STATISTICAL ANALYSIS FOR THE ABRASIVE WEAR BEHAVIOR
Statistical Analysis For The Abrasive Wear Behavior of Bagasse Fiber Reinforced Polymer CompositeSTATISTICAL ANALYSIS FOR THE ABRASIVE WEAR BEHAVIOROF BAGASSE FIBER REINFORCED POLYMER COMPOSITEPUNYAPRIYA MISHRADepartment of Mechanical Engineering, VSSUT, Burla, Odisha, IndiaEmail:- priya.punya@gmail.comAbstract— In the present study, a mathematical model has been developed to predict the abrasive wear behavior of bagassefiber reinforced polymer composite. The experiments have been conducted using full factorial design in the design ofexperiments (DOE) on pin-on-disc type wear testing machine, against 400 grit size abrasive paper. A second orderpolynomial model has been developed for the prediction of wear loss. The model was developed by response surface method(RSM). Analysis of variance technique at 95% confidence level was applied to check the validity of the model. The effect ofvolume percentage of reinforcement, applied load and sliding velocity on abrasive wear behavior was analysed in detail. Tojudge the efficiency and ability of the model, comparison of predicted and experimental response values outside the designconditions was carried out. The result shows, good correspondence, implying that, empirical models derived from responsesurface approach can be used to describe the tribological behavior of the above composite.Keywords- Response surface methodology (RSM), Full factorial design, Wear loss, bagasse fiber.INTRODUCTIONagent has significantly influenced the wear resistanceof sisal fibre reinforced PP composites.In the recent years, natural fiber reinforced withpolymer matrix have attracted the attention becauseof their low cost, lightweight, renewability, lowdensity, high specific strength, non-abrasivity,combustibility, non-toxicity,low costandbiodegradability. The availability of natural fibresand ease of manufacturing have tempted researchersto try locally available inexpensive fibres and to studytheir feasibility of reinforcement purposes and towhat extent they satisfy the required specifications ofgood reinforced polymer composite for tribologicalapplications [1]. In tropical and equatorial countries,fibrous plants such as banana, oil palm, bamboo,sugarcane, etc. are available in abundance [2, 3] andfibres like sugarcane [4, 5 and 6] appear to have aconsiderable interest as reinforcement in polymermatrices for low-cost composites. They are widelyused in the production of bearing components used inautomobile industries such as gears, wheels, bushes,etc. [7-10] in which friction and wear are criticalissues. The importance of tribological propertiesconvinced many researchers to study the friction andwear behavior and to improve the wear resistance ofpolymeric composites.Little information concerning the tribologicalperformance of natural fibre reinforced compositematerial [11–14] has been reported. Basavarajappa etal. [15] studied the dry sliding wear behavior ofgraphite filled glass epoxy composites and concludedthat Addition of Graphite in glass–epoxy compositeexhibits lower weight loss, whose value drops as thepercentage of Graphite increases in the composite.U.K.Dwivedi et al. [16] investigated on the influenceof MA-g-PP on abrasive wear behavior of choppedsisal fiber reinforced polypropelene composites. Theyconcluded that the addition of MA-g-PP couplingBesides experimental work on natural fiber basedcomposite, researchers have worked on differentmathematical models to predict the materialproperties. Most of these researchers have worked onMetal Matrix composite (MMCs). Sahin and Ozdin[17] investigated the abrasive wear behaviour ofaluminium based composites using pin on disc typeof machine and developed in terms of the appliedload, sliding distance and particle size using factorialdesign. N.S.M. El-Tayeb et al.[18] Studied thecryogenic effect on frictional behaviour of titaniumalloy sliding against tungsten carbide using responsesurface methodology (RSM) approach and expressedthe interrelationship between the friction coefficient(response) and independent variables such as speed,load, and sliding distance. Farias et al. [19] studiedthe sliding wear of austenitic stainless steels. Theyadopted to obtain an empirical model of wear rate asa function of applied load and sliding velocity usingRSM. From these discussions it is clear that thoughlot of work has been done on MMCs, as per theinformation of author no work has been done on theuse of RSM technique to predict the tribologicalperformance of natural fiber composite.Therefore in the present work an attempt has beenmade to investigate the abrasive wear behaviour ofbagasse fiber reinforced epoxy composite undervarious testing conditions. RSM was adopted toobtain an empirical model of wear loss (response) asa function of amount of reinforcement, applied loadand sliding velocity (input factors).International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Vol-2, Iss-2, 20127
