M.S. Senthil Kumar PDF
M.S. Senthil Kumar PDF
M.S. Senthil Kumar PDF
Technical Report
a r t i c l e i n f o a b s t r a c t
Article history: In this work, a detailed analysis was performed to profoundly study the tribological property of various
Received 13 October 2014 nano clay (Cloisite 25A) loaded epoxy, with and without inclusion of E-glass fiber using Taguchi’s tech-
Accepted 20 December 2014 nique. For this purpose, the test samples were prepared according to the ASTM standard, and the test was
Available online 31 December 2014
carried out with the assistance of pin-on-disk machine. To proceed further, L25 orthogonal array was con-
structed to evaluate the tribological property with four control variables such as filler content, normal
Keywords: load, sliding velocity and sliding distance at each level. The results indicated that the combination of fac-
Nano clay
tors greatly influenced the process to achieve the minimum wear and coefficient of friction. Overall, the
Wear
Friction coefficient
experiment results depicted least wear and friction coefficient for fiber reinforced laminates. In the same
Taguchi way, appreciable wear and friction coefficient was noted for without fiber laminates. Additionally, the SN
ANOVA ratio results too exhibited the similar trend. Moreover, ANOVA analysis revealed that the fiber inclusion
Surface morphology on laminates has lesser contribution on coefficient of friction and wear when compared to without fiber
laminates. At last, the microstructure behavior of the test samples was investigated with an assistance of
Scanning Electron Microscope (SEM) to analyze the surface morphology.
Ó 2014 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.matdes.2014.12.033
0261-3069/Ó 2014 Elsevier Ltd. All rights reserved.
2 M.S. Senthil Kumar et al. / Materials and Design 70 (2015) 1–9
2. Experimental details
Table 1
Properties of nanoclay.
Table 2 machine and involves a sequence for the experiment to yield opti-
Levels of the variables used in the experiment. mum parameters for minimizing tribological properties [19]. Tagu-
Control factors Levels chi technique uses a range of the orthogonal arrays based on the
I II III IV V Units condition control factors and levels that helps to study the entire
parameter with only a minimum number of experiments. Further,
A: Filler content 2 4 6 8 10 %
B: Normal load 15 20 25 30 35 N
the signal-to-noise ratio (S/N) was calculated which is the logarith-
C: Sliding velocity 1 2 3 4 5 m/s mic function used to measure the performance of desired output.
D: Sliding distance 500 1000 1500 2000 2500 m In General, the S/N ratio is chosen based on three characteristics;
lower-the better, nominal-the better, higher-the better. Also, the
process parameter with the highest signal-to-noise ratio continu-
Table 3
ally yields the optimum quality with lowest variance. Besides,
Orthogonal array for L25 (54) Taguchi design.
the current study is focused on selecting better testing characteris-
Expt. no. A B C D tics by choosing lower-the better (LB) performance characteristics
1 1 1 1 1 for coefficient of friction (COF), frictions force (FF) and wear (w)
2 1 2 2 2 which can be calculated as logarithmic transformation of loss func-
3 1 3 3 3
tion as given in Eq. (1) [30–32].
4 1 4 4 4
5 1 5 5 5
S 1 X 2
6 2 1 2 3 ¼ 10 log y ð1Þ
7 2 2 3 4 N n
8 2 3 4 5
9 2 4 5 1 where n = number of observations and y = observed data, S/N = sig-
10 2 5 1 2 nal to noise ratio.
11 3 1 3 5 The sliding wear investigation was carried out with four control
12 3 2 4 1
variables such as Filler content (A), Normal load (B), Sliding veloc-
13 3 3 5 2
14 3 4 1 3 ity (C) and Sliding distance (D) each at five levels as listed in Table 2
15 3 5 2 4 in connection with L25 orthogonal array. In usual factorial experi-
16 4 1 4 2 mental design, it would require 54 = 625 runs to review four
17 4 2 5 3 parameters each at five levels, whereas Taguchi’s approach reduces
18 4 3 1 4
19 4 4 2 5
it to exclusively 25 runs providing an excellent advantage in terms
20 4 5 3 1 of experimental time cost with noticeable accuracy. Furthermore,
21 5 1 5 4 the tests results were subjected to the Analysis of Variance
22 5 2 1 5 (ANOVA). The tests were conducted keeping in mind the experi-
23 5 3 2 1
mental design which is given in Table 3.
24 5 4 3 2
25 5 5 4 3
2.4. Microstructure
2.3. Experimental design The worn out surface of the specimens was investigated by
using scanning electron microscope (TESCAN – VEGA 3 – SBU)
Taguchi technique is one among the important statistical tech- underneath 20 kV accelerating voltage. In order to create the con-
niques which is in turn used in the present study to address the ducting layer on the worn out specimens, they were coated with
impact of multiple variables at the same time in pin-on-disk sputtering for a few nanometer thicknesses.
