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Optimisation of Polymer Concrete for the Manufacture of the Precision Tool

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Optimisation of Polymer Concrete for the Manufacture of the Precision Tool Optimisation of polymer concrete for the manufacture of the precision tool machines bases By Header Haddad BSc & Master (Honours) in Advanced Manufacturing Technologies A thesis submitted in fulfilment of the requirements for the degree of Doctor of Philosophy Faculty of Engineering & Industrial Sciences Swinburne University of Technology Hawthorn, Melbourne, Australia August 2013 Declaration I certify that except where due acknowledgement has been made, the work is that of the author alone; the work has not been submitted previously, in whole or in part, to qualify for any other academic award; the content of the thesis is the result of work which has been carried out since the official commencement date of the approved research program. Header Haddad II Acknowledgments I acknowledge the limited guidance of my principal supervisor Dr. Igor Sbarski in the experimental work and other related aspects of my research. I also would like to thank Dr. Mohammad Al Kobaisi, and Professor Robert Sanks, from RMIT University, for their continuous support and valuable guidance throughout my research. I acknowledge financial support in the form of a scholarship provided by Advanced Manufacturing Cooperative Research Centre and ANCA Pty Ltd. (AMCRC/ANCA). My thanks are extended to the following people for their help at various stages of my PhD research: Professor Emad Gad and Dr. Ibrahim Alsiaidi from the Civil Engineering at Swinburne University for their advice in conducting the vibration test for polymer concrete composite system; Dr. Larry Gordon and Sam Quint, from AMCRC, for their support; and Grant Rivett, from Melbourne University, for his assistance in conducting the compression and flexural tests for polymer concrete composite system. I also acknowledge the continuous support of Professor Pam Green the director of the research office in Swinburne University, in various stages of my PhD study. I wish to express my gratitude to my family for their endless support, love and encouragement throughout my entire education. Thank you III Publications Published conference paper The effect of material composition on thermal expansion and mechanical strength of polymer concrete used for manufacturing a base of CNC grinding machine. Header Haddad, Igor Sbarski, Davide McPherson, Ajay Arora, In: Preceeding of ANTEC 2011, pp. 967-972 . Published journal paper Optimization of the polymer concrete used for manufacturing bases for precision tool machines. Header Haddad Mohamad Alkobaisi. Journal of Composite material Part B: Engineering, 43, 8, pp. 3061-3068. Influence of moisture content on thermal and mechanical properties and the curing behaviour for polymeric matrix and polymer concrete composite. Header Haddad, Mohamad Alkobaisi. Submited to Materials & Design 49, pp. 850-856. IV Abstract One of the main operational drawbacks of the polymer concrete (PC) bases of precision tool machines is the high coefficient of thermal expansion (CTE). The non-uniform distribution of thermal expansion for the base under operational conditions induces high variation in the deflections on the base rails. The rails have direct contact with other mechanical components that hold the workspace in precision tool machines, impacting negatively on their accuracy. Reducing the CTE of the PC base to reach the CTE of the metal inserts (rails, pads, stands etc.) is essential to enhance the accuracy of the precision machine. Other parameters affecting performance directly such as damping ratio, flexural strength, moisture, dimethyl aniline (DMA) (promoter) and maturity need to be optimized to improve the PC used in the base of precision tool machines. In the present study, optimization of the PC base was undertaken according to the application requirements. The optimization process started with the optimization of the resin monomeric composition to lay the ground for further optimization of the PC aggregate composition. The optimization of both the PC resin binder and the composition of the aggregate were based on lowering the CTE and increasing both the flexural strength and damping ratio, since these properties are essential key controls for the thermal and mechanical stability of the bases used for precision tool machinery. Commercial unsaturated polyester (ARAPOL) resin was investigated along with other copolymers, methyl methacrylate (MMA) and styrene (St), in various proportions. The proportions of the resin monomer composition determine the thermal, mechanical and rheological properties of the resin. It was found that the optimum resin for use as a binder for PC base is 40% ARAPOL mixed with 60% MMA. In an effort to determine the optimum aggregate composition, six aggregates (basalt, river gravel, spodumene, fly ash, sand, and chalk) were investigated. PC samples were prepared with various aggregate V compositions containing the same resin volume fraction (aggregate 83% and resin 17%). Four-point flexural testing was utilized to measure the flexural strength of PC samples, and the CTE was measured using a custom-built device. The initial optimum composition with the highest flexural strength and lowest thermal expansion coefficient was found to be basalt, spodumene and fly ash. A basalt, sand and fly ash composition was nominated for further optimisation to reduce the resin volume fraction because of the ability of aggregate composition to adopt less resin. A reduction in the resin volume fraction (17% - 13%) in the PC reduces the value of CTE by 31% and flexural strength by 36%. This has no major effect on the PC base’s structural rigidity because of the large size of the base and the relatively small loads of the machine mounted on it. However, the damping ratio reduction is approximately 40%. This shortcoming can be overcome by increasing the structural damping properties of the whole machine. This can be achieved by installing a mechanical damper to the PC base to maintain the required damping ratio. The optimized aggregate composition was validated for the base of precision tool machinery using ANSYS 13.0 CAE software and comparing various aggregates compositions. Results show that the optimum composition offers more thermal stability and variation in the deformation of the base rails is reduced to negligible levels, which enhances the performance of the precision tool machine. The optimum composition (filler 87%, resin 13%) also offers the advantage of cost- effectiveness. The effects of the moulding temperature, mixing technology and the amount of DMA (promoter) on moulding were investigated, and the technology for mixing the resin with the aggregate was also investigated. Three mixing technologies were proposed and the optimum mixing technology nominated according to the level of mechanical strength of the PC sample. The effect of DAM amount (promoter) and the moulding temperature were investigated. An empirical relationship regulating the amount of DMA according to the moulding temperature was obtained. PC sample compaction was also investigated, and VI various PC samples were subjected to a variety of frequencies for packing using a vibrating table. The optimum frequency is identified based on the mechanical strength of PC samples. The initial water (moisture) in the coarse aggregate of the PC composite components was studied, and a volumetric ratio of 1-5% water was included in the initial resin components. The effect of this water on the curing process, the CTE and the mechanical properties of both the resin and PC composites were investigated. It was found that moisture increases the curing time and the CTE for the resin binder, the PC composite, and the damping factor for the binding resin. It also decreases the flexural and compressive strength at various rates. A maturity study of the polymer concrete was conducted, under which the PC samples were cured at various temperatures for different periods of time. Flexural strength was measured for each time and temperature used for the curing. An empirical mathematical model describing the relationship between the relative flexural strength of PC and the curing time and temperature was obtained. In essence, this thesis has brought together the most essential aspects required to optimize polymer concrete for the manufacture of bases for precision tool machinery. These aspects relate to the PC composite material, polymeric binder, the effect of moisture on polymer and PC, mixing technology, maturity of PC, and moulding technology. All of these aspects were connected to the performance of the precision machine through the investigation of the material properties and the optimization process in accordance with the optimization criteria of the PC base used for the precision tool machinery. Results of this research showed improvements in these aspects and recommendations in terms of resin compositions, PC composition, DMA, manufacturing process were all adopted by the industrial partner. VII Significant contributions of the thesis include: § The optimization of the chemical composition of the binding resin to be used as a resin binder in polymer concrete. The purpose of the optimised resin is to use the most suitable binder when manufacturing bases for precision tool machinery according to the application requirements. The optimized resin binder produces the second lowest coefficient of thermal expansion (CTE), the highest damping factor, the highest flexural strength, the highest tensile strength, and the shortest curing time and is second in the ranking for level of hardness compared to other compositions.
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