CHAPTER I

1.INTRODUCTION
Natural fiber composites mostly consists fibres of jute, cotton, hemp and non-
conventional fibers such as coir and many empty fruit bunches. Natural fiber thermoplastic
composites are attractive as they are cheaper, stiffer, paintable, rot-resistant and also can be
given the look of wood in addition to all this they have more life- cycle.. These composites
are gaining importance due to their non-carcinogenic and bio-degradable nature. Natural fiber
composites are very cost-effective material especially in building and construction purpose
packaging, automobile and railway coach interiors and storage devices. These can be
potential candidates for replacement of high cost glass fiber for low load bearing applications.
Coir is a natural fiber extracted from the husk of Coconut fruit. The husk consists of Coir
fiber and a corky tissue called pith. It is a fiber abundantly available in India the second
highest in the world after Philippines. It consists of water, fibers and small amounts of
soluble solids. Because of the high lignin content coir is more durable when compared to
other natural fibers. With increasing emphasis on fuel efficiency, natural fibers such as coir-
based composites enjoying wider applications in automobiles and railway coaches & buses
for public transport system. There exist an excellent opportunity in fabricating coir based
composites towards a wide array of applications in building and construction such boards and
blocks as reconstituted wood, flooring tiles etc. Value added novel applications of natural
fibers and coir-based composites would not go in a long way in improving the quality of life
of people engaged in coir cultivation, but would also ensure international market for cheaper
substitution. Natural fibers have the advantages of low density, low cost and biodegradability.
However, the main disadvantages of natural fibers and matrix and the relative high moisture
absorption. Therefore, chemical treatments are considered in modifying the fiber surface
properties.

II.MATERIALS USED
Raw materials to be used in safety helmet are
a. Coconut Fiber
b. Banana Fiber
c. Epoxy Resin
A. Coconut Fiber:-
Coconut palms are mainly obtained from tropical regions of the world and the product form
the coconut are applied in food and non-food products, which sustain the livelihood of people
all over the world. The coconut palm comprises of a white meat which has a total percent by
weight of 12 and 35 respectively .

The husk from

the coconut palm comprises 30% weight of fiber and 70% weight of pith material. The fiber
are extracted from the husk by several methods such as retting, which is a traditional way,
decorations, using bacteria and fungi, mechanical and chemical process, for the production pf
building and packaging material, ropes and yarns, brushes and padding of mattresses and so
on.
B. Banana Fiber:-
Banana fiber, a lingo-cellulosic fiber, obtained from the pseudo-stem of banana plant (Musa
sepientum), is a best fiber with relatively good mechanical properties. The ‘‘pseudo-stem’’ is
a clustered, cylindrical aggregation of leaf stalk bases. Banana fiber at present is a waste
product of banana cultivation and either not properly utilized or partially done so. The
extraction of fiber from the pseudo stem is not a common practice and much of the stem is
not used for production of fibers. This is reflected from the relatively expensive price of
banana fibers when compared to other natural fibres. The buyers for banana fibers are erratic
and there is no systematic way to extract the fibres regularly. Useful applications of such
fibers would regularize the demand which would be reflected in a fall of the prices
The Epoxy resin acts as a binder for the reinforcement while controlling the physical shape
and dimensions of the part. Its primary purpose however is to transfer the load, or stress,
applied to the part to the reinforcement. The matrix also protects the reinforcement from
adverse environmental effects. The reinforcement’s function is to enhance the mechanical
properties of the composite and is typically the main load bearing element. Reinforcements
are usually in the form of either fibers or particles. Matrix and reinforcement materials can be
polymers, metals, ceramics, or carbon.

