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6 Guitar Manufacturing Process THE UNIVERSITY OF QUEENSLAND Bachelor of Engineering Thesis The Manufacture of a Bio-Composite Acoustic Guitar Made From Wood-PHA Composites Student Name : Afiqah Zafirah ABU HURAIRAH Student Number : 43100608 Course Code : MECH4500 Supervisory Team : Dr Luigi Vandi Dr Bronwyn Laycock Dr Steven Pratt Mr John Milne Submission Date : 28th of October 2016 A thesis submitted in partial fulfilment of the requirements of Bachelor Engineering Degree in Mechanical Engineering UQ Engineering Faculty of Engineering, Architecture and Information Technology The Manufacture of a Bio-Composite Acoustic Guitar Made from Wood-PHA Composites Acknowledgement First and foremost, as the author and writer of this report, I would like to state my sincere gratefulness and appreciation to the people that offered their assistance and made meaningful contributions towards the accomplishment of the project. Without the leadership, direction, and assistance, this project would not have reached the level of work by which it is required. Special appreciation and distinctive thanks are given to my supervisor Dr. Luigi Vandi for his incessant support of my thesis project, for his patience, motivation, enthusiasm and immense knowledge. Furthermore, he has provided me with the invaluable advice, feedbacks, and guidance throughout my thesis research project. Without his supervision, the project would not have been possible. His contributions is significantly appreciated. Moreover, I am also indebted to Mr. John, and Clement Chan who have helped me a lot in the lab. Their advice offered was instrumental to the project. I am happy to record my deepest appreciation for what they have provided me, theoretically and practically. My sincere gratitude to Airbus Helicopter Composites for allowing the use of their ovens and guided me to a tour around their plant. Not to forget, LSM Advanced Composites for their use of Autoclave and giving me the opportunity to be exposed to the composites work prospect. I also want to take this opportunity to thank my parents, siblings, and friends for their continuous supports throughout the year. The opportunity provided to me motivates and strengthen my career development. I shall make an effort to use the learned skills and knowledge in the most favourable way, and I will continue to work on their development, in order to achieve the desired career objectives. i | P a g e The Manufacture of a Bio-Composite Acoustic Guitar Made from Wood-PHA Composites Abstract Rare-wood which has traditionally been used in the making of the acoustic guitar, has been the growing concerns among producers due to the environmental issue and scarcity in obtaining high-quality wood. Technological advancement had paved the way for producing musical instruments including guitars using bio-composite, bio-sourced and/or biodegradable materials. The scope of the project is to produce, manufacture and demonstrate the use of PHA polymer and wood to produce a biodegradable composite acoustic guitar whilst achieving high-quality surface finish and at the same time obtaining an insight and understanding of the wood plastic processing properties. The project’s methodology is by way of research and experiment carried out at the UQ laboratory to select the most suitable wood-PHA combination (wood fibre or wood flour with PHA). Various different compositions and combination of wood-PHA (50%-50%, 30%-70%, and 20%-80%) material samples were tested by curing it at different curing cycle to obtain the optimum melting temperature and time which is then used as the basis to produce the guitar. Besides, a study had also been done to determine the wet processing of the guitar (distilled water or ethanol) which is then used to manufacture the body of the guitar. The techniques used in this project are via vacuum bagging and oven processing. From the findings, the most suitable combination is using the wood flour and PHA and melting it at a temperature of 180oC for 20 minutes. For the wet processing of the guitar body, it is investigated that mixing the material with ethanol gives a better result than using distilled water. The body of the guitar is being cured in the autoclave with a total pressure of 2.5 bars to overcome issues with porosity as well as to gives a high-quality surface finish. The soundboard was manufactured separately with a thickness of 3 mm. The soundboard is first being hard- pressed to ensure most of the air is taken out before being cured. Numerous challenges and difficulties were faced during the manufacturing process, the solutions to which were herein discussed. The primary challenges were to ensure that the material has a good vacuum and enough pressure while it’s being cured. Overall, the project is a success and has met its objectives of making the acoustic guitar using the wood-PHA composite materials with some reinforcement to address the deformation and cracking due to the lack of stiffness properties of the wood-PHA material. ii | P a g e The Manufacture of a Bio-Composite Acoustic Guitar Made from Wood-PHA Composites Table of Contents Acknowledgement ....................................................................................................................... i Abstract ....................................................................................................................................... ii List of Tables .............................................................................................................................. v List of Figures ............................................................................................................................ vi 1 Introduction ...................................................................................................................... 1 1.1 Motivation .................................................................................................................... 2 1.1 Thesis Outline .............................................................................................................. 3 2 Project Overview .............................................................................................................. 5 2.1 Project Goals ................................................................................................................ 5 2.2 Project Objectives ........................................................................................................ 5 2.3 Triple Bottom Line ...................................................................................................... 6 2.3.1 Environmental Considerations ............................................................................. 6 2.3.2 Economic Considerations ..................................................................................... 6 2.3.3 Social Considerations ........................................................................................... 6 2.4 Project Restrictions ...................................................................................................... 6 2.5 Project Assumptions .................................................................................................... 7 2.6 Project Scope ............................................................................................................... 7 2.7 Project Stages ............................................................................................................... 8 3 Background and Literature Review ............................................................................... 9 3.1 Acoustic Guitar ............................................................................................................ 9 3.2 Bio-composite Acoustic Guitar ...................................................................................... 11 3.2.1 Current Bio-composite guitar ............................................................................. 11 3.3 Wood Plastic Composites (Wood-PHA) ................................................................... 12 3.3.1 Wood as reinforcement ....................................................................................... 13 3.3.2 Polyhydroxyalkanoates (PHAs) ......................................................................... 14 3.3.3 Manufacturing Process ....................................................................................... 16 3.4 Literature Review Findings ....................................................................................... 19 iii | P a g e The Manufacture of a Bio-Composite Acoustic Guitar Made from Wood-PHA Composites 4 Materials Processing Method ........................................................................................ 20 4.1 Vacuum Bagging ....................................................................................................... 20 4.2 Oven Processing ........................................................................................................ 22 5 Experimental Approach ................................................................................................. 23 5.1 Selection of wood reinforcement and content ........................................................... 24 5.1.1 Wood Fibre and PHA ......................................................................................... 25 5.1.2 Wood Flour and PHA ......................................................................................... 27 5.1.3 Summary .................................................................................................................
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