Table 4
Experimental design using L25 orthogonal array (without fiber).
Runs A (%) B (N) C (m/s) D (m) COF S/N ratio (db) WR (lm) S/N ratio (db)
1 2 15 1 500 0.52 5.76 58.50 35.34
2 2 20 2 1000 0.42 7.55 3.86 11.74
3 2 25 3 1500 0.05 26.24 5.35 14.56
4 2 30 4 2000 0.03 31.04 1.25 1.94
5 2 35 5 2500 0.05 25.68 2.54 8.10
6 4 15 2 1500 0.25 11.98 19.55 25.82
7 4 20 3 2000 0.15 16.42 34.75 30.82
8 4 25 4 2500 0.17 15.51 31.20 29.88
9 4 30 5 500 0.41 7.82 62.70 35.95
10 4 35 1 1000 0.23 12.69 132.70 42.46
11 6 15 3 2500 0.06 24.19 14.47 23.21
12 6 20 4 500 0.52 5.68 101.20 40.10
13 6 25 5 1000 0.15 16.67 76.70 37.70
14 6 30 1 1500 0.42 7.53 137.40 42.76
15 6 35 2 2000 0.30 10.39 102.07 40.18
16 8 15 4 1000 0.17 15.53 15.40 23.75
17 8 20 5 1500 0.17 15.49 41.47 32.35
18 8 25 1 2000 0.31 10.20 56.20 34.99
19 8 30 2 2500 0.40 7.96 91.70 39.25
20 8 35 3 500 0.43 7.43 241.70 47.67
21 10 15 5 2000 0.05 25.68 39.53 31.94
22 10 20 1 2500 0.22 13.20 39.29 31.88
23 10 25 2 500 0.82 1.68 98.23 39.85
24 10 30 3 1000 0.58 4.70 85.20 38.61
25 10 35 4 1500 0.44 7.07 94.30 39.49
4 M.S. Senthil Kumar et al. / Materials and Design 70 (2015) 1–9
Table 5
Experimental design using L25 orthogonal array (with fiber).
Runs A (%) B (N) C (m/s) D (m) COF S/N ratio (db) WR (lm) S/N ratio (db)
1 2 15 1 500 0.273 11.266 9.14 19.22
2 2 20 2 1000 0.260 11.683 11.43 21.17
3 2 25 3 1500 0.376 8.496 57.26 35.16
4 2 30 4 2000 0.347 9.187 128.67 42.19
5 2 35 5 2500 0.407 7.811 141.43 43.01
6 4 15 2 1500 0.645 3.802 27.43 28.77
7 4 20 3 2000 0.400 7.930 51.50 34.24
8 4 25 4 2500 0.247 12.133 11.70 21.36
9 4 30 5 500 0.050 26.016 10.18 20.15
10 4 35 1 1000 0.225 12.969 3.27 10.30
11 6 15 3 2500 0.741 2.599 36.53 31.25
12 6 20 4 500 0.199 14.000 8.60 18.69
13 6 25 5 1000 0.619 4.165 88.47 38.94
14 6 30 1 1500 0.271 9.982 267.73 48.55
15 6 35 2 2000 0.467 6.620 245.37 47.80
16 8 15 4 1000 0.588 4.612 16.30 24.24
17 8 20 5 1500 0.230 12.762 43.37 32.74
18 8 25 1 2000 0.196 14.140 40.67 32.18
19 8 30 2 2500 0.222 13.073 30.23 29.61
20 8 35 3 500 0.512 5.815 127.30 42.10
21 10 15 5 2000 0.433 7.263 23.73 27.51
22 10 20 1 2500 0.331 9.610 32.47 30.23
23 10 25 2 500 0.804 1.891 64.03 37.41
24 10 30 3 1000 0.528 5.552 43.50 32.77
25 10 35 4 1500 0.618 4.185 56.70 35.07
Fig. 3. (a) and (b) Effect of control factors on friction coefficient and wear (without fiber).
M.S. Senthil Kumar et al. / Materials and Design 70 (2015) 1–9 5
Fig. 4. (a) and (b) Effect of control factors on friction coefficient and wear (with fiber).
Table 6 Table 7
S/N ratio response table for coefficient of friction (without fiber). S/N ratio response table for wear (without fiber).
