Development And Characterization of Mechanical Properties of Al6063 Alloy Reinforced Fly Ash And E-Glass Fiber Composite
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Date
2021-07
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Addis Ababa University
Abstract
Currently, one of the key concerns in automotive engineering is the weight minimization
of a part without any reduction in load carrying capacity and stiffness. The present
investigation deals with investigating the hardness, compression, and flexural properties
of Al6063/ E-glass fiber/ Fly ash Composite as a possible replacement to the existing
steel outer door panel of the Toyota Hiace four-wheel vehicle. In this study ten composite
specimens were prepared as per ASTM standards size by machining operations to
conduct flexural, hardness, and compression tests. Comparing the ten composites the
result showed the composite with 7% of E-Glass fiber/ 6% fly ash had the maximum
mechanical property of hardness and compression strength with the value of 116.73HRB
and 850.31MPa respectively. And maximum flexural strength was found with composite
5% of E-Glass fiber/ 9% fly ash with the value of 340.1MPa. In this study, a volume
fraction of 5% E-Glass fiber with 9% Fly ash was selected as a composite for the outer
door panel because for all mechanical properties listed above it shows a better result.
Then this paper effort to attain, designing less deformed and stressed than that of the
existing Toyota Hiace vehicle steel outer door panel. The solid modeling of the outer door
panel was done on SOLIDWORK 2017 and analyzed using ANSYSR18.1 workbench
software. From transient structural analysis, it is seen that weight reduction of the outer
door panel is obtained up 66.24% in the case of the composite than structural steel, and
the equivalent stress-induced and deformation in the Al6063/E-Glass fiber/ fly ash
composite outer door panel is 66.24 % and 26.3 % respectively less than the current steel
outer door panel. Lastly, based on this result, the study concludes that the recently
designed Al6063/E-Glass Fiber/ Fly ash composite outer door panel has a better
presentation than that of the conventional steel outer door panel of the Toyota Hiace Van
vehicle.
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Keywords
AMMC, Al6063/Fly ash/E-Glass Fiber, Stir casting, FEA