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Cornerstone International College
Chennai
DEPARTMENT : MECHANICAL
LEARNER NAME : XXXX
REGISTARATION NO : XXXX
UNIT NO & LO : UNIT 138 & LO 4
UNIT NAME : COMPOSITE MATERIALS IN
ENGINEERING
ASSIGNMENT
TITLE
:
INVESTIGATE
APPLICATIONS OF COMPOSITES WITHIN
EXISTING AND DEVELOPING MARKETS
DATE OF ISSUE : 25/11/2016
SUBMISSION DATE : 15/12/2016
NUMBER OF PAGES : 21

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(Assessment criteria 4
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Composites are used in a wide variety of applications like automobile manufacturing,
construction, aerospace, business appliances, consumer products, electrical equipments,
marine applications etc
...

Corrosion resistance:
Corrosion is a natural process where a material is converted from its refined form to more
chemically stable form like hydroxide, sulfide, oxide etc
...
Metals are the usual materials that get corroded
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Corrosion resistance of composite materials are
determined by the resin chosen and the reinforcements that are used for the application
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The corrosion resistant resins that are mostly used are chlorendic
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These resins are used in order
to minimize corrosion in various conditions like acidic environments, oxidizing chemicals,
alkaline environments, caustic solutions and high temperatures
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Steel cannot withstand oxidizing, caustic or alkaline environments, due to which
their rate of corrosion is very high
...

Nowadays composites have replaced most of the conventional materials in various
applications
...
Corrosion resistant fibre reinforcements like C-glass, E-glass, E-CR
glass and carbon are used as laminates which do not corrode and provides a long life time for
the components
...
Iron or steel bearings or fasteners are also replaced by composite
materials to reduce corrosion
...
Unlike other conventional materials that are used to manufacture components,
composites can be used easily to produce them with less constraints and any desired shape can
be manufactured with ease
...

Composites offer complex design capability and restyling
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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



Complex design capability – composites can be used to achieve design cues which are
impossible with most of the metals, because they can flow over the molds and into
curves, deep pockets and other complex shapes that cannot be achieved by metals
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Restyling – Quick design refresh is much more easier to perform on a platform update
or the current platform because of the lower tooling costs required by the composites
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Conventional materials like metals cannot be designed into complex shapes or
structures with such flexibility
...
and are not as flexible as composites during production
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Fiberism can be attained only by composites and no other materials
...

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Conventional materials that are used like
steel, aluminium, iron, nickel, cobalt etc
...
This may incur more processing time
and the end product also will not have a good finish
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Intricate contours and shapes are possible without any need of high pressure tools since
composites are formed when the resin solidifies or cures during production
...
Unlike other materials, composites
provide good surface appearance, precise properties and innovative geometrics when they
are designed for complex structures
...


2) Prepare a written report justifying the materials selection for the road design
providing smooth and high-friction surface for vehicles
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(Assessment criteria 4
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Analysis of the selected composite with other product
II
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Design
IV
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Roads consists of the following components





Sub base
Base course
Sub Grade
Surface/wearing course

Roads are generally constructed using various materials like gravel, concrete, asphalt, lime
stone, sand etc
...
Nowadays roads are
constructed by means of composite materials in order to increase the efficiency of the roads
and to increase their life time
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The vehicles or automobiles which uses the roads should be able to move easily on
the road and at the same time, the tyres of the vehicles should have more friction with the
road
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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Figure 4 different layers of road (aboutcivil, 2014)

Composite roads consists of a thin top functional layer of high quality asphalt or concrete that is
bonded to the lower layer of concrete materials
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The surface layer can consist of composite mixture of hot-mixed asphalt, rubber-asphalt porous
friction courses and stone matrix asphalt
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Figure 5 hot mixed asphalt (etasphalt, 2015)

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Hot mix asphalt can be selected for road design other than the conventional
concrete because of its durability, deformation resistance, smooth surface, fatigue resistance,
moisture damage resistance, skid resistance, workability and high frictional property
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They also provide smooth
surface which increase the fuel efficiency of the automobiles
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On the other hand
concretes wear away easily and is prone to cracking at high temperatures
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Justification:
Hot mixed asphalt is the best suitable composite material for constructing high friction and
smooth roads
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Asphalt is also cheap when compared to concrete
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Hot mixed asphalt also has the ability to highly resist stress which are imposed by slight
settlements of subgrade without any cracking
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Figure 6 mechanical properties of hot mix asphalt (Peled, 2012)