III.DESIGN OF INDUSTRIAL SAFETY HELMET

A. Dimensions of the Helmet according to BS EN 397:1995:-
Table 5.Dimensions of the helmet according to BS EN 397:1995
Sr.No Parts Dimensions
1 External vertical distance not more than 80 mm.
2 Internal vertical distance not more than 50 mm
3 Horizontal distance not less than 5 mm.
4 Wearing height 80 mm for helmets mounted on head form
5 Cradle width shall be not less than 15 mm
6 Chin strap not less than 10 mm
 CHAPTER II
2.LITERATURE REVIEW
Yan Le at all presents a summary of recent developments of coconut Fiberand its composites.
The properties of coconut Fiberitself interface between coconut Fiberand matrix, properties of
sisal fiber-reinforced composites and their hybrid composites have been reviewed. Suggestions
for future work are also given. In the review they describe in detail about the properties of sisal
fiber, Interface properties between coconut Fiberand matrix; Properties of sisal-fiber-reinforced
composites; Sisal/glass-fiber-reinforced hybrid composites; Price; Interface modifications;
Treatment of sisal fiber; Alkali treatment; Isocyanate treatment; Peroxide treatment;
Permanganate treatment; surface Treatment of fiber/matrix interfaces; Sisal/polyester
composites; Sisal/epoxy composites; Sisal/phenol formaldehyde composites; Sisal/polyethylene
composites; Sisal-fiber-reinforced thermo set matrices; Sisal-fiber-reinforced thermoplastics
matrices; Processing methods; Properties of coconut Fiberreinforced polyethylene; Properties of
sisal fiber-reinforced polystyrene matrices; Properties of sisal-fiber-reinforced PVC composite;
Sisal-fiber-reinforced rubber matrix; Sisal-fiber-reinforced gypsum and cement matrices; Sisal
and synthetic hybrid-fiber composites; and they evaluate the Dynamic mechanical properties.

Electrical properties and Ageing properties. Finally they conclude that different matrix systems
have different properties. The mechanical and physical properties of sisal-fiber-reinforced
composites are very sensitive to processing methods, fiber length, fiber orientation and fiber-
volume fraction. Sisal and glass fiber can be combined to produce hybrid composites which take
full advantage of the best properties of the constituents; almost all the mechanical properties have
show positive hybrid effects.

K. Murali Mohan Rao., at all aims at introducing new natural fibers used as fillers in a polymeric
matrix enabling production of economical and lightweight composites for load carrying
structures. An investigation of the extraction procedures of vakka (Roystonea regia), date and
bamboo fibers has been undertaken

The cross-sectional shape, the density and tensile properties of these fibers, along with
established fibers like sisal, banana, coconut and palm are determined experimentally under
similar conditions and compared. The fibers introduced in the present study could be used as an
effective reinforcement for making composites, which have an added advantage of being
lightweight.

K. Murali Mohan Rao., at all have carried out a study to investigate the tensile, flexural and
dielectric properties of composites made by reinforcing vakka as a new natural fiber into a
polyester resin matrix. The fibers extracted by retting and manual processes have been used to
fabricate the composites. These composites are tested for tensile, flexural and dielectric properties
and compared with those of established composites like sisal, bamboo and banana made under the
same laboratory conditions.

The composites are fabricated up to a maximum volume fraction of fiber of 0.37 in the case of
tensile testing and 0.39 for flexural and dielectric testing. It has been observed that the tensile
properties increase with respect to volume fraction of fiber for vakka fiber composite and are also
more than those of sisal and banana composites and comparable to those of bamboo
composites.The flexural strength of vakka fiber composite is more than that of banana composite
and is closer to coconut Fibercomposite with respect to the volume fraction of fiber, where as the
flexural modulus is much higher than those of banana and coconut Fibercomposites and also very
much closer to bamboo fiber composites.
 CHAPTER - 3

MATERIALS AND METHODS

This chapter describes the details of processing of the composites and the
experimental procedures followed for their mechanical characterization. The raw
materials used in this work are

3.1. MATERIALS USED

 Epoxy resin (LY-556)

 Hardener(HY-951)

 Synthetic fiber (Glass fiber cloth)

 Natural Fibers (coconut fiber)

 NaOH Solution

3.1.1 Epoxy resin (LY-556)

Features of Epoxy

 Light weight

 Resists most alkalis and acids

 Resists stress cracking

 Retains stiffness and flexibility

 Low moisture absorption

 Non-staining

 Easily fabricated
Applications of Epoxy

 Structural applications

 Industrial tooling and composites

 Electrical system and electronics

3.1.2. Hardener (HY-951)

Hardener is a curing agent for epoxy or fiberglass. Epoxy resin requires a

hardener to initiate curing; it is also called as catalyst, the substance that
hardens the adhesive when mixed with resin. It is the specific selection and
combination of the epoxy and hardener components that determines the final
characteristics and suitability of the epoxy coating for given environment.

