Fabrication and analysis of micro carbon fiber filled nylon filament reinforced with Kevlar, Fiberglass, and HSHT Fiberglass using dual extrusion system
Sumit Gahletia, Ashish Kaushik, Ramesh Kumar Garg, Deepak Chhabra, András Kovács, Rohit Khargotra, Tej Singh
Abstract
The optimal composition of Fiberglass, Kevlar, and high speed high temperature fiberglass (HSHT) in micro carbon fiber filled nylon polymer enhances properties like strength, wear resistance, and surface finish. Thus, the polymer composite fabricated by mixing Fiberglass, Kevlar, and HSHT in micro carbon fiber filled nylon filament designed to create strong, high-quality unrivalled parts will be extensively used in aerospace, automotive industry, and various engineering applications. In this work, continuous layers of Fiberglass, Kevlar, and HSHT have been reinforced in micro carbon fiber filled nylon filament to fabricate the composite at variable process parameters like fiberfill type, the thickness of the fiber layer, and the nature of the reinforcement. The tensile strength, wear strength, and surface roughness have been investigated for each test specimen using Universal Testing Machine, Pin on disc, and surfcom roughness tester as per American standards of testing (ASTM) ASTM D638 Type IV and ASTM G99 standard. Response surface methodology (RSM) has been implemented using a central composite design (CCD) approach for the modelling between input parameters and output responses. It is observed that fiber layer thickness of 1.071 mm, fiberglass and isotropic fill pattern provide the maximum tensile strength of 139 MPa, the minimum surface roughness of 3.087 µm, and wear rate of 0.4262 mm 3 /m. Further, the MOGA-ANN approach is used to optimize the multi response objectives. It is observed that 0.744 mm of fiber layer thickness, fiberglass reinforcement, and isotropic infill pattern provide the maximum tensile strength of 152.80 MPa and minimum surface roughness of 2.83 µm, 0.11709 mm 3 /m wear rate in MOGA-ANN. The balance and optimal response are accomplished in MOGA-ANN evolutionary hybrid algorithm, and the same has been validated experimentally. Data used for this research paper is available upon request from the corresponding author. Data are provided in detail for all methods, results, and conclusions drawn throughout the paper. • The Kevlar, Fiberglass and HSHT Fiberglass have been reinforced in micro carbon fibre filled nylon to fabricate filament. • Tensile strength, surface roughness and wear rate of the parts using fabricated filament have been inspected. • Response surface methodology based on face central composite design matrix was developed for input factors combination. • The multi-objective genetic algorithm integrated with artificial neural network has been used for training and optimization. • MOGA-ANN optimal parameters have improved desired mechanical properties of fabricated composite filament