Design and production method used:
Hot mixed asphalt is produced by heating asphalt binder to decrease the viscosity, and then
drying the aggregate to remove the moisture from it before mixing
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Paving and compaction is performed
while the asphalt is hot
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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the compacted base does not cool the asphalt too much before it is packed to the desired
density
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Geogrids are used to
reinforce sub base and to strengthen the roads further
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First the gravel, sand and stone are
mixed and stored together as aggregate
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The amount of
each of the aggregate is controlled combination of the conveyor belt speed and gate opening at
bottom at bottom
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In a
parallel flow drum the aggregates move in the same direction as that of the hot air
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The emission control system which is also
called as the bag house is a system which traps and then removes dust particles and fine sand
and then returns them to the mix
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Batch plants does not require storage silos but have them often
in order to increase production
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A hot mix asphalt can be stored in a storage silo for many days
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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3) Prepare a written report on adopting a composite material as a
replacement to conventional material in the following application?
Consider high performance composite V-Belt and rubber V-belts for the
reference (Assessment Criteria 4
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The cross sectional shape of a V-belt is
trapezoidal and are generally endless
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The V-belt also tends to be wedged into the mating
groove of the pulley as the load increases
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This makes V-belts effective because they
need less width and tension than other flat belts
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Rubber V-belts have low lifespan and
also other low properties
...
These high performance composite V-belts are made from
polyurethane elastomers that are reinforced with multiple flies of polyester fabric
...

High performance composite V-belts are used in variety of applications like stone conveyor
drive, brick manufacture, bowling center pinsetter, airport baggage handling, woodworking
equipments, steel rolling mill drives etc
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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Figure 9 high performance composite V-belts made of polyurethane
elastomers and polyester fabric (probe, 2012)

Comparison of properties of composite V-belts and rubber B-belts:
 Composite V-belts can be made to any required length and can be installed within
minutes without dismantling the drive system components, whereas rubber V-belts can
be produced only to certain lengths and the installation requires much time
...

 It can last longer than conventional rubber belts in tougher conditions and is unaffected
by extreme temperatures, grease, oil and other industrial solvents
...

 Unlike rubber V-belts, composite V-belts can be used in a range of applications that
requires high grip, low contact surface, non- marking, abrasion resistance, oil and
chemical resistance, high temperature etc
...

Material design and Manufacturing details to supersede an existing product design:
Composite V-belts are made from polyurethane elastomers that are reinforced with multiple
flies of polyester fabric
...

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The composite V-belt back side cushion is used to protect the other tensile
members and also permits the usage of backside idlers
...

The below steps can be followed for manufacturing an endless raw edge type power
transmission composite V-belt with greater properties,








Winding of at least one ply of the polyester fabric around a cylindrical mandrel
Winding a first layer of polyurethane elastomer and an adhesive layer on the polyester
fabric in stated order
Winding spirally a continuous cord in a layer form on the first adhesion layer
Winding again a second layer of adhesion and a second layer of polyurethane elastomer
layer around the continuous cord in the described order
Winding of one ply of the second polyester fabric around the second polyurethane
elastomer in order to obtain a belt sleeve
...


4) With the help of a study on research paper from an international journal, you
need to demonstrate the awareness of the current and the predicted
development of composite in various fields as mentioned below
...

Field – Transport and Military equipments
Composites play an important role in various fields like transport and military
...
Many new composite materials are being produced by means of research in order to
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They are used due
to their huge advantages over conventional materials
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Automobiles, planes, bicycles and trains use
composites extensively
...
Criteria like weight saving is very important in
transportation
...

Light rail and bus manufacturers use composites to increase fuel efficiency and to enhance the
interiors
...
This
includes various gel coats, resins, reinforcements, adhesives and putties for transportation
market
...
No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

12

Figure 11 bicycle made of carbon fibre composite (xinbocomposites, 2016)

Composites are identified as a potential material for transportation infrastructures like gantries,
railway bridges, platforms, large span footbridges etc
...
The advantages of using these lightweight composite
structures by replacing prefabricated concrete structures and older metals is their much light
weight which reduces the time for installation, delays to road or rail traffic during the
installation and consequent disruption of the traffic
...

