What Do We Do?
The ODU compression molding group is a senior design team that test materials made with Glass Fiber Composites (GFC). This includes, research, material testing, acquisition and analysis of composites made from recycled materials from a compression molding process. The project is sponsored by Mar-Bal Inc., which produces thermosets that can withstand high amounts of heat and stress. However, Mar-Bal wastes 3 lbs. of material for every 8 lbs. used, about 40% waste. The research will focus on reusing these waste products to create material that can withstand a predefined load.
The material being analyzed includes discontinuous woven of Glass Fibers with prepreg epoxy. When subjected to a high pressure and temperatures the epoxy cures, which creates a solid composite plastic. In the experiment, the recycled material will be processed three ways, the corners of the recycled material cut into a large portion, into trimmed 1x1 in. squares, and into 1x.05 in. rectangles. Combinations of these materials will be used to form sandwich structures, which are materials that have a stiff inner layer to resist bending.
The project included manufacturing of these materials at Mar-Bal Inc.'s headquarters in Dublin, VA. Material processing of the finished products into appropriate testing shape. Three tests will be performed. for the experiment, three point bending, compression testing, and a tension testing which will be performed in ASTM standard test.
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With properties from material testing, a manhole cover will be modeled in Abaqus, a finite element software. Different configurations will be tested with a 40 Kip load delivered through a 10 inch cylinder in the middle of the manhole cover. Analysis of the material will include documenting its properties, failure modes, and any defect that might occur when manufacturing with compression molding. The end results will be a set of properties and substitute suggestions for Mar-Bal Inc. to give them an insight into their research for which material to use when manufacturing high quality manhole covers while reducing the waste.
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