Transcript CASE STUDY OF FAILURE OF HELICAL SPRING OF CARRIAGE …

INTRODUCTION TO
COMPOSITES MATERIALS
(FRP) AND ITS USES IN INDIAN
RAILWAYS.
ARVIND LAL
Chief Instructor (Met)
IRIMEE, Jamalpur.
E-mail – arvindlal65@ yahoo.co.in
INTRODUCTION
COMPOSITE MATERIALS.
COMPOSITES, THE WONDER MATERIALS
* WITH LIGHT WEIGHT,
* HIGH STRENGTH TO WEIGHT RATIO,
* HIGH STIFFNESS AND MORE CORROSION RESISTANCE
HAVE COME IN A LONG WAY BY REPLACING THE CONVENTIONAL
MATERIALS LIKE WOODS METALS ETC

COMPOSITES MATERIALS ARE DERIVED BY COMBING OF TWO OR MORE OF
MATERIALS WITH THE INTENT OF ACHIEVING SUPERIOR PROPERTIES/
PERFORMANCE COMPARED TO EACH INDIVIDUAL MATERIALS.
EXAMPLES- BONES, WOOD, MUSCLE FRP, CERMETS ETC.

FRP- (FIBER GASS REINFORCED PLASTICS ) - IS A LARGE FAMILY OF COMPOSITE
MATERIALS.
ONE OF THE CONSTITUENT MATERIALS IS CALLED MATRIX WHILE THE OTHER IS
CALLED REINFORCEMENT.
CONVENTIONAL MATERIALS .
METALS AND ALLOYS. (A)
ORGANIC POLYMERS. (B)
CERAMICS AND GLASSES. (C)
B+C –
A+BA+C-
FRP( FIBER-REINFORCED PLASTICS.
MRP( METAL- REINFORCED
CERMETS
PLASTICS.
FRP-FEW FACTS.
IN FRP : F – FIBRE. (G-GLASS.)
R- REINFORCEMENT.
P- POLYMER ( PLASTICS) BEHAVES LIKE MATRIX.
FIBRE:-
ANY POLYMER, METAL OR CERAMIC THAT HAS BEEN DRAWN INTO
LONG AND THIN FILAMENT IS TERMED AS FIBRE. SOME OF THE FIBRES
USED AS REINFORCEMENTS ARE :- GLASS FIBRES, CARBON FIBRES &
ARAMID FIBRES
GLASS FIBRE:-GLASS FIBRES ARE THE MOST COMMON OF ALL
REINFORCING FIBRES FOR POLYMER MATRIX COMPOSITES. THE PRICIPLE
ADVATAGES OF GLASS FIBRES ARE THE LOW COST AND HIGH STREGTH.
FORMS OF GLASS FIBRE.
1.
CHOPPED-STRAND MAT AND CONTIUOUS-MAT.
2.
FIBRE GLASS ROVING.
3.
WOVEN ROVING. 4. SURFACE MAT.
MATRIX (RESIN) MAY BE :POLYMERIC MATRICES:* THERMOSETS;- POLYESTER, PHENOLICS,
EPOXY, & SILICONES.
* THERMOPLASTIC:- PS,PE,PC,NYLON-6,6 PEEK ETC.
METAL MATRICES:AL, Ni AND Ti
POLYESTERS ARE WIDELY USED BECAUSE OF THERE LOW COST.
Phenolic resins;- high temperature resistance is required.
Epoxy resins: impart good mechanical properties.
Silicon resins:-excellent thermal & elecrrical properties.
GLASS FIBERS:Glass fibers are the most common of all reinforcing fibers for
polymer matrix composites. The principal advantages of glass
fibers are the low cost and high strength.
TYPES OF GLASS FIBERS & their nominal formula:E-glass: - Calcium aluminoboroslicate.
E (Electrical)- 15 Al2O3, 17 CaO, 5MgO, 8B2O3
S-glass: - Magnesium aluminosilicate.
