composite in metal matrix composite

1. MECHANICAL BEHAVIOUR OF ALUMINIUM BASED
METAL MATRIX COMPOSITES REINFORCED WITH
SiC AND A𝒍 𝟐 𝑶 𝟑FOR SHAFT
PRESENT BY:
A.Kalaiyarasan & Ragupathi.P
Assistant Professor,
Department of mechanical Engineering ,
Muthayammal Engineering college
Rasipuram.

2. PRESENTATION TOPICS
 Objective
 Introduction
 Literature Survey
 Methodology
 Identification of problem
 Material Selection
 Aluminum Series
 Properties of reinforcement
 Core Materials
 Parameter selection
 Testing
 Type of analysis
 Static Analysis
 Modal Analysis
 Analysis Results
 Application
 Work in progress
 Future work
 References

3. OBJECTIVE
 The main objective of project to avoid whirling vibration. The operating
parameter of the composite as its control the properties of the composite
material.
 These is focus on the study of mechanical behavior of Aluminum metal
matrix composite with varies composition of reinforcement particles of
graphite or nanoparticles, Sic and Al2O3 composite produced by the stir
casting technique. Different percentage of reinforcement is used. Tensile
test, Hardness test and torsional test.

4. INTRODUCTION
 A composite material is defined as a material system which consist of a
mixture or a combination of two or more different materials which are
insoluble in each other and differ in form or chemical composition.
 Composite materials should comprise component materials that are
congenital with each other. In the field of high modulus composites, resin-
matrix composites find considerable interest is easy to fabricate into
engineering structures.
 Two Phase of Composite materials.(i)Matrix (ii)Reinforcement.
 Classification of composite materials:
1. Based on matrix material.
2. Based on material structure.

5. INTRODUCTION (Cont.…)
 The major composite classes based on structural composition of the matrix
are:
 Polymer-matrix composites
 Metal- matrix composites
 Ceramic- matrix composites
 Carbon- carbon composites
 The composite gives indication of the combinations of two or more
materials in order to improve the properties of monolithic material for
adjusting to global need for reduced weight, low cost,quality,and high
performance in structural materials.

6. LITERATURE SURVEY
SI.
No
TITLE AUTHOR YEAR INFERENCE
1. Preparation of Aluminum matrix
composite by using stir casting method
Rajesh Kumar
Gang Aram
Bhandare
2013 Stir casting
process,
Aluminum Matrix
reinforcement,
mixing and
agitation.
2.
A review of friction stir welding of
aluminum matrix composite
Umar S.Salih,
Hengan
2015 Friction stir
welding, Al-
Matrix
,microstructural
and mechanical
properties.
3. Characterization of Silicon Carbide
reinforced Aluminum matrix composite
M.D.Habibur
Rahman,H.M.
Mamunal
Rashed
2013 MMCs,stir
casting,Hardness,
Micro Structure,
wear resistance.

7. LITERATURE SURVEY(Cont...)
SI.
No
TITLE AUTHOR YEAR INFERENCE
4. Fabrication of Al-Sic composite through
power metallurgy process and testing
properties.
C.S.Verma
RajeshPurohit,
R. S.Rana
2012 MMCs,mechanical
alloying, micro-
structural analysis.
5.
Effects of process parameter of stir
casting on metal matrix composite.
Alok Barnwal
Shubham
Mathur
2013 Silicon carbide,
Stir pouring
temperature,UTM,
Hardness.
6. A study on microstructure of Al matrix
composite.
Pardeep
shrma,Dinesh
khanduja
2015 Al –MMC
graphite,
Microstructure
scanning.
7. Experimental investigation on
machining characteristics of Al6061
hybrid metal matrix composite
processed by EDM
C.Velmuruga
Subramanian
2011 Aluminum
composite, stir
casting, Hybrid
composite.

8. LITERATURE SURVEY(Cont...)
SI.
No
TITLE AUTHOR YEAR INFERENCE
8. Characterization of SiC particulate
reinforced AA6061 Aluminium alloy
composite produced via stir casting.
N. Chawla,
J.J. Williams,
G. Piotrowski,
and R. Saha
2014 Tensile strength,
microstructure,
stir casting,
MMCs.
9.
Material optimization and weight
reduction of drive shaft using composite
material.
G. B. Veeresh
Kumar, C. S.
P. Rao, N.
Selvaraj, M. S.
Bhagyashekar
2013 Composite,
propeller shaft,
transmission,
universal joint.
10. Experimental investigation to study tool
wear during turning of alumina
reinforced Aluminium.
Balasivanandh
a Prabu,L.
Karunamoorth
y, S.
Kathiresan, B.
Mohan
2013 MMC graphite,
Harness
toughness,
Microstructure
scanning.