Level Filler content Normal load Sliding velocity Sliding velocity Level Filler content Normal load Sliding velocity Sliding velocity
(%) (N) (m/s) (m) (%) (N) (m/s) (m)
1 19.255 16.629 9.877 5.673 1 14.34 28.01 37.49 39.78
2 12.884 11.669 7.912 11.427 2 32.99 29.38 31.37 30.85
3 12.892 14.061 15.797 13.663 3 36.79 31.40 30.97 31.00
4 11.321 11.809 14.965 18.745 4 35.60 31.70 27.03 27.97
5 10.465 12.649 18.266 17.309 5 36.35 35.58 29.21 26.46
Delta 8.789 4.960 10.354 13.072 Delta 22.45 7.56 10.45 13.32
Rank 3 4 2 1 Rank 1 4 3 2
parameters were obtained by conducting the experiments as per the 3.2. ANOVA and the effects of factors
orthogonal array as shown in Tables 4 and 5. Also, Figs. 3 and 4 show
the effect of the four control factors on coefficient of friction and In order to observe statistical significance of various factors like
wear for both with and without fiber laminates. In addition to, the Filler content (%), Normal load (B), Sliding velocity (m/s), and Slid-
S/N ratio responses for coefficient of friction and wear are shown ing distance (m) on coefficient of friction and wear for both fiber
in Tables 6–9. Overall, the results direct to the conclusion that com- reinforced and without fiber laminates, Analysis of Variance
bination of factors A1B1C5D5 and A1B1C4D5 offer minimum friction (ANOVA) was performed on experimental data using MINITAB.
coefficient and wear for without fiber laminates. Conversely, Tables 10–13 show the results of the ANOVA with the coefficient
A2B4C5D1 and A2B1C4D2 offer minimum friction coefficient and wear of friction and wear. This analysis is undertaken for a level of con-
for fiber reinforced laminates. fidence of significance of 5%. The last columns of the tables (p-val-
Table 9
S/N ratio response table for wear (with fiber).
Level Filler content (%) Normal load (N) Sliding velocity (m/s) Sliding velocity (m)
1 35.15 26.20 28.10 27.52
2 22.96 27.41 32.95 25.48
3 37.05 33.01 35.10 36.06
4 32.18 34.66 28.31 36.78
5 32.60 35.65 32.47 31.09
Delta 14.08 9.46 7.00 11.30
Rank 1 3 4 2
Table 10
Analysis of variance for COF with fiber, using adjusted SS for tests.
Table 11
Analysis of variance for COF without fiber, using adjusted SS for tests.
Table 12
Analysis of variance for wear with fiber, using adjusted SS for tests.
Table 13
Analysis of variance for wear without fiber, using adjusted SS for tests.
Fig. 5. (a)–(f) Scanning electron microscope of 0 wt%, 2 wt%, 4 wt%, 6 wt%, 8 wt% and 10 wt% MMT filled epoxy.
ues) signify that the main effects are more and or less significant greater influence of fiber inclusion on epoxy laminates which
(i.e. the effects are statistically more significant only when the p- might have primarily lead to the lesser contribution on coefficient
values are less than 5%). From Table 10 (for fiber reinforced lami- of friction and wear when compared to without fiber laminates.
nates), one can observe that filler content, normal load, sliding
velocity, and sliding distance have relatively less significant contri- 3.3. Surface morphology
bution on coefficient of friction when compared to without fiber
laminates (see Table 11). This analogous trend could also be wit- Fig. 5a–f shows the images of the worn out surfaces of Scan-
nessed in the case of wear results for both with and without fiber ning Electron Microscope (SEM) for 0 wt%, 2 wt%, 4 wt%, 6 wt%,
laminates (see Tables 12 and 13). These trends clearly show the 8 wt% and 10 wt% MMT filled epoxy without fiber. Likewise,
8 M.S. Senthil Kumar et al. / Materials and Design 70 (2015) 1–9
Fig. 6. (a)–(f) Scanning electron microscope of 0 wt%, 2 wt%, 4 wt%, 6 wt%, 8 wt% and 10 wt% MMT filled epoxy with glass fiber.
Fig. 6a–f shows the images of the worn out surfaces of Scanning loading and 10 wt% loading too exhibited appreciable adhereness
Electron Microscope (SEM) for 0 wt%, 2 wt%, 4 wt%, 6 wt%, 8 wt% and similarities in their surface morphology. This adhereness
and 10 wt% MMT filled epoxy with E glass fiber. These images might be due to the better attraction between the MMT layers
obviously depict that neat epoxy composite is brittle in nature and the epoxy. Additionally, this trend might be due to the filling
and the outer surface of the composite is rough. Furthermore, it up of the micro-cracks gap by nano clay. This enhancement might
was observed that 2 wt% loading and 4 wt% loading disclosed bet- also be due to the superior matrix interface with glass fiber which
ter adhereness with epoxy than 6 wt% loading. Similarly, 8 wt% would have yielded reduced impact strength.
M.S. Senthil Kumar et al. / Materials and Design 70 (2015) 1–9 9
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