OPTIMIZATION OF TENSILE BEHAVIOUR OF ALKALINE TREATED BANANA FIBER REINFORCED CARDANOL RESIN COMPOSI

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 3, Jun 2020, 423–432 © TJPRC Pvt. Ltd.

OPTIMIZATION OF TENSILE BEHAVIOUR OF ALKALINE TREATED BANANA FIBER REINFORCED CARDANOL RESIN COMPOSITES VIA RESPONSE SURFACE METHODOLOGY A. PARRE*1 & B. KARTHIKEYAN2 1

Research Scholar, Department of Mechanical Engineering, Faculty of Engineering and Technology, Annamalai University, Tamil Nadu, India

2

Professor, Department of Mechanical Engineering, Faculty of Engineering and Technology, Annamalai University, Tamil Nadu, India

ABSTRACT Now-a-days renewable materials are either eco friendly or recyclable. A natural fibre for instance, alkaline treated banana fibre has numerous advantages and it is considerably useful to the automobile industry. The advantages comprise fairly good mechanical strength, low density and low cost. This study aimed to produce optimised Alkaline Treated Banana Fibre Reinforced Cardanol Resin (ATBF/CR) biocomposites, by observing the effect of processing tensile strength behaviour. Many test runs with different parameter combinations of compression moulding using ‘Minitab 17’ were conducted by Response Surface Methodology (RSM) and Central Composite Design (CCD). As a result, the optimized value obtained for the maximum tensile strength is 25.11 MPa. KEYWORDS: Alkaline Treated Banana Fiber, Cardanol Resin, Biocomposite, Response Surface Methodology & Central Composite Design

Original Article

conditions under different combinations of Weight (%), Fiber Length (mm) and NaOH Treatment (%) respectively on

Received: Mar 28, 2020; Accepted: Apr 18, 2020; Published: May 07, 2020; Paper Id.: IJMPERDJUN202039

1. INTRODUCTION Biocomposites are widely used in recent years owing to the environmental awareness. Recently, natural fibers are well known applications in composite manufacturing. Based on the sustainability importance, plant fibers are replaced by synthetic fibers in composites. Hence, fibers are used to manufacture various biocomposites[1].We found most of the studies have been carried out on fiber plants such as pineapple, bagasse, oil palm, coir and coconut shell. Also, there are only few reports on reinforcement of banana fibre. So, our study on banana fibre would fulfil the gap. Banana fibre can significantly be used in composite structures and advanced technology. A careful study has been carried out to improve mechanical properties such as structures, fibre loading, and fiber length and mercerization effect [2].

Banana fibers are generally lignocellulose material, consisting of helically wound cellulose micro fibrils in amorphous matrix of lignin and hemicelluloses. The mechanical properties of banana fibres are influenced by the cellulose content and microfibril angle. High cellulose content with low microfibril angle makes desirable mechanical properties of banana fibres.

The presence of Lignins and hemicelluloses gives banana fibres a natural rot-resistant property [3].

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It is proved in various studies that by treating the surface of cellulose fibres with appropriate method improve the matrix-reinforcement interaction through mechanical bonding. The widely used method for producing high quality fibres is alkali treatment. It notably develops the adhesion strength of fibre-matrix by eliminating natural and artificial impurities.

So, better fibre-matrix adhesion and increased mechanical properties can be attained by the development of rough surface topography and enhanced aspect ratio [4].

Cardanol is the chief constituent of cashew nut shell liquid (CNSL). When we involve cardanol under polycondensation reaction along with formaldehyde, we get a polymeric matrix resin. This resultant phenolic resin is used by wood, lignocellulosic and paper industries as a binder. Heating Cardanol with formaldehyde will result in polycondensation reaction while water is removed as a by-product. The release of water from the reaction helps the active OH- groups of CNSL to come closer to attach with aldehyde and form a resin like product [5-7]. On other hand, it greatly helps the environment since bio polymers play a major role in neutralizing the CO2 from the atmosphere [8].

Extensive studies carried out on lignocellulosic fibers of banana have shown that lignocellulosic fibers have the potential to be an effective reinforcement in thermoplastics and thermosetting materials [9 - 11]. One of the studies shows the effect of fiber length based tensile properties [12]. The research studies on husk fibre and coconut shell [13, 14] introduced new variety of composites in material science and engineering. In this continuation, the role of biocomposites was also reviewed in another study [15].