9. METHODOLOGY
OBJECTIVE
SELECTION OF MATERIAL
STARTING ALUMINUM ALLOY LM6 WITH
REINFORCEMENT SiC AND Al2O3
PROBLEM DEFINITION
DATA COLLECTION
PRODUCTION OF
COMPOSITE BY
STIR CASTING
TENSILE TEST HARDNESS TEST TORSIONAL TEST
STATIC AND MODAL ANALYSIS OF SHAFT
RESULT AND CONCLUSION
Characterization
(SEM,XRD)

10. IDENTIFICATION OF PROBLEM
 The passenger cars, trucks and vans should have the torque transmission
capacity more than 3500Nm and the natural frequency must be higher than
6500 rpm to avoid whirling vibration.
 In that the critical speed of shaft is inversely proportional to the square of
the length.so that the vibration problem could be solve by increasing the
length of shaft but its not permitted due to space limitations.
 So that its only for manufacturers and manufacture the shaft in two pieces.

11. SCHEMATIC ARRANGEMENT OF UNDERBODY
OF AN AUTOMOBILE

12. MATERIAL SELECTION
 Aluminum alloy
 Silicon carbide and alumina (Reinforcement Particles)
 Graphite particles

13. ALUMINUM SERIES
ALLOY SERIES FEATURES APPLICATION
Al2024 Good corrosion
resistance & High
strength
High strength
structural(aircraft),
automotive parts, screws
and rivets.
Al6061 Good formability, weld
ability, corrosion
resistance and strength.
Automobile parts,
Marine, aircraft's
Al7079 High strength alloy Aircraft and structure,
recreation equipment's.

14. PROPERTIES OF REINFORCEMENT MATRIX
PROPERTY Al2O3 SiC GRAPHITE
Density(at 20℃)
g/c𝑚3
3.97 3.22 2.09-2.23
Melting point ℃ 2288 2973 3915
Thermal
expansion
(𝜇𝑚/℃)
7.1 4 2.6
Thermal
conductivity
(W/m K)
35.6 126 85
Young's modulus
GPa
370 410 10

15. CORE MATERIALS
PROPERTIES/
MATERIALS
ALUMINUM STEEL
Stiffness(N/m) 22.9𝑒3
22.65𝑒3
Density(Kg/𝑚3) 2700 7800
Weight Low High
Young's modulus(GPa)
70 21
Poisson ratio 0.33 0.3
Co.eff of Thermal
expansion (𝜇𝑚/𝑚℃)
23.4 12
Correction resistance High Low

16. VOLUME FRACTIONS
Fiber and Matrix volume fraction is,
Sum of volume fraction is
volume of composite, fiber, and matrix
density of composite, fiber, and matrix

17. MASS FRACTIONS
Fiber and Matrix mass fraction is
mass of composite, fiber, and matrix
Sum of volume fraction is
DENSITY of the composite

18. PARAMETER SELECTION
PARAMETERS NEW MATERIAL OLD MATERIAL
Density(Kg/𝑚3
) 2810 2700
Poisson ratio 0.31 0.33
Young modulus(Pa) 1.21e11 7.0e10

19. TESTING
 Tensile test
 Hardness test
 Torsional test
 Characterization (SEM,XRD)

20. TYPE OF ANALYSIS
 Static analysis of composite shaft
 Torsional analysis
 Dynamic analysis (modal)

21. STATIC ANALYSIS
 A static analysis is used to determine the displacements, stresses, strains
and forces in structures or components caused by loads that do not induce
significant inertia and damping effects.
 In static analysis loading and response conditions are assumed, that is the
loads and the structure responses are assumed to vary slowly with respect
to time.

22. BOUNDARY CONDITION

24. STATIC ANALYSIS RESULTS
Al-SiC Aluminium Steel
Total
Deformation
[m]
6.893
𝑒−6
1.1927𝑒−5 4.147𝑒−6
Equivalent
(von-
miss)stress[P
a]
1.3985
𝑒6
1.3985𝑒6
1.4634𝑒6
Equivalent
Elastic
Strain[No
Unit]
1.1604
𝑒−5
2.0716𝑒−5 7.3721
𝑒−6
STEEL
Al -SiC
0.00E+00
2.00E+05
4.00E+05
6.00E+05
8.00E+05
1.00E+06
1.20E+06
1.40E+06
1.60E+06
STEEL
Al
Al -SiC

25. MODALANALYSIS
 The natural frequencies and the mode shapes are important parameters in
the design of a structure for dynamic loading conditions. Modal analysis is
used to determine the vibration characteristics such as natural frequencies
and mode shapes of a structure or a machine component while it is being
designed.
 The natural frequency depends on the diameter of the shaft, thickness of the
hollow shaft, specific stiffness and the length.