S (HIGH-STRENGTH) --- 25 Al2O3 , 10 MgO
C- glass: - Sodalime borosilicate.
C (CHEMICAL) - 4 Al2O3,13CaO , 3 MgO, 8Na2O, 5 B2O3.
Properties of E-glass & S-glass fibers.
Propertied units
E-glass
S-glass
Density, g/cm3
2.54
2.49
Tensile strength, MPa
3448
4585
Elastic modules, GPa
72.4
85.5
Range of diameter Um
3.20
8-13
5.0
2.9
Coefficient of thermal
Expansion 10-6/0C
Over 90% of the glass fibers made are E grade. The more
expensive S grade is used for the highest strength, and the C
grade for chemical resistance. The composition of the glass
that is most commonly drawn into fibres is contained as
(composition, wt %) –
SiO2- 52-56%, CaO-16-25%, Al2O3 –12-16%,
B2O3 – 8-13%, 4MgO.
SELECTION OF RAW MATERIALS (FRP)
1.GLASS FIBRE .
2.RESINS. ISOPHTHLATE POLYESTER RESINS IS:6746/72.
EXCEPTIONALLY GOOD CHEMICAL RESISTANT
TOWARDS MINIRAL & ORGAIC ACIDS.
3.STABILIZERS:-TO GIVE RESIN A REASONABLE SHELF
LIFE.
4. CATALYSTS AND ACCELERATORS:-TO CONVERT
RESIN TO A HARD AND INFUSIBLE SOLID WITHIN A
SHORT TIME TO MAKE MOULDING POSSIBILITY.
A. FOR COLD CURING:- CATALYST- MEKP
ACCELERATOR-COBALT NAPHTHENATE.
B. HOT CURING:- CATALYST-MEKP.
SELECTION OF RAW MATERIALS (FRP)
5. COLOURING MATERIAL & FILLERS
IORGANIC PIGMENTS.
6. MOULD RELEASE AGENT :- PVA IN WATER. HARD
WAX SUCH AS CARNAUBA. ARE USED ON POLISHED
METAL MOULDS.
FIBRE REIFORCED COMPOSITES.
(FIBROUS COMPOSITES)
PARTICLE REINFORCED COMPOSITES
(PARTICULATE COMPOSOTES)
LAMINATES COMPOSITES.
ARRAGEMENT OF FIBRE
ARRAGEMET OF GLASS FIBRE.
ARRAGEMET OF FIBRE
ADVANTAGE OF C.M.(FRP) OVER
CONVENTIONAL MATERIALS:1. EXCELLENT CORROSION RESISTANCE.
2. LONG LIFE OFFERS EXCELLENT FATIGUE,
IMPACT , ENVIRONMENTAL RESISTANCE AND
REDUCED MAINTENANCE.
3. LESS NOISY WHILE IN OPERATION & PROVIDE
LOWER VIBRATION TRANSMISSION THAN
METALS.
4. IMPROVED APPERANCE WITH SMOOTH
SURFACES & DECORATIVES.
ADVANTAGES (CONT)
5. WIDE PERFORMANCE RANGE.(BY PROPER SELECTING FIBRES
AND MATRICES)
6. LOW MANUFACTURING COST.
7. SUPERIOR STYLING.
8. HIGH TENSILE STRENGTH (4 to 6 times greater than steel & Al.)
9. MORE FATIGUE LIFE.( UPTO 60% OF UTS).
10. HIGH STRENGTH TO WEIGHT RATIO.( 30 TO 45% LIGHTER THAN AL.
11. ELIMINATE JOINTS & INTEGRATED DESIG COMPARED TO
CONVENTIONAL METALLIC PARTS.
12. LESS CHANCE OF THEFT.
FUNCTION OF MATRIX PHASE.
1.
IT BINDS THE FIBRES TOGETHER BY VIRTUE OF
ADHESIVE
FORCE.
2.