Statistical Analysis For The Abrasive Wear Behavior of Bagasse Fiber Reinforced Polymer CompositeMATERIALS AND METHODSDesign of experiments (DOE)Fabrication of compositesA full factorial design is used with three design factors ofeach of three levels to describe response of the wear lossand to estimate the parameters in the second-order model.Overall 33 27 wear experiments are carried out.The type of epoxy resin used in the presentinvestigation is LY 556 and hardener HY951supplied by Ciba- Geigy of India Limited. Epoxy ismixed with hardener in the ratio 10:1 by weight.Different volume fraction of chopped bagasse fibers(10, 15 and 20%) were added separately in the aboveepoxy mix and stirred for 10 min by a glass rod toobtain uniform dispersion. The final resultant mix ofchopped bagasse fiber and resin was poured intocylindrical mould [Fig.1] and fixed properly. Duringfixing some of the polymer mix squeezed out. Carewas being taken for this in the experiment to makecomposite pins of length 35 mm and diameter of 10mm. The samples were kept in the moulds for curingat room temperature (29 0C) for 24 hr. Cured sampleswere then removed from the moulds and used fordifferent measurements.Table 1. Important factors and their levels for abrasive wear.Pin-on-disc wear testWear tests were carried out by using a pin-on-discwear tester supplied by Magnum, Bangalore.Abrasive paper of 400 grade (grit-23 µm) was pastedon a rotating disc (EN 31 Steel disc) of 120mmdiameter using double-sided adhesive tape. Thesample pin was fixed in a holder and was abradedunder different applied loads (5N, 7.5N and 10N).Each set of test was carried out 6 times for a period of15 mins run. After each 15 mins run the test pieceswere removed from the machine and weightedaccurately to determine the loss in weight.Response surface methodology (RSM)Response surface methodology (RSM) is practical,economical and relatively easy to use. RSM is acollection of mathematical and statistical techniquesthat are useful for the modeling and analysis ofproblems in which output or response is influencedby several input-variables and objective is to find thecorrelation between the response and the inputvariables. It comparises: designing a set ofexperiments, determining a mathematical model anddetermining the optimal value of the response tobetter understanding of the overall system behaviour[20]. A polynomial model of second order type wasproposed to represent the relationship between wearloss and tribo test independent variables. Theperformance of the model depends on a large numberof factors that can act and interact in a complexmanner. In the present work, the input variables arewt. % of reinforcement (R) or fiber concentration,Sliding velocity (V), and Normal applied load (L) andthe output (response) is wear loss (w). A responsesurface model is usually expressed as:kkkRESULTS AND DISCUSSIONDevelopment of wear modelBy using the full factorial design, a total of 27experiments are conducted and regressioncoefficients are calculated. The full models forabrasive wear loss (w) can be expressed in term of thecoded values of the independent variables in equation(2).w 0.300370 - 0.113333*R 0.076667*L 0.151667*V 0.025556*R2 0.002222*L22 0.020556*V -0.031667*R*L - 0.055833*R*V 0.003333*L*V(2)kAnalysis of variance (ANOVA)y 0 i xi i xi2 ij xi x j fori 1i 1i 1 j 1Analysis of variance (ANOVA) and the F-ratio testhave been performed to check the adequacy of themodel as well as the significance of the individualmodel coefficients. The ANOVA was carried out onthe model for a confidence level of 95%. The resultsof ANOVA tables for wear loss are listed in Table (2,3). Table 2 presents the ANOVA table for the secondorder model propose for wear loss given in equation(2). It can be appreciated that the P-value is less than0.05 which means that the model is significant at 95%confidence level. Furthermore, the significance ofeach coefficient in the full model was examined bythe t-values and P-values and the results are listed inTable 3. The larger values of t-test and smaller valuesof ‘‘P” indicate that the corresponding coefficient isi j(1)where β0, βi (i 1, 2, . . . , k) and βij (i 1, 2, . . . , k, j 1, 2, . . . , k) are the unknown as regressioncoefficients to be estimated by using the method ofleast squares. In this equations ε are experimentallyrandom errors and x1, x2 . xk are the inputvariables that influence the response y, k is thenumber of input factors. The method of least square isused to estimate the coefficients of the second ordermodel. The response surface analysis is then done interms of the fitted surface. The degree of significanceof the model was tested by analysis of variance(ANOVA) using the software MINITAB-14.International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Vol-2, Iss-2, 20128
