properties. The investigation revealed the suitability of bamboo fiber as an effective reinforcement in epoxy matrix. Practical implications As bamboo fibers are biodegradable, recyclable, light weight and so on, their applications are numerous. They are widely used in automotive components, aerospace parts, sporting goods and building industry. With this scenario, the obtained result of bamboo fiber reinforced composites is not ignorable and could be of potential use, since it leads to harnessing of available natural fibers and their composites rather than synthetic fibers. Originality/value This work enlists the effect of fiber length and fiber content on tensile and flexural properties of bamboo fiber/epoxy composite, which has not been attempted so far.

Study on properties of decolorizing yakwool fiber and spun yarn

2019 ◽  
Vol 31 (1) ◽  
pp. 90-102
Author(s):  
Qin Xiaoxuan ◽  
Hui’e Liang ◽  
Xuzhong Su ◽  
Xinjin Liu
Keyword(s):  
Mechanical Properties ◽  
Design Methodology ◽  
Natural Fiber ◽  
Physical And Mechanical Properties ◽  
Optimal Process ◽  
Textile Processing ◽  
Content Type ◽  
Oxidation Reduction ◽  
Spun Yarn

Purpose As a natural fiber, yakwool has attracted much attention in textile processing due to its excellent properties and wearabilities. However, the main colors of yakwool are black and brown. Therefore, for extending the application scopes of the fiber, the decolorization of the yakwool fiber is usually needed, especially for the black fiber. The paper aims to discuss this issue. Design/methodology/approach In the paper, the properties of the yakwool fiber were tested first, especially the melanin granules in the fiber. Then, the decolorization of the yakwool fiber was studied using the oxidation–reduction decolorization method, and corresponding optimal process of the decolorization was given. Then, the properties of the decolorized yakwool fiber were tested and compared with those of the original fiber. Findings It is shown that, after decolorization, the physical and mechanical properties of the fiber were deteriorated, especially in terms of the strength and elongation. Therefore, the fiber became shorter and thinner, and the scales were damaged. When compared with the yarn spun from the original yakwool fiber, it was observed that the properties of the yarn spun from the decolorized yakwool fiber deteriorated because of the deterioration in the properties of the original fiber. Originality/value In the paper, for extending the application scopes of the yakwool fiber, the decolorization of the yakwool fiber was studied.

UV curable urethane acrylate coatings formulation: experimental design approach

2014 ◽  
Vol 43 (2) ◽  
pp. 61-68 ◽  
Author(s):  
Ghodsieh Mashouf ◽  
Morteza Ebrahimi ◽  
Saeed Bastani
Keyword(s):  
Mechanical Properties ◽  
Experimental Design ◽  
Physical And Mechanical Properties ◽  
Scratch Resistance ◽  
Urethane Acrylate ◽  
Uv Curable ◽  
Content Type ◽  
Mathematical Equations ◽  
Acrylate Monomers ◽  
Mixture Experimental Design

Purpose – The purpose of this work was to perform a systematic study on the effect of formulation on the physical and mechanical properties of ultaviolet (UV) curable urethane acrylate resins. In addition, the authors wanted to derive mathematical formula for the prediction of physical and mechanical properties for the aforementioned system. Design/methodology/approach – The experiments were carried out based on mixture experimental design to determine the effect of different multifunctional acrylates (i.e. 1,6-hexanediol diacrylate (HDDA), tripropylene glycol diacrylate (TPGDA), trimethyolpropane triactylate (TMPTA)) concentration on the physical and mechanical properties of a UV curable polyurethane acrylate system. The urethane oligomer was synthesized and characterized by the research team. Microhardness, adhesion strength and scratch resistance of the cured films were evaluated as the physical and mechanical properties. Findings – The results revealed that the resin and TMPTA concentrations had the most significant effects on the microhardness property. Adhesion strength of the films showed a linear trend with respect to all variables. Moreover, all components also had a significant and complex influence on the scratch resistance of the cured systems. In addition, mathematical equations proposed by mixture experimental design were derived for all the mentioned properties. Research limitations/implications – Other multifunctional acrylate monomers (i.e. more than three functional) can be used in the formulations. The kinetics of the curing can affect on the network formation and consequently on the properties of the cured films. Practical implications – The obtained results can be used by the researchers who are active in the field of structure-property relationship of polymers and surface coatings. The reported data and the mathematical equations can also be used for the formulating of an appropriate formulation based on a specific application. Originality/value – A systematic and statistical-based approach, i.e. mixture experimental design, was used to evaluate the effect of formulation on some of the properties of a UV curable polyurethane acrylate system. A urethane oligomer and three different multifunctional acrylate monomers as reactive diluents were used in the formulations. Noteworthy to mention that several mathematical models were derived by using analysis of variance for the prediction of the properties studied in this system.

scholarly journals Hybrid Mold: Comparative Study of Rapid and Hard Tooling for Injection Molding Application Using Metal Epoxy Composite (MEC)