3.1.3 Natural fibers such as Coconut fiber cloth& Synthetic fibers

such as Glass fiber cloth
 Fiber-reinforced polymer composites have played a dominant role for a long
time in a variety of applications for their high specific strength and modulus.
The manufacture, use and removal of traditional fiber–reinforced plastic,
usually made of glass, carbon or aramid fibers–reinforced thermoplastic and
thermoset resins are considered critically because of environmental
problems. By natural fiber composites we mean a composite material that is
reinforced with fibers, particles or platelets from natural or renewable
resources, in contrast to for example jute or sisal fibers that have to be
synthesized

3.1.4 Advantages of Natural Fibers

Comparing to conventional reinforcing fibers like glass, carbon and

Kevlar, natural fibers have the following advantages:

 Environmentally friendly

 Fully biodegradable

 Non toxic

3.2 METHODOLOGY

3.2.1 Step 1: Selection of matrix material

Epoxy LY-556 (di-glycidal ether of Bisphenol-A, DGEBA having density

1.16gm/cm3) resin belonging to the Epoxide family was taken as the matrix.
HY 951 (tri-ethylene tetra-amine having density 0.95 gm/cm3) was used as the
hardener.

MANUFACTURER: Araldite industrial adhesives

3.2.2 Step 2: Selection of reinforcement and Natural fibers

 Natural fibers such as Sisal and jute were taken to fill as reinforcements
in the Polymer composite.
 Synthetic fiber that is glass fiber (7 mill , 200 ± 20 GSM)

3.2.3 Step 3: Availability of Natural fiber (Sisal & Jute) 0.7mm

thickness each , Sponsored by IIT Roorkee

Coconut Fibercloth:

 Sisal is a natural fiber (Scientific name is Agave sisalana) of Agavaceae

(Agave) family yields a stiff fiber traditionally used in making twine and
rope.

 Sisal is fully biodegradable and highly renewable resource.

 Coconut Fiber is exceptionally durable and a low maintenance with minimal

wear and tear.
 Fig. 3.2.3.1 coconut Fiber

3.2.4 Step 4: Availability of Synthetic fiber (Glass) 7mill & 200±20

GSM, Sponsored by TEXPLAS INDIA PVT. LTD.
(HARIDWAR)

Glass Fiber cloth:

 Strong and long-lasting: Pound for Pound fiberglass is stronger than sheet

metal. Fiberglass has a high resistance to corrosion, it will not rust.

 Design Freedom: There are very few restrictions with molding fiberglass,

giving the engineer unlimited possibilities. 
 Appearance: Using fiberglass for product covers and enclosures definitely
improves its esthetics.  Achieve any look and feel desired.  Finishes give
fiberglass components a high tech appearance.

 Cost Effectiveness: With steel being dependent on China’s steel prices, you

will have stable prices with fiberglass. Lower costs for maintenance and
warranty work. 

 Special Characteristics: Fiberglass is non-conductive and radio frequency

transparent.  Perfect for housing electronics without disturbing their
performance and protect employees from hazards inside.

3.2.5 Step 4: Surface treatment of fibers

Freshly drawn fibers generally include lots of impurities that can adversely
affect the fiber matrix bonding. Consequently the composite material made
from such fibers may not possess satisfactory mechanical properties. Therefore
it is desirable to eliminate the impurity content of the fibers and perhaps
enhance the surface topography of the fibers to obtain a stronger fiber-matrix
 bonding. The fibers were left to treat with 5% NaOH for 3-4 hrs. Later they
were drawn and dried under sunlight for 1-2 hours.