Statistical Analysis For The Abrasive Wear Behavior of Bagasse Fiber Reinforced Polymer Compositehighly significant [21]. Hence, the results given inTable 3 suggest that the influence of Load (L2),Reinforcement x Load (R x L) and Load Velocity(L V) and are non-significant and therefore can beremoved from the full model to further improve themodel. By doing so, the full model for the wear losscan be reduced as:w 0.30185 - 0.11333*R 0.07667*L 0.15167*V 0.02556*R2 0.02056*V2 - 0.05583*R*V(3)Table-2.SourceResidual Plots for wear lossThe regression model is used for determining theresiduals of each individual experimental run. Thedifference between the measured values and predictedvalues are called residuals. The residuals are calculated andranked in ascending order. The normal probabilities ofresiduals are shown in Fig. 1. The normal probability plotis used to vary the normality assumption. As shown inFig. 1, the data are spread roughly along the straight line.Hence it can be concluded that the data are normallydistributed [22].ANOVA for wear loss (Full model)DF Seq SSAdj SSAdj MSFPFigure 2 is used to show the correlation betweenthe residuals and from this, it is emphasized that atendency to have runs of positive and negative residualsindicates the existence of a certain correlation. Also theplot shows that the residuals are distributed evenly in bothpositive and negative along the run. Hence the data can besaid to be independent.Regression 9 0.807108 0.807108 0.089679 31.11 0.000(Significant)Linear3 0.751050 0.751050 0.250350 86.84 0.000Square3 0.006483 0.006483 0.002161 0.75 0.537Interaction 3 0.049575 0.049575 0.016525 5.73 0.007Residual 17 0.049010 0.049010 0.002883ErrorTotal26 0.856119Figure 3 indicates the residuals versus fitted values,which shows only the maximum variation of-0.5 to 0.5mm in wear loss between the measured and the fittedvalues. This plot does not reveal any obvious pattern andhence the fitted model is ample.Fig. 1: Normal probability plot of the residuals (Response is w)ANOVA was performed on the reduced model andthe results are presented in Table (4, 5) and found thatthe model is highly significant. Thus, Eq. (3)represents the coded form of final empirical modelfor wear loss of composite. It should be noted that theabove equations are valid over the range of conditions10% Reinforcement 20%; 0.837m/s; Slidingvelocity 1.675 m/s and 5N Normal applied load 10N for abrasive wear of above composite against400 grit size.Fig. 2: Residual versus order of the data (Response is w)International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Vol-2, Iss-2, 20129
Statistical Analysis For The Abrasive Wear Behavior of Bagasse Fiber Reinforced Polymer Compositeconfidence level. This model is valid within theranges of selected experimental parameters of fiberconcentration, applied load and sliding velocity. Theaccuracy of the RS model was verified with three setsof experimental data which were never used inmodeling and average percentage deviation calculatedas 7.542%.REFERENCEFig. 3: Residuals versus the fitted values (Response is w)[1]Eleiche, A.M. Amin, G.M. (1986), “The effect ofunidirectional cotton fibre reinforcement on the friction andwear characteristics of polyester”, Wear, 112 (1), 67-78.[2]Joseph, S. Sreekalab, M.S. Oommena, Z. Koshyc, P. Thomas,S. A. (2002), “Comparison of the mechanical properties ofphenol formaldehyde composites reinforced with bananafibres and glass fibres”, Comput Sci Technol, 62, 1857–1868.[3]Savastano, Jr. H. Warden, P.G. Coutts, R.S.P. (2003),“Potential of alternative fibre cements as building materialsfor developing areas”, Cem Concr Compos, 25, 585–592.[4]El-Tayeb, N.S.M. (2008), “A study on the potential ofsugarcane fibers/polyester composite for tribologicalapplications”, Wear, 265 (1–2), 223–235.[5]El-Tayeb, N.S.M. (2008), “Abrasive wear performance ofuntreated SCF reinforced polymer composite”, Mater ProcessTechnol, 206 (1–3), 305–314.[6]El-Tayeb, N.S.M. “Two-Body abrasive behaviour ofuntreated SC and R–G fibres polyester composites”, Wear,IH-4590, accepted for publication.[7]El-Tayeb, N.S.M. Mostafa, I.M. (1996), “The effect oflaminate orientations on friction and wear mechanisms ofglass reinforced polyester composite”, Wear, 195, 186–191.[8]Chand, N. Naik, A. Neogi, S. (2000), “Three-body abrasivewear of short glass fibre polyester composite”, Wear, 242,38–46.