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 665
Author(s):  
Radhwan Hussin ◽  
Safian Sharif ◽  
Marcin Nabiałek ◽  
Shayfull Zamree Abd Rahim ◽  
Mohd Tanwyn Mohd Khushairi ◽  
...  
Keyword(s):  
Injection Molding ◽  
New Product Development ◽  
Epoxy Composite ◽  
Mixing Time ◽  
Mold Insert ◽  
Physical And Mechanical Properties ◽  
Critical Factor ◽  
Curing Temperature ◽  
Mass Composition ◽  
Control Factors

The mold-making industry is currently facing several challenges, including new competitors in the market as well as the increasing demand for a low volume of precision moldings. The purpose of this research is to appraise a new formulation of Metal Epoxy Composite (MEC) materials as a mold insert. The fabrication of mold inserts using MEC provided commercial opportunities and an alternative rapid tooling method for injection molding application. It is hypothesized that the addition of filler particles such as brass and copper powders would be able to further increase mold performance such as compression strength and thermal properties, which are essential in the production of plastic parts for the new product development. This study involved four phases, which are epoxy matrix design, material properties characterization, mold design, and finally the fabrication of the mold insert. Epoxy resins filled with brass (EB) and copper (EC) powders were mixed separately into 10 wt% until 30 wt% of the mass composition ratio. Control factors such as degassing time, curing temperature, and mixing time to increase physical and mechanical properties were optimized using the Response Surface Method (RSM). The study provided optimum parameters for mixing epoxy resin with fillers, where the degassing time was found to be the critical factor with 35.91%, followed by curing temperature with 3.53% and mixing time with 2.08%. The mold inserts were fabricated for EB and EC at 30 wt% based on the optimization outcome from RSM and statistical ANOVA results. It was also revealed that the EC mold insert offers better cycle time compared to EB mold insert material.

scholarly journals Optimization of Ingredients upon Development of the Protective Polymeric Composite Coatings for the River and Sea Transport

2021 ◽  
Vol 23 (2) ◽  
pp. B89-B96
Author(s):  
Andriy Buketov ◽  
Serhii Yakushchenko ◽  
Abdellah Menou ◽  
Oleh Bezbakh ◽  
Roman Vrublevskyi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Epoxy Composite ◽  
Composite Coatings ◽  
Physical And Mechanical Properties ◽  
Polymeric Composite ◽  
Epoxy Oligomer ◽  
Mathematical Planning ◽  
Sea Transport ◽  
Operational Characteristics ◽  
Critical Content

It is proved that in order to increase the operational characteristics of parts of the river and sea transport, including their physical and mechanical properties, it is advisable to use the protective polymeric composite coatings. The effect of fillers on the flexural stresses of the developed epoxy composite was analyzed. The critical content of components was determined by the method of mathematical planning of the experiment: the synthesized powder mixture - 0.05 pts.wt., discrete fibers - 0.10 to 0.15 pts.wt. per 100 pts.wt. of epoxy oligomer ED-20. Introduction of such ingredients into the epoxy binder allows to increase the flexural stresses to σ f=77.4…78.6 MPa. The obtained results allow to create materials with improved values of physical and mechanical properties.

Study and evaluation of the mechanical properties on sawdust reinforced epoxy composite

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Shailendra Singh Chauhan ◽  
Vaibhav Singh ◽  
Gauranshu Saini ◽  
Nitin Kaushik ◽  
Vishal Pandey ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Water Absorption ◽  
Epoxy Composite ◽  
Research Work ◽  
Processing Parameters ◽  
Epoxy Composites ◽  
Green Composite ◽  
Absorption Properties ◽  
Content Type ◽  
The Impact

Purpose The growing environmental awareness all through the world has motivated a standard change toward planning and designing better materials having good performance, which are very much suited to the environmental factors. The purpose of this study is to investigate the impact on mechanical, thermal and water absorption properties of sawdust-based composites reinforced by epoxy, and the amount of sawdust in each form. Design/methodology/approach Manufacturing of the sawdust reinforced epoxy composites is the main area of the research for promoting the green composite by having good mechanical properties, biodegradability or many applications. Throughout this research work, the authors emphasize the importance of explaining the methodology for the evaluation of the mechanical and water absorption properties of the sawdust reinforced epoxy composites used by researchers. Findings In this paper, a comprehensive review of the mechanical properties of sawdust reinforced epoxy composite is presented. This study is reported about the use of different Wt.% of sawdust composites prepared by different processes and their mechanical, thermal and water absorption properties. It is studied that after optimum filler percentage, mechanical, thermal properties gradually decrease, but water absorption property increases with Wt.% of sawdust. The changes in the microstructure are studied by using scanning electron microscopy. Originality/value The novelty of this study lies in its use of a systematic approach that offers a perspective on choosing suitable processing parameters for the fabrication of composite materials for persons from both industry and academia. A study of sawdust reinforced epoxy composites guides new researchers in the fabrication and characterization of the materials.

Sign in / Sign up

Export Citation Format

Share Document