3.2.6 Step 5: Wet Hand lay-up technique

Hand lay-up technique is the simplest method of composite processing. The

infrastructural requirement for this method is also minimal. The processing steps
are quite simple. First of all, a release gel is sprayed on the mold surface to avoid
the sticking of polymer to the surface. Thin plastic sheets are used at the top and
bottom of the mold plate to get good surface finish of the product. Reinforcement in
the form of woven mats or chopped strand mats are cut as per the mold size and
placed at the surface of mold after perspex sheet. Then thermosetting polymer in
liquid form is mixed thoroughly in suitable proportion with a prescribed hardner
(curing agent) and poured onto the surface of mat already placed in the mold.

The polymer is uniformly spread with the help of brush. Second layer of mat is
then placed on the polymer surface and a roller is moved with a mild pressure on
the mat-polymer layer to remove any air trapped as well as the excess polymer
present. The process is repeated for each layer of polymer and mat, till the
required layers are stacked. After placing the plastic sheet, release gel is sprayed
on the inner surface of the top mold plate which is then kept on the stacked layers
and the pressure is applied.

After curing either at room temperature or at some specific temperature, mold is

opened and the developed composite part is taken out and further processed. The
schematic of hand lay-up is shown in figure 1. The time of curing depends on type
of polymer used for composite processing. For example, for epoxy based system,
normal curing time at room temperature is 24-48 hours. This method is mainly
suitable for thermosetting polymer based composites. Capital and infrastructural
requirements less as compared to other methods. Production rate is less and high
volume fraction of reinforcement is difficult to achieve in the processed
composites. Hand lay-up method finds application in many areas like aircraft
components, automotive parts, boat hulls, dias board, deck etc.

Calculation :

The first component to validate was the shell of the helmet. The goal of this validation was to
compare the stress and displacement values of a hemispherical shell under top loading
(Figure 16) between an Abaqus simulation and physical equations. This would indicate if
Abaqus was properly representing the shell of the helmet. The constitutive equations from
Roarks's Formulas for Stress and Strain for a partial spherical shell with a load concentrated
on a small circle at the pole with any edge support can be seen below in equations 7, 8 and 9.
Factors A, B and C are given by equation 10 and Table 2. [18]
Image accompanying equations for a partial spherical shell from Roark's Formulas for Stress
and Strain indicating the variables needed to complete the analysis
Table 2. Table of A, B and C values with respect to values of mu to calculate maximum
deflection, membrane stress, and bending stress for a partial spherical shell under loading at one
pole

The maximum displacement observed

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛=𝛿= (A*P*R (1- 𝜈2 )1/2)/ 𝐸𝑡2

A =.386
P =100N
R=15cm

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛=𝛿=100*.15*0.386(1-.222 )1/2 /70x109 x0.012

𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛=𝛿=8.096x10-6N/mm

𝑀𝑎𝑥 𝑚𝑒𝑚𝑏𝑟𝑎𝑛𝑒 𝑠𝑡𝑟𝑒𝑠𝑠= 𝜎1=𝜎2 == (B*P* (1- 𝜈2 )1/2)/ 𝑡2

=0.196*100*(1-.222 )1/2 / x0.012

𝑀𝑎𝑥 𝑚𝑒𝑚𝑏𝑟𝑎𝑛𝑒 𝑠𝑡𝑟𝑒𝑠𝑠=0.19MPa.

𝑀𝑎𝑥 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠= 𝜎′1=𝜎′2= (C*P* (1+𝜈 )/ 𝑡2

=0.554*100(1+22) /0.012

𝑀𝑎𝑥 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠=.675MPa

CHAPTER IV
FINITE ELEMENT SOLVING ON HELMET
4. INTRODUCTION OF FINITE ELEMENT SOFTWARE

The Basic concept in FEA is that the body or structure may be divided into smaller
elements of finite dimensions called “Finite Elements”. The original body or the
structure is then considered as an assemblage of these elements connected at a finite

number of joints called “Nodes” or “Nodal Points”. Simple functions are chosen to
approximate the displacements over each finite element. Such assumed functions are
called “shape functions”. This will represent the displacement within the element in

terms of the displacement at the nodes of the element. Mathematically, the structure to
be analyzed is subdivided into a mesh of finite sized elements of simple shape. Within
each element, the variation of displacement is assumed to be determined by simple

polynomial shape functions and nodal displacements. Equations for the strains and
stresses are developed in terms of the unknown nodal displacements. From this, the
equations of equilibrium are assembled in a matrix form which can be easily be

programmed and solved in software. After applying the appropriate boundary

conditions, the nodal displacements are found by solving the matrix stiffness equation.
Once the nodal displacements are known, element stresses and strains can be
calculated.