[9]Hutton, T.J. Johnson, D. McEnaney, B. (2001), “Effects offiber orientation on the tribiology of a model carbon–carboncomposite”, Wear, 249, 647– 655.Checking Adequacy of Mathematical ModelsThe goodness of fit of the mathematicalmodels was also tested by coefficient ofdetermination (R2) and adjusted coefficient ofdetermination (R2adj). The R2 is the proportion of thevariation in the dependent variable explained by theregression model. On the other hand, R2adj is thecoefficient of determination adjusted for the numberof independent variables in the regression model.Unlike R2, the R2adj may decrease if the variables areentered in the model that does not add significantly tothe model fit. The R2 and R2adj values of mathematicalmodels are found 0.929 and 0.907 respectively whichclearly indicate the excellent correlation between theexperimental and the predicted values of theresponses.Validity of the ModelsThe performance of the developed model wastested using five experimental data which were neverused in the modeling process. The results predicted bythe developed model were compared with the measuredvalues and also average percentage deviation (φp) wascalculated and presented in the Table 6. The resultsindicate that the model predicted wear loss has goodvalidity with acceptable percentage deviation.[10] Sampathkumaran, K.P. Seetharamu, S. Murali, A. Kumar,R.K. (2001), “On the SEM features of glass–epoxy compositesystem subjected to dry sliding wear”, Wear, 247, 208–213.[11] Yousif, B.F. EL-Tayeb, N.S.M. (2006), “Mechanical andtribological characteristics of OPRP and CGRP composites”,in: The Proceedings ICOMAST, GKH Press, Melaka,Malaysia, 384–387, ISBN 983-42051- 1-2.Table 6: Comparison of the predicted and measured results as a[12] Tong, J. Arnell, R.D. Ren, L.-Q. (1998), “Dry sliding wearbehaviour of bamboo”, Wear, 221, 37–46.[13] Tong, J. Ma, Y. Chen, D. Sun, J. Ren, L. (2005), “Effects ofvascular fiber content on abrasive wear of bamboo”, Wear,259, 37–46.[14] El-Sayed, A.A. El-Sherbiny, M.G. Abo-El-Ezz, A.S. Aggag,G.A. (1995), “Friction and wear properties of polymericcomposite materials for bearing applications”, Wear, 184,45–53.Avg. deviation: 7.542%CONCLUSION[15] Basavarajappa, S. Ellangovan, S. Arun, K.V. (2009), “Studieson dry sliding wear behaviour of Graphite filled glass–epoxycomposites”, Materials and Design, 30, 2670–2675.In this study, full factorial design of experiments hasbeen employed to develop a second-order polynomialequation for describing abrasive wear behaviour ofbagasse fiber reinforced Epoxy composites. Therelationship of abrasive wear loss with fiberconcentration, applied load and sliding velocity hasbeen successfully obtained by using RSM at 95%[16] Dwivedi, U.K. Navin Chand. (2009), “Influence of MA-g-PPon abrasive wear behaviour of chopped sisal fibre reinforcedpolypropylene composites”, Journal of Materials ProcessingTechnology, 209, 5371–5375.International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Vol-2, Iss-2, 201210
Statistical Analysis For The Abrasive Wear Behavior of Bagasse Fiber Reinforced Polymer Composite[17] Sahin, Y. Ozdin, K.A. (2008), “Model for the AbrasiveBehaviour of Aluminium Based Composites”, Materials &Design, 29, 728-733.[20] Myers, R.H. Montgomery D.C. (2002), “Response SurfaceMethodology: Process and Product Optimization UsingDesigned Experiments”, John Wiley & Sons Inc., New York.[18] El-Tayeb, N.S.M. Yap, T.C. Venkatesh, V.C. Brevern, P.V.(2009), “Modeling of cryogenic frictional behaviour oftitanium alloys using Response Surface Methodologyapproach”, Materials and Design, 30, 4023–4034.[21] Majumder, A. Goyal, A. (2008), “Enhanced production ofexocellular glucansucrase from Leuconostoc dextranicumNRRL B1146 using response surface method”, BioresourTechnol, 99, 3685–3691.[19] Farias, M.C.M. Souza, R.M. Sinatora, A. Tanaka, D.K.(2007), “The influence of Applied Load, Sliding Velocity andMartensitic Transformation on the Unlubricated Sliding Wearof Austenitic Stainless Steels”, Wear, 263, 773-781.[22] Shew, Y.W. and Kwong, C.K. (2002), “Optimization ofthe Plated through hole process using experimental designand response surface methodology”, Int. Adv. Manuf. Technol.,20, 758-764. International Journal of Applied Research in Mechanical Engineering (IJARME) ISSN: 2231 –5950, Vol-2, Iss-2, 201211
Table 1. Important factors and their levels for abrasive wear. Pin-on-disc wear test Wear tests were carried out by using a pin-on-disc wear tester supplied by Magnum, Bangalore. Abrasive paper of 400 grade (grit-23 µm) was pasted on a rotating disc (EN 31 Steel disc
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