IT ACTS AS A MEDIUM BY WHICH VIRTUE AN
EXTERNALLY APPLIED LOAD IS TRANSMITTED AND
DISTRIBUTED TO THE DISPERSED PHASE.
3.
IT PTROTEST THE INDIVIDUAL FIBRES FRON CHEMICAL
REACTION WITH ENVIRONMENT AND FROM THE SURFACE
DAMAGE DUE TO MECH.ABRACTION.
4.
IT KEEPS THE REINFORCING FIBRES IN THE PROPER
POSITIO AND ORENTATION SO THAT THEY CAN CARRY
THE INTENDED LOADS.
5.
IT PTEVENTS THE PROPAGATION OF BRITTLE CRACKS
BY ITS RELATIVE SOFTNESS AND PLASTICITY.
THE ESSETIAL REQUIREMETS OF A
GOOD MATRIX MATERIALS ARE :1. IT SOULD BE DUCTILE.
2. THE BONDIG STRENGTH BETWEEN THE MATRIX AND
THE FIBRE MUST BE HIGH.
3. IT SOULD BE MORE CORROSION RESISTANCE.
4.
IT SHOULD BE MORE ENVIRONMENTAL RESISTANCE.
5. IT SHOULD DETERMINES THE OVERALL SERVICE
TEMPERATURE LIMITATIONS.
( POLYMERS ARE LIMITATED TO SERVICE
TEMPERATURES BELOW 300c)
COMPOSITES IN RAILWAYS:
INDIAN SCENARIO
C.M. HAVE ALREADY BEEN IDENTIFY AS A POTENTIAL MATERIAL FOR ITS
APPLICATION IN THE INDIAN RAILWAYS BY THE CONCERTED EFFORTS OF
RDSO.LKO & ICF.CHENNAI.
WHY NEEDS FOR IR ?
1. HIGHER TRAIN SPEED.
2. LOWER PRODUCTIO, OPERATION & MAINTENANCE COST FOR CARRIAGES.
3. LOWER ENERGY CONSUMPTION.
4 MINIMUM ENVIRONMENTAL IMPACT.
5. LOWER NOISE LEVEL.
6. IMPROVED PASSENGER COMFORTS & AESTHETICS.
7.
LESS TRACK WEAR & THE ABILITY TO CARRY GREATER PAY LOADS.
8.
TO PROVIDE GREATER VERSATILITY IN TRAIN DESIGN AND OPTIMIZATION OF
TRAIN PERFORMANCE.( LOWERING THE CENTRE OF GRAVITY TO ENHANCE
STABILITY).
COMPONENTS USED IN IR
COMPONENTS OF COACHES ARE GENERALLY MADE OF
FRP-COMPOSITE MATERIALS.
1.
WINDOW FRAMES & SHUTTERS.
2.
WALL PROTECTOR IN TOILETS.
3.
TRAYS FOR BATTERY BOXES ( FOR AC & NON AC COACH.)
4.
SNACKS TABLE.
5.
CHAIN COVER FOR JMP JACK.
6.
FRP AIR GRILL FOR AC COACH.( RAJDHANI)
7.
TOILET PAN FOR GUARAD VAN BRAKE.
8.
FRP- TOILET MODULES.
9.
FRP-COMMODE ADOPTER.
10.
AXLE BOX COVERS.
11.
LUGGAGE BIN.
12.
PANELS.
COMPONENTS USED IN IR (CONTINUE).
FLOOR, CEILING & ROOF PANELS.
14. MODULAR INTERIOR PANEL & DOORS.
15. DOUBLE DECK FLOORING.
16. INTERNAL SIDE WALL PANELS.
17. EXTERNAL STRUCTURAL SIDE PANELS.
IN ADDITION , RDSO HAS IDENTIFIED A NUMBER OF
PARTS FOR REPLACEMENT WITH COMPOSITES I N THE
NEAR FUTURE.
THESE INCIUDES.