RSM helps any researcher to arrive at an optimal response from a set of approximation models. This model is widely used in experiments as it is user friendly and easy to operate. It compares several input and output factors (variables) involved in the study with various statistical techniques and suggests the optimum result [16]. RSM thoroughly evaluates each and every parameters (variable) level of participation and its dominance in the process as a single entity or as a blend of variables. By knowing this, we can adjust the values of the parameters to obtain the optimum or the desired result [17]. The research studies on use of Response surface methods in composites were suggested [18]. The present investigation is focussed on ATBF/CR composites to improve the tensile properties of the biocomposites using RSM.

2. EXPERIMENTAL PROCEDURES 2.1. Materials The banana fibre was purchased from the seller ‘Sri Achu Fibres’ at Erode, Tamil Nadu, India. Sodium Hydroxide (NaOH) was procured from the seller ‘Indian Scientific Solution’, Mayiladuthurai, Tamil Nadu, India.

2.2. NaOH treatment of banana fibers The dried banana leaf fibers were separately immersed in 1, 3, 5, 7, and 9% NaOH (Relative to banana fiber weight %) for 24 hrs at normal room temperature. The fibers were then cleansed with distilled water to remove any NaOH particles on the fiber surface [19 - 21]. Then the banana fibers were dried for two days under sunlight and kept in hot air oven at 90 – 100 o C for 24 hrs to remove the moisture contents [22, 23].

2.3. Preparation of Cardanol Resin The cardanol/formaldehyde resins were synthesized by reacting cardanol and formaldehyde molar ratios ({CNSL:HCHO:KOH}, {1:1.6:0.136}) by using Potassium Hydroxide (KOH) as catalyst was initially dissolved in CNSL with a magnetic stirrer (300 rpm) for 30 minutes in a glass beaker at 60 °C. Then, formaldehyde (48g) is added to a glass

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beaker and placed over a magnetic stirrer. After complete addition, the temperature of reaction kettle was maintained to 80 °C, and stirred at this temperature for one hour until the mixture becomes homogenous with mud colour. Then, reacted resin was collected in a two neck flat bottomed flask equipped with a thermometer and condenser. The resin was subjected to constant stirring and refluxing and heated to a temperature range of 100 – 120 °C for 3 hrs. After which, the reaction mixture was cooled to room temperature.

2.4. Fabrication of ATBF/CR composites The above mixture was poured into specially made moulds. The surfaces of moulds were coated on the inside with wax to avoid adhesion of the mixture and to allow easy removal of the composites. The mixture was then spread equally on the surface of the moulds. Composite sheets of size 300×300×3 mm were prepared by a closed mould method. The mould was then closed and kept under pressure (10 N/mm2) 70 – 90 oC for 30 minutes. Finally, all the specimens were post-cured at 70 °C for 12 hrs at hot air oven.

2.5. Experimental Design and Optimization

Sl. No. 1 2 3

Table 1: Framework for Experimental Design Methodology Variation levels Factors symbol Low (-1.633) (-1) Medium (0) (+1) Weight (%) X1 5 10 15 20 Fiber Length (mm) X2 5 10 15 20 NaOH Treatment (%) X3 1 3 5 7

Sl. No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

High(+1.633) 25 25 9

Table 2: Arrangement of Experimental Design Methodology Variables (Coded value) Variables (Real value) Weight Fiber Length NaOH Treatment Weight Fiber Length NaOH Treatment (%) (mm) (%) (%) (mm) (%) 1.000 -1.000 -1.000 20 10 3 0.000 0.000 0.000 15 15 5 1.000 1.000 1.000 20 20 7 0.000 0.000 0.000 15 15 5 -1.000 1.000 -1.000 10 20 3 -1.000 -1.000 1.000 10 10 7 0.000 0.000 -1.633 15 15 1 0.000 1.633 0.000 15 25 5 1.633 0.000 0.000 25 15 5 -1.633 0.000 0.000 5 15 5 0.000 0.000 1.633 15 15 9 0.000 -1.633 0.000 15 5 5 0.000 0.000 0.000 15 15 5 0.000 0.000 0.000 15 15 5 -1.000 -1.000 -1.000 10 10 3 0.000 0.000 0.000 15 15 5 0.000 0.000 0.000 15 15 5 1.000 -1.000 1.000 20 10 7 1.000 1.000 -1.000 20 20 3 -1.000 1.000 1.000 10 20 7

ATBF/CR biocomposites were prepared according to the experimental design. The optimization study of compression moulding process was carried out according to the CCD of RSM using Minitab 17 software for selected 3 factors and 5 levels, as shown in Table 1. Equation 1 shows the generalized response surface model. The 20 experiments which consist www.tjprc.org

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of 15 factorial design runs and 5 replicates were shown in Table 2: Y = b0 + b1X1 + b2X2 +........+ bkXk --------------------- (1) Where ‘Y’ was the response variable of tensile strength, b0 was the constant, X was predictor variable and b1, b2.....bk are coefficients.

