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STATIC and DYNAMIC MECHANICAL PROPERTIES of AMORPHOUS RECYCLED POLY-(ETHYLENE TEREPTHALATE) by ARJUN RAJAKUTTY Bachelor Of

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STATIC and DYNAMIC MECHANICAL PROPERTIES of AMORPHOUS RECYCLED POLY-(ETHYLENE TEREPTHALATE) by ARJUN RAJAKUTTY Bachelor Of STATIC AND DYNAMIC MECHANICAL PROPERTIES OF AMORPHOUS RECYCLED POLY-(ETHYLENE TEREPTHALATE) By ARJUN RAJAKUTTY Bachelor of Engineering in Mechanical Engineering Anna University Chennai, Tamil Nadu, India 2010 Submitted to the Faculty of the Graduate College of the Oklahoma State University in partial fulfillment of the requirements for the Degree of MASTER OF SCIENCE July, 2012 STATIC AND DYNAMIC MECHANICAL PROPERTIES OF AMORPHOUS RECYCLED POLY-(ETHYLENE TEREPTHALATE) Thesis Approved: Dr. Jay C. Hanan Thesis Adviser Dr. Ranji Vaidyanathan Dr. Kaan Kalkan Dr. Sheryl A. Tucker Dean of the Graduate College ii TABLE OF CONTENTS Chapter Page LIST OF TABLES .......................................................................................................... vii LIST OF FIGURES ....................................................................................................... viii CHAPTER I ...................................................................................................................... 1 1. INTRODUCTION ..................................................................................................... 1 1.1. Poly (ethylene Terephthalate) .............................................................................. 1 1.1.1 Properties of PET .......................................................................................... 3 1.1.2 Solid State Polymerization ............................................................................ 6 1.1.3 PET Bottle Manufacturing Process ............................................................... 9 1.2. Recycled PET..................................................................................................... 12 1.2.1 Recycled PET in the Market ....................................................................... 14 1.2.2 rPET in Composites .................................................................................... 16 1.2.3 PET Recycling Processes ............................................................................ 17 1.2.4 rPET Decontamination................................................................................ 22 1.2.5 PET Color Measurements ........................................................................... 24 CHAPTER II ................................................................................................................... 28 2. STUDYING BEHAVIOR OF RECYCLED PET ................................................. 28 2.1. Motivation .......................................................................................................... 28 2.2. Resin Ranking Parameters ................................................................................. 29 2.3. Mechanical and Thermal Properties .................................................................. 30 2.4. Dynamic Behavior of PET ................................................................................. 32 2.4.1. Modeling for Dynamic Behavior ................................................................ 35 2.5. PET Yellowing and Degradation ....................................................................... 38 2.6. Friction ............................................................................................................... 42 2.7. Finite Element Analysis (FEA) .......................................................................... 43 iii CHAPTER III ................................................................................................................. 48 3. MATERIALS AND METHODS ............................................................................ 48 3.1. Materials ............................................................................................................ 48 3.2. Mechanical Testing ............................................................................................ 50 3.2.1. Tensile Testing ............................................................................................ 50 3.2.2. Fixture Design ............................................................................................. 51 3.2.3. Tensile Testing Procedure ........................................................................... 53 3.2.4. Dynamic Testing ......................................................................................... 55 3.2.5. Defective Sample Study: Polariscope Imaging........................................... 56 3.3. Rheometry .......................................................................................................... 56 3.4. Crystallinity Measurement: Differential Scanning Calorimetry (DSC) ............ 57 3.5. Color Measurements .......................................................................................... 61 3.6. Friction Measurement ........................................................................................ 63 3.7. Wall Thickness Measurements .......................................................................... 66 3.8. 3D Scanning and CAD Model Generation ........................................................ 67 3.9. Hoop Strength Measurement: Feel Test Setup for bottle stiffness .................... 70 3.10. Top Load Testing ............................................................................................... 71 3.11. Finite Element Analysis ..................................................................................... 72 3.11.1. Material Parameters for Simulations .......................................................... 75 CHAPTER IV.................................................................................................................. 78 RESULTS ........................................................................................................................ 78 4.1. Tensile Test Results ........................................................................................... 78 4.2. Dynamic Mechanical Properties ........................................................................ 80 4.3. Shear Viscosity and Molecular Weight Measurements ..................................... 85 4.4. DSC Results; Crystallinity Measurements......................................................... 87 4.5. Color Measurement Results ............................................................................... 90 4.6. Friction Testing Results ..................................................................................... 93 iv 4.7. Wall Thickness Measurements .......................................................................... 95 4.8. Hoop Strength; Feel Test Results for Bottle Stiffness ....................................... 96 4.9. Top Load Results ............................................................................................... 97 4.10. Density Measurements ....................................................................................... 98 4.11. Energy Cost Results ........................................................................................... 99 4.12. FEM Results for Lean Test ................................................................................ 99 CHAPTER V ................................................................................................................. 103 5. DISCUSSION ......................................................................................................... 103 5.1. Mechanical Behavior ....................................................................................... 103 5.1.1. Failure Behavior........................................................................................ 110 5.2. Crystallinity...................................................................................................... 111 5.3. Inferences from Yellowness Measurements .................................................... 114 5.4. End Product Behavior ...................................................................................... 116 5.4.1. Friction ...................................................................................................... 116 5.4.2. Structural Performance ............................................................................. 119 5.4.3. Finite Element Simulation of Lean Test ................................................... 119 CHAPTER VI................................................................................................................ 123 6. CONCLUSIONS .................................................................................................... 123 CHAPTER VII .............................................................................................................. 126 7. FUTURE WORK ................................................................................................... 126 REFERENCES .............................................................................................................. 129 APPENDICES ............................................................................................................... 137 APPENDIX A: Virgin PET Resins Classification ...................................................... 137 APPENDIX B: Young’s Modulus and Yield Strength Values for PET Resins.......... 137 APPENDIX C: Engineering Stress-Strain Curves for different Extension Rates. ...... 138 APPENDIX D: DSC First Heating Curves for all Preform Samples .......................... 139 APPENDIX E: Melt Viscosity and Molecular Weight Summary .............................. 141 v APPENDIX F: Effect of Toner Addition to Recycled PET
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