1. COMPOSITE BRAKE- BLOCKS & BREAK- GEAR BUSHES.
2. FRP-GEAR CASE FOR LOCOMOTIVES.
3. AXLE BOX COVERS (SMC)
4. BERTH & CHAIR BACKINGS.
COMPONENTS USED IN IR
(CONTINUE).
5. PANELING IN THE COACHES.
6. ROOF WATER TAKS.
7. TOILET MODULES.
8. LAVATORY CHUTES.
9. WINDOW GUIDES.
10. DOORS.
( MAIN ENTRANCE , SLIDING DOOR FOR 1ST AC COMPARTMENT, INTER
COMMUNICATION DOOR IN AC CAOCHES, SLIDING DOORS FOR EMU/DMU,
SLIDING/ FLUSH DOORS FOR TOILETS, VESTIBULE DOORS ETC.)
11. CAOPY END FOR EMU/DMU COACHES.
12. TOILET CABINETS.
13. FOLDING TABLES.
14. FUEL IJECTION PUMP COVER.
15. LUGGAGE RACKS ETC.
SOME NEW PROJECTS
OR
COMPOSITES FOR RAILWAYS: CASE STUDY
“ADVANCED COMPOSITES MISSION ” OF TIFAC
( TECHNOLOGY INFORMATION, FORECASTIG & ASSESSMENT COUNCIL) AN
AUTONOMOUS ORGANIZATION UNDER DST (DEPARTMENT OF SCIENCE &
TECHNOLOGY GOVT OF INDIA AND DRDO WORKING WITH SOME OF PVT
AGECIES ON THE DEVELOPMENT OF COMPOSITES FOR THEIR USES UNDER THE
GUIDE LINE OF RDSO & ICF
THESE ARE:-
1. FRP GEAR CASE FOR RAILWAY LOCOMOTIVES.
A.C.M OF TIFAC IN PARTNERSHIP WITH
M/S PERMALI WALLACE Ltd, BHOPAL. & RRL,BHOPAL
WHY IT IS FELT TO REPLACE THESE BY FRP GEAR CASE.
1. THE HEAVY WEIGHT OF STEEL GEAR-CASE SOMETIMES CAUSES ITS
DETACHMENT FROM THE TRACTION MOTOR DUE TO VIOLENT JERKS OR IMPACT
OR DAMAGE BY STONE BALLAST WHICH IS VERY COMMON FOR LOCOMOTIVES.
COMPOSITES FOR RAILWAYS: CASE STUDY
(CONTINUE)
2. LOSS OF EXPESIVE LUBRICATING MEDIUM BY LEAKAGE.
SL
NO.
PARAMETER
MS GEAR
CASE.
FRP-GEAR-CASE.
1.
CORROSION
RESISTANCE.
HIGHLY
SUSCEPTIBLE
NON-CORROSIVE.
2
WEIGHT PER LOCO
134x6=804 KGS
68X6=408 KGS
WEIGHT SAVING OF 396KGS
3
QUALITY OF JOINTS.
COULD BE POOR.
JOINTLESS CONSTRUCTION.
4.
LIFE CYCLE COST.
HIGH
2 TO 3 YEARS.
LOW
6 YEARS.
CASE STUDY (CONTINUE)
SL
NO.
5.
PARAMETER
FITMENT
MS GEAR
CASE.
DUE TO DEFORMATION MAY
POSE PROBLEMS.
FRP-GEAR-CASE.
ENSURES REPEATABILITY
6.
IMPACT
RESISTANCE.
VERY GOOD.
7.
HEAT
DISSIPATION.
VERY GOOD.
8.
FITMENT
EFFORTS
9.
CHANCES OF
FALLING
HIGH CAN BE DISASTROUS.
VERY LOW.
10
OIL LEAKAGE
COST.
HIGH.
MINIMUM.
HIGH.
GOOD.
DESIGN PROVEN THROUGH
FIELD TRIALS.
LOW.
CASE STUDY (CONTINUE)
•
60-FRP-GEAR-CASES HAVE ALREADY BEEN
ORDER.