2.6. Tensile Test The tensile measurement experiments were performed on Universal Testing Machine (UTM Model: UNITEK 94100). For tensile tests, the composite samples were cut into dog bone shape with cross sectional dimension of 165 × 19 × 3 mm in accordance with ASTM D638

3. RESULTS AND DISCUSSIONS Table 3 represents the experimental results obtained from RSM tensile strength at different various combinations of ATBF/CR composites.

RSM was used in my earlier study to compare the impact strength of various mixture of ATBF/CR emphasize the biocomposites whereas, now, the same method RSM is used again to refer the tensile properties of banana fibre. [24] Table 3: Experimental and Predicted for Tensile Strength Independent Variables Tensile Strength (MPa) Sl. No.

Weight (%)

Fiber Length (mm)

NaOH Treatment (%)

Experimental

Predicted

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

20 15 20 15 10 10 15 15 25 5 15 15 15 15 10 15 15 20 20 10

10 15 20 15 20 10 15 25 15 15 15 5 15 15 10 15 15 10 20 20

3 5 7 5 3 7 1 5 5 5 9 5 5 5 3 5 5 7 3 7

13 25 18 25 16 12 17 16 12 10 18 14 25 25 12 25 25 14 16 10

12.2654 25.7243 17.4002 25.7243 15.4654 12.4204 17.7732 16.6080 12.8530 9.3585 17.4383 13.6035 24.6827 24.6827 12.4588 24.5577 24.5577 14.3936 15.4386 10.5936

3.1 Analysis of Variance CCD Table 4 represents the various factors of ATBF/CR composites are significant with p value <0.05 such as in two way interaction X1* X3 with p value 0.008.

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Table 4: Analysis of Variance for ATBF/CR Composites Tensile Strength Source DF Adj SS Adj MS F-Value P-Value Model 11 586.184 53.289 64.43 0.000 Blocks 2 5.091 2.546 3.08 0.102 Linear 3 26.688 8.896 10.76 0.004 X1 1 15.264 15.264 18.46 0.003 X2 1 11.284 11.284 13.64 0.006 X3 1 0.140 0.140 0.17 0.691 Square 3 538.029 179.343 216.85 0.000 X1* X1 1 342.334 342.334 413.93 0.000 X2* X 2 1 170.334 170.334 205.96 0.000 X3* X 3 1 93.012 93.012 112.46 0.000 2-way interaction 3 16.375 5.458 6.60 0.015 X1* X 2 1 3.125 3.125 3.78 0.088 X1* X 3 1 10.125 10.125 12.24 0.008 X2* X 3 1 3.125 3.125 3.78 0.088 Error 8 6.616 0.827 Lack-of-fit 5 6.616 1.323 * * Pure error 3 0.000 0.000 Total 19 592.800 Table 5 shows that VIF values of all composite factors are closer to 1 which indicates that there is strong association between the variables.

Table 5: Coded Coefficients for ATBF/CR Composites Term Effect Coef SE Coef T-Value P-Value Constant 24.988 0.371 67.38 0.000 Blocks 1 -0.431 0.297 -1.45 0.185 2 0.736 0.297 2.48 0.038 X1 2.140 1.070 0.249 4.30 0.003 X2 1.840 0.920 0.249 3.69 0.006 X3 -0.205 -0.103 0.249 -0.41 0.691 X 1* X 1 -10.183 -5.091 0.250 -20.35 0.000 X 2* X 2 -7.183 -3.591 0.250 -14.35 0.000 X3* X 3 -5.308 -2.654 0.250 -10.60 0.000 X 1* X 2 1.250 0.625 0.322 1.94 0.088 X1* X 3 2.250 1.125 0.322 3.50 0.008 X2* X 3 -1.250 -0.625 0.322 -1.94 0.088