4.1ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package. Finite
Element Analysis is a numerical method of deconstructing a complex system into very small
pieces (of user-designated size) called elements. The software implements equations that
govern the behaviour of these elements and solves them all; creating a comprehensive
explanation of how the system acts as a whole. These results then can be presented in
tabulated, or graphical forms. This type of analysis is typically used for the design and
optimization of a system far too complex to analyze by hand. Systems that may fit into this
category are too complex due to their geometry, scale, or governing equations.
4.1.1.Static structural Solver

A. Importing External geometry

B. Meshing
C. Material Properties Apply 0
D. Boundary Condition
E. Solveig
F. Post processing

4.3.2. Importing External Geometry;

After preparing the model in CATIA it is improved to ANSYS. the file is imported from CATIA by
file>import>STEP
4.3.3GENERATE MESH:

For Solving purpose and boundary condition we want to generate element which was done
through mesh option

Sizing

Use Advanced Size

On: Curvature
Function
 Relevance Center Medium

Initial Size Seed Active Assembly

Smoothing Medium

Span Angle Center Coarse

Curvature Normal Angle Default (30.0 °)

Min Size Default (4.0980 mm)

Max Face Size Default (20.490 mm)

Growth Rate Default

Minimum Edge Length 10.0 mm

Inflation

Use Automatic Inflation None

Inflation Option Smooth Transition

Transition Ratio 0.272

Maximum Layers 2

Growth Rate 1.2

Inflation Algorithm Pre

View Advanced Options No

Statistics

Nodes 754

Elements 724

4.3.4Linear structural analysis:

4.3.4.1Boundary condition for Helmet

 Fixed
Object Name Force
Support

State Fully Defined

Scope
 Scoping Method Geometry Selection

Geometry 2 Faces 4 Faces

Definition

Type Fixed Support Force

Suppressed No

Define By   Components

Coordinate
  Global Coordinate System
System

X Component   0. N (ramped)

Y Component   0. N (ramped)

Z Component   100. N (ramped)

Material Data
Polyethylene

TABLE 15
Polyethylene > Constants
Density 9.5e-007 kg mm^-3

Coefficient of Thermal Expansion 2.3e-004 C^-1

Specific Heat 2.96e+005 mJ kg^-1 C^-1

Thermal Conductivity 2.8e-004 W mm^-1 C^-1

Poisson's Shear Modulus

Young's Modulus MPa Bulk Modulus MPa
Ratio MPa

1100 0.42 2291.7 387.32

Deformation:
Composite material analysis in Ansys

Material constrain :

Material Data
Sisal Fiber

TABLE 22
Sisal Fiber > Constants
Density 1.45e-006 kg mm^-3

Coefficient of Thermal
1.2e-005 C^-1
Expansion

Specific Heat 4.34e+005 mJ kg^-1 C^-1

Thermal Conductivity 6.05e-002 W mm^-1 C^-1

Resistivity 1.7e-004 ohm mm

TABLE 23
Sisal Fiber > Compressive Ultimate Strength
Compressive Ultimate Strength MPa

TABLE 24
Sisal Fiber > Compressive Yield Strength
 Compressive Yield Strength
MPa

250

TABLE 25
Sisal Fiber > Tensile Yield Strength
Tensile Yield Strength MPa

250

TABLE 26
Sisal Fiber > Tensile Ultimate Strength
Tensile Ultimate Strength MPa

460

TABLE 27
Sisal Fiber > Isotropic Secant Coefficient of Thermal Expansion
Reference Temperature
C