 Jute coir composite boards which are used as wood substitute
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 Energy efficient axial flow fans using lightweight composites
...
Polycarbonate
materials are also used for making the windows
...
Thick filament wound layer of composite and a thick resin
rich passive layer are used for lining the tanker
...
The various components include
rear and front panels, dash board, rear and front bumper, front grill, engine hood etc
...
Composite
bracket assembly are highly corrosion resistant and thus have reduced maintenance
...
No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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Military equipments:
Composites have a wide range of use and application for manufacturing military equipments
...
Usage of conventional materials like steel have high disadvantages like weight, less
maneuverability etc
...

The various composites that are used in military are fiberglass, Kevlar and carbon fibre with
varied orientations
...
Conventional materials like titanium
and aluminium are replaced by PEEK composite and carbon fibre nylon
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Figure 12 composite military combat helmet (cim, 2015)

The various applications of composites currently and predicted development in military
equipments include avionics cabinets, missile containers, radar panels, refueling probe fairings,
lightweight transportation boxes, composite doors and covers, radomes, sensor probes, spall
liners, light weight protection for gunners, protection of weapon stations, protection of
optronics, avionic racking, floor panels, medical stretcher assemblies, rotor blade boxes,
armour for military vehicles, armour for light vehicles, protection against landmines etc
...
Composites also reduce weight of mortar tubes so that it places less burden on

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Composites can reduce the weight of the entire equipment by 50% to
60 %
...
Stiletto is built entirely of carbon fibre that reduces its weight by over 45tonnes
and also maintains the ships structural strength
...
Ballistic
wallpapers are designed to protect the soldiers in urban war zones when they take cover
...

These lightweight ballistic wallpapers are adhesive and can be put up quickly inside the walls in
order to fortify the shelters in war zones
...


Figure 14 ballistic wall panels (wallboardsupplyco, 2016)

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The Polymer resin matrix of this new composite is made from special
formulation of resveratrol which is sustainably and economically manufactured in an industrial
scale using fermentation and advanced biotechnology is converted to thermosetting monomer
and are then polymerized and molded/shaped using fabrication techniques
...
These polymers are lighter than aluminum, able to withstand long exposure
to heat, halogen free, and flame impingement without structural degrading or without
combustion
...
No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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Plagiarism report:
98
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No: [XXXX]
Learner Name: [XXXX]
Unit No & Name: [138 - Composite materials in Engineering]

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http://www
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org/road-structure-cross-section
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[Online]
Available at: http://www
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org/road-structure-cross-section
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alexandriava, 2016
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alexandriava
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pdf
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alexandriava
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pdf
[Accessed 2016]
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memphis, 2016
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ce
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edu/3137/Powerpoint%20Handouts/15%20%20Asphalt%20Production%20and%20Paving
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[Online]
Available at: http://www
...
memphis
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pdf
[Accessed 2016]
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https://www
...
com/morgan-launches-lightweightcomposite-military-helmet/
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composites-manufacturing
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directindustry, 2016
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directindustry
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html
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directindustry
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html
[Accessed 2016]
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http://www
...
com/products/
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etasphalt
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indiamart, 2016
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indiamart
...
html
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indiamart
...
html
[Accessed 2016]
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http://www
...
com/m80-stiletto1
...
[Online]
Available at: http://www
...
com/m80-stiletto1
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pcminnovation, 2012
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pcminnovation
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[Online]
Available at: http://www
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com/en/produits/moules-en-materiauxcomposites-2/
[Accessed 2016]
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A
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https://www
...
com/patents/WO2012160554A1?cl=en
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google
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plasticstoday, 2014
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plasticstoday
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[Online]
Available at: http://www
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com/content/jec-asia-show-composites-

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probe, 2012
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probe
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html
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probe
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html
[Accessed 2016]
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http://www
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com/corrosion-testing
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tami-imi
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wallboardsupplyco, 2016
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wallboardsupplyco
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[Online]
Available at: http://www
...
com/building-supplies/drywall-specialtypanels
[Accessed 2016]
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http://www
...
com/article/carbon-composites-inthe-application-of-the-transportation
...
[Online]
Available at: http://www
...
com/article/carbon-composites-in-theapplication-of-the-transportation
...


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