VIF

1.47 1.47 1.00 1.00 1.00 1.01 1.01 1.01 1.00 1.00 1.00

Model Summary S = 0.909416 R-sq=98.88% R-sq (adj) =97.35% R-sq (pred) =85.78% Regression Equation in Uncoded Units T (MPa) = 24.988 + 1.070 X1 + 0.920 X2- 0.103 X3- 5.091 X12 -3.591 X22 -2.654 X32 + 0.625 X1X2 + 1.125 X1X 3- 0.625 X2 X3 ---------------- (2) Where X1, X2, and X3 are the coded values of the independent variables Weight (X1), Fiber length (X2) and NaOH treatment (X3) respectively. T represents Tensile strength. www.tjprc.org

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3.2 Response Surface and Contour Plots of Tensile Strength (combination of 2) Three Dimensional (3D) response surface and Two Dimensional (2D) contour plots were generated, as shown in Figures 1, 2 and 3. These plots show the predicted effects of process variables such as Weight (%), Fiber length (mm), NaOH treatment (%) on the tensile strength. The 3D & 2D plots are the graphical representation of the regression equations in order to determine the optimum value of the variables within the design space [25].

Surface Plot of T Mpa vs L mm, w%

Contour Plot of T Mpa vs L mm, w% 1 .5

T Mpa < 0 0 – 5 5 – 10 10 – 15 1 5 – 20 20 – 25 > 25

1 .0

L mm

0.5

20

T M pa

0.0

-0.5

10 1 0

0 -2

-1 .0

L mm

-1

-1

0

w%

1

-2

-1 .5 -1 .5

-1 .0

-0.5

0.0

0.5

1 .0

1 .5

w%

Figure 1: Fiber Length (mm) versus Concentration (wt%).

Surface Plot of T Mpa vs T%, w%

Contour Plot of T Mpa vs T%, w% 1 .5

T Mpa < 0 0 – 6 6 – 12 12 – 18 1 8 – 24 > 24

1 .0

T%

0.5

20

T M pa

0.0

-0.5

10 1 0

0 -2

-1 .0

T%

-1

-1

w%

0

1

-2

-1 .5 -1 .5

-1 .0

-0.5

0.0

0.5

1 .0

1 .5

w%

Figure 2: NaoH Treatement (%) versus Concentration (wt %).

Contour Plot of T Mpa vs T%, L mm

Surface Plot of T Mpa vs T%, L mm 1 .5

T Mpa < 10 10 – 15 1 5 – 20 20 – 25 > 25

1 .0

0.5

T M pa

T%

24

0.0

18

-0.5 12 1 6

0 -2

T%

-1 .0

-1

-1

L mm

0

1

-2

-1 .5 -1 .5

-1 .0

-0.5

0.0

0.5

1 .0

1 .5

L mm

Figure 3: NaoH Treatment (%) versus Fiber Length (mm).

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The optimal values of the process variables were found to be combinations of Figure 1 X1X2, Figure 2 X1X3 and Figure 3 X2X3. This result shows that the optimal values from the RSM above achieved an increase in tensile strength for the Figure 2 X1X3 combinations.

3.3. Optimization Responses and Confirmation Test of ATBF/CR Composite The optimization of tensile strength ATBF/CR composites were predicted by Minitab 17 software using the second order regression equation (equation 2). In this case, the predicted optimum combination of variables weight 15(%), length 15 (mm) and Treatment 5(%) were with a desirability value 1, as shown in Table 6, followed by figures 4 and 5 which represents the optimisation effect of combination of 2 in 15 runs.

Figure. 4 Sample after Tensile Test

Table 6: Optimum Condition for Maximum Tensile Strength

Sl. No.

Weight (%)

Fiber Length (mm)

NaOH Treatment (%)

Lower (MPa)

Upper (MPa)

Tensile strength (MPa)

Desirability (D)

1

15

15

5

11

25

25.11

1

Figure 5: Optimisation Value of Combination of 2.

The optimum value of tensile obtained by RSM is also closer to the experimental values which show the effective optimization of RSM procedure.

4. CONCLUSIONS It is found in our studies that the RSM was greatly optimizing the mechanical properties on tensile strength of ATBF/CR composites. The desired tensile strength was achieved with the following optimal combination of Weight loading of 15.5%, Fiber length of 15.5 mm and NaOH treatment of 5%. Thereby the optimised tensile strength achieved was 25.11 MPa. The results also revealed that there is a possibility to further improve the tensile strength by developing good adhesion between ATBF/CR composites.

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