22

TABLE 28
Sisal Fiber > Alternating Stress Mean Stress
Alternating Stress
Cycles Mean Stress MPa
MPa

3999 10 0

2827 20 0

1896 50 0

1413 100 0

1069 200 0

441 2000 0

262 10000 0

214 20000 0

1.e+00
138 0
5

2.e+00
114 0
5

86.2 1.e+00 0
 6

TABLE 29
Sisal Fiber > Strain-Life Parameters
Strength Cyclic Strain
Strength Ductility Ductility Cyclic Strength
Coefficient Hardening
Exponent Coefficient Exponent Coefficient MPa
MPa Exponent

920 -0.106 0.213 -0.47 1000 0.2

TABLE 30
Sisal Fiber > Isotropic Elasticity
Temperature Young's Modulus Bulk Modulus
Poisson's Ratio Shear Modulus MPa
C MPa MPa

3770 0.32 3490.7 1428

TABLE 31
Sisal Fiber > Isotropic Relative Permeability
Relative Permeability

10000

Epoxy E-Glass UD

TABLE 32
Epoxy E-Glass UD > Constants
Densit
2.e-006 kg mm^-3
y

TABLE 33
Epoxy E-Glass UD > Orthotropic Elasticity
Young's Young's Young's
Shear Shear Shear
Modulu Modulu Modulu Poisson' Poisson' Poisson'
Temperatur Modulu Modulu Modulu
sX sY s Z s Ratio s Ratio s Ratio
eC s XY s YZ s XZ
directio directio directio XY YZ XZ
MPa MPa MPa
n MPa n MPa n MPa

45000 10000 10000 0.3 0.4 0.3 5000 3846.1 5000

TABLE 34
Epoxy E-Glass UD > Orthotropic Strain Limits
Tensile Tensile Tensile
Compressiv Compressiv Compressiv
Temperatur X Y Z Shea Shea Shea
eX eY eZ
e C directio directio directio r XY r YZ r XZ
direction direction direction
n n n

2.44e- 3.5e- 3.5e- 1.6e- 1.2e- 1.6e-

-1.5e-002 -1.2e-002 -1.2e-002
002 003 003 002 002 002
 TABLE 35
Epoxy E-Glass UD > Orthotropic Stress Limits
Tensile Tensile Tensile Compressiv Compressiv Compressiv
Shea Shear Shea
Temperatur X Y Z eX eY eZ
r XY YZ r XZ
e C directio directio directio direction direction direction
MPa MPa MPa
n MPa n MPa n MPa MPa MPa MPa

46.15
1100 35 35 -675 -120 -120 80 80
4

TABLE 36
Epoxy E-Glass UD > Puck Constants
Temperature Compressive Compressive Tensile Tensile
C Inclination XZ Inclination YZ Inclination XZ Inclination YZ

0.25 0.2 0.3 0.2

TABLE 37
Epoxy E-Glass UD > Additional Puck Constants
Interface Weakening Degradation Parameter
Degradation Parameter M
Factor s

0.8 0.5 0.5

TABLE 38
Epoxy E-Glass UD > Tsai-Wu Constants
Temperature Coupling Coefficient
Coupling Coefficient XY Coupling Coefficient XZ
C YZ

-1 -1 -1
Composites Pre-processing: ANSYS WB Mechanical:

Fiber arranged to make laminate

Simulation result with Composite material:

Total deformation :
 CHAPTER V

5.CONCLUSION

S.no Material Total deformation Strain

1 Polyethylene 0.22 0.00033

2 Natural fiber 0.011 5.86x10-6

Since both the geometries are same and same load is applied; the equivalent stress
distribution is same in both the cases. But the equivalent max strain in polycarbonate
composite is 0.0000058 mm/mm which is less than the max strain 0.0003mm/mm in
Polyethylene. Max total deformation in Natural composite is 0.011mm which is less than
total deformation 0.22mm in Polyethylene. Hence in the preliminary ANSYS test show that
the Polyethylene composite with 10% glass reinforcement possess better mechanical strength
than the traditional HDPE material.

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