26. MODE 1 & 2

27. MODE 3 & 4

28. MODE 5 & 6

29. MODE 7

30. MODALANALYSIS RESULTS
0
100
200
300
400
500
600
700
800
900
1000
Mode 1 mode 2 mode 3 mode 4 mode 5 mode 6 mode 7
Al-SiC
Al-SiC

31. APPLICATIONS
 Aircrafts structures
 Automotive parts
 Aerospace
 Marine

32. WORK IN PROGRESS
FIRST
REVIEW
• Field Research
• Literature Survey
SECOND
REVIEW
• Problem Identification
• Material selection
THIRD
REIVEW
• Design and Analysis of shaft
• Static and Dynamic Analysis is done using ANSYS Workbench
15.0

33. PRESENT CONCLUSION
 The behaviour of Aluminium alloy (LM6) and Silicon carbide literature
was collected and studied.
 The finite element analysis is used in this work to predict the deformation
of shaft.
 The fabrication of the section will be done in the next phase. Fabrication of
section will be based on the design created in the first phase.
 The modeling and analysis of shaft is done by using ANSYS Workbench.

34. FUTURE WORK
 The volume fraction (5%,10%,15%,20%) of aluminum alloy(LM6) and
SiC with Alumina will be fabricate through stir casting technique.
 The specimen will be evaluated by using Hardness test, tensile test,
Torsional test and SEM/XRD.
 The specimens are going to be prepared by liquid metallurgy method, the
Anna University CEG campus, Chennai was identified to prepare casting
of composite materials by stir casting method.
 The testing is identified at Root India Pvt ltd, Ganapathi Coimbatore.
Material
purchase
Specimen
preparation
Submission
Project
PhaseII
Report
Mechanical
testing and
Result
analysis

35. REFERENCES
 Manoj,S. Dwivedi,D.D., Lakhvir,S.andVikas,C.(2009):”Development of Aluminum
Based Silicon Carbide Particulate Metal Matrix Composite". Journal of Minerals
and Materials Characterization and engineering, Vol.8,No.6,pp455-467.
 Dunia Abdul Sahib, Aluminum silicon carbide and aluminum graphite particulate
composites,ARPN J.Engg Appl. Sci.6(2011)41-46.
 Muhammad Hayat Jokhio,Muhammad Ibrahim Pan war, and Mukhtiar Ali Unar
“Manufacturing of aluminum composite material using stir casting process”.
Mehran University Research Journal of Engineering and Technology, volume
30,NO.1, January,2011[ Issan 0254-7821].
 Hashmi Looney L, Hashmi MSJ(1996).MMCs: Production by stir casting method.
Journal of Materials Processing Technology,92-93pp1-7
 Lilholt H , Aspects of Deformation of Metal Matrix Composites, Materials.
 Kurt A, Uygur I, Cete E. Surface modification of aluminum by friction stir
processing. J Mater Process Techno 2011;211:313–7.
 Mostafapour Asl A, Khandani ST. Role of hybrid ratio in microstructural,
mechanical and sliding wear properties of the Al5083/Graphite /Al2O3p a surface
hybrid Nano composite fabricated via friction stir processing method. Mater Sic
Eng. A 2013;559:549–57.

36. REFERENCES(Cont...)
 Vijayarangan.S., Rajendran.I,Optimal design of a composite leaf spring using
Genetic algorithm computers and Structure 79 2001:pp.1121-1129.
 T.Rangaswamy “Optimal design and analysis of Automotive Composite Drive
Shaft” International symposium of research students on materials science and
engineering December 2002-004 Chennai India.
 Kim C.D 1992”Critical speed analysis of laminated shafts". Composite
engg.vol.3,pp.633-643.
 J.H.Park,J.H.Wang 2001.”Stacking sequences design of Composite laminates for
maximum strength using Genetic Algorithm". Journal of Composite
Structure,Vol.52.pp.217-231.
 Mr.V.I.Narayana, Mr.D.Mojeswararao and Mr. Kumar. ”Optimization of composite
drive shaft assembly and comparison with conventional steel drive shaft,vol.I issues
6 august 2012.
 https://www.google.co.in/properties of aluminum
 https://www.google.co.in/properties of steel
 https://www.google.co.in/properties of stainless steel pdf
 https://www.google.co.in/properties of silicon carbide