INDUCTED BY IR AGAINST DEVELOPMENT
• EFFOORTS ARE CURRENTLY UNDERWAY TO DEVELOP FRP-GEAR CASES FOR NEW TYPE OF TR
MOTOR WITH CYLINDRICAL ROLLER BEARING.
• HITACHI MODEL FOR ELECTRIC LOCOMOTIVES.
2. FRP SLEEPERS FOR RAILWAY GIRDER BRIDGES.
THE PROJECT WAS INSTITUTED AT RESEARCH & DEVELOPMENT
ESTABLISHMENT(ENGINEER) , PUNE IN ACTIVE COLLABORATION WITH RDSO.
• SUBJECTED TO FIELD TRILS AT 3-4 LOCATIONS EACH AT DIFFERENT RAILWAY ZONES.
•VIBRATION DAMPING. & HIGH RESISTACE AGAINST STRENGTH AND WATER RESISTANCE
• DYNAMIC PANEL TEST OF 8 LONG SLEEPERS IS CURRENTLY UDERGOING AT RDSO.
• THE FULL LENGTH FRP SLEEPERS DEVELOPED BY RTM PROCESS AS PER RDSO.
CASE STUDY (CONTINUE)
3. ENERGY EFFICIENT FRP AXIAL FLOW FANS. OR 1680 MM DIA
FAN FOR RADIATOR COOLING FOR DIESEL LOCOMOTIVES
THE PROJECT WAS LACHED IN PARTERSHIP WITH
PARAG FANS & COOLING SYSTEMS Ltd, DEWAS & ACTIVE SUPPORTED BY IIT,
MUMBAI.
EFFICIENCY OF THE FAN HAS BEEN PROVED SUPERIOR TO THE CONVENTIONAL
FANS WITH ALUMINIUM IMPELLERS.
4. JUTE-COIR COMPOSITES- AN ALTERNATIVE TO
WOOD PRODUCTS.
* M/S DUROFLEX LIMITED BANGALORE.
* APPLICATION.
• PARTITIONING. ( 80% NATURAL FIBRES SUCH AS JUTE & COIR WITH PHEOLIC RESIN)
• FALSE CEILING
• SURFACE PAELING
• FURNITURE ( SLEEPER BERTH BACHING IN IR COACHES.)
CASE STUDY (CONTINUE)
5. DEVELOPMENT OF
FRP-PULTRUDED
PROFILES.
M/S SUCRO FILTERS Pvt Ltd PUNE & TECHNOLOGY SUPPORT
FROM NCL, PUNE.
APPLICATION IN RAILWAYS FOR FRAME SECTIONS FOR DOOR
WINDOWS LUGGAGE RACKS STRIPS LADDERS RODS ETC.
Conclusion.
* NOW THE COMPOSITES HAVE BECOME A PART
EVERYDAY LIFE.
OF OUR
* COMPOSITES IMPART AN AESTHETIC APPEARANCE FOR THE
RAILWAY COACHES.
* NOW WITH THE INTRODUCTION OF LHB COACHES IN THE
INDIAN RAILWAYS IN THE NEAR FUTURE, THE USAGE OF
COMPOSITES IS EXPECTED TO GROW MORE AND MORE.
* GLASS FIBRE IS MOST WIDELY USED REINFORCEMENT.E-GLASS
FIBRE HAS EXCELLENT CORROSION AND ENVIROMENT
RESISTANCE.
* CARBON FIBRES SHOW NO EXPASION OR CONTRACTION
ACROSS WIDELY TEMPERATURE DIFFERECE, & APPLICABLE TO
ELECTRONICS.
* SELECTION OF CORRECT RAW MATERIALS & RIGHT
MANUFACTURING TECHNIQUE.
CONCLUSION.(CONT)
* DISPOSAL OF USED COMPOSITE MATERIALS.
* TESTING FACILITIES OF COMPOENT
MATERIALS SOULD BE AVAILABLE AT PU.
THANKS .