Nasuha Sa'ude

Effect of Powder Loading and Binder Materials on Mechanical Properties in Iron-ABS Injection Molding Process

This paper presents the development of a new polymer matrix composite (PMC) feedstock material by the injection molding machine. The material consists of iron powder filled in an acrylonitrile butadiene styrene (ABS) and surfactant powder (binder) material. In this study, the effect of powder loading and binder content on the mechanical properties was investigated experimentally. The detailed formulations of compounding ratio by Brabender Mixer and injection molding machine of the sample specimen was used with various combinations of the new PMC material. Based on the result obtained, it was found that, higher powder loading of iron filler affected the hardness, tensile and flexural strength of PMC material. With 32% iron powder loading in ABS composites increase the flexural force, maximum stress and force of PMC material through an injection molding process.

A Study on the Mechanical Properties of Polymer-Ceramic Composite Using Injection Moulding

This paper presents the development of a new polymer-ceramic composite material for use in injection molding machine. The material consists of palm oil fly ash (POFA) in a high density polyethylene (HDPE) powder. In this study, the effect of POFA was investigated as a filler material in polymer-ceramic matrix composite and HDPE was chosen as a matrix material. The detailed formulations of mixing ratio with various combinations of the new polymer-ceramic composite are investigated experimentally. Based on the result obtained, it was found that, the weight percentage increment of POFA filler affected the flexural and hardness strength. This work represents a major development in recycling of waste material from palm oil empty fruit bunch out of the refinery to produce polymer/ceramic matrix composite.

Sustainable Natural Bio Composite for FDM Feedstocks

This paper presents the development of a new Wood Plastic Composite (WPC) material for Fused Deposition Modeling (FDM) feedstocks. In this study, a biodegradable polymer matrix (POLYACTIDE, PLA) was mixed with natural wood flour (WF) by Brabender mixer, and the samples produced by injection molding machine. The effect of wood was investigated as a filler material in composite FDM feedstock and the detailed formulations of compounding ratio by weight percentage. Based on results obtained, it was found that, compounding ratio of PLA80%:WF20% has a goods result on the tensile strength and PLA60% : WF40% gave a higher value of flexural strength. An increment of 20% to 40% WF filler affected the flexural strength, and hardness results. The highly filled WF content in PLA composites increases the mechanical properties of PMC material through the injection molding process. The potential of development of a sustainable composite material will be explored as the FDM feedstocks in the rapid prototyping process.

Mechanical Properties of Highly Filled Iron-ABS Composites in Injection Molding for FDM Wire Filament

This paper presents the development of a new polymer matrix composite (PMC) material for use in injection molding machine. The material consists of iron powder filled in an acrylonitrile butadiene styrene (ABS) and surfactant powder material. In this study, the effect of iron powder was investigated as a filler material in polymer matrix composite and ABS was chosen as a matrix material. The detailed formulations of compounding ratio by volume percentage (vol. %) with various combinations of the new PMC are investigated experimentally. Based on the result obtained, it was found that, vol. % increment of iron filler effected on the hardness, tensile and flexural strength. With highly filled iron content in ABS composites increase the hardness and tensile strength of PMC material through an injection molding process.

Melt flow behavior of metal filled in polymer matrix for fused deposition modeling (FDM) filament

This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene (ABS), Polyproplene (PP), Polylactic Acid (PLA), ABS mix 10% Copper and ABS mix 10% Iron in the simulation. In this study, the effect MFB of ABS mix with 10% Iron and 10% Copper material was investigated based on the viscosity, density, thermal conductivity, melting temperature and specific heat of material properties. The MFB of metal filled in polymer matrix composite (PMC) through the FDM nozzle was investigated using Finite-Element Analysis (ANSYS CFX 12). Based on the result obtained, pressure outlet of mix ABS copper and ABS iron in extruder nozzle was higher value compared with others plastic material. The velocity was increased since the nozzle diameter is smaller than the entrance diameter. It can be observed that, the melt flow behavior of metal filled in PMC are affected on pressure drop, velocity and the nozzle size at the exit nozzle.

Melt Flow Behavior of Polymer Matrix Extrusion for Fused Deposition Modeling (FDM)

This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene (ABS), High Density Polyethlene (HDPE), Polyproplene (PP) and a combination of ABS-Iron in the extrusion process. In this study, the effect MFB of varietys polymers and ABS mix with 10% Iron material was investigated based on the viscosity, density, thermal conductivity, melting temperature and specific heat material properties. The MFB of FDM system was investigated using Finite-Element Analysis (FEA) by ANSYS CFX 12. Based on the result obtained, it was found that, the material velocity increase when the nozzle diameter is smaller than the entrance diameter. The higher temperature distribution along the MFB of ABS mix with 10% Iron is 43.15 K compared with original ABS, which is 539.15K.

A Study on Contact Angle and Surface Tension on Copper-ABS for FDM Feedstock

This paper presents the development of a new Copper-ABS feedstock material by the injection molding machine. The material consists of copper powder filled in an acrylonitrile butadiene styrene (ABS) binder and surfactant material. In this study, the effect of metal filled ABS and binder content on the contact angle and surface tension was investigated experimentally. The detailed formulations of compounding ratio with various combinations of a new Copper-ABS feedstock was done by volume percentage (vol. %). Based on the result obtained, an increment by vol. % of copper filler in ABS effected on contact angle and surface tension results. With highly filled copper content in ABS composites increase the surface tension value. It can be observed that, the tendency of the liquid surface that allow to resist an external force in PMC material through an injection molding process.

Optimisation of Processing Condition Using Taguchi Method on Strength of HDPE-Natural Fibres Micro Composite

Injection molding usually uses to produce part from plastic. Other than it is cheap, it also can produce part in large quantity. In this paper, Taguchi Methods was used to define the optimization of process parameter for an injection molding machine to produce a dumbbell product from High-density Polyethylene (HDPE) + natural fiber (Kenaf). Taguchi Methods with L9-34 approaches will be used in this work. Four different formulation of material will be tested to find the best formulation and its parameter setting. Here, an orthogonal array (OA), signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are employed to analyze the effect of injection molding parameter. The significant of formulation and parameter setting from injection molding through the hardness and the strength value of the specimen. Furthermore, test will be conducted through hardness test and tensile test. Changes in the parameter setting will give different hardness and tensile strength value. The optimum parameter setting was set base on the S/N ratio. For each formulation, it has their optimum parameter setting for hardness and for tensile strength. The optimum parameter setting was predicting their S/N ratio using Minitab software.

Melt Flow Index of Recycle ABS for Fused Deposition Modeling (FDM) Filament

This paper presents the melt flow index (MFI) of acrylonitrile butadiene styrene (ABS) and recycle ABS filament wire for Fused Deposition Modeling (FDM) machine. In this study, the effect of MFI on recycle ABS material was investigated experimentally based on the melting temperature, density, screw speed and material properties. The MFI result on ABS recycle in wire filament was investigated using Melt Indexer Machine (MIM). Based on the result obtained, it was found that, ABS recycle was increase the density and MFI results. It can be observed that, the higher temperature was melt the recycle ABS material through the MIM and extruder machine.

A Study on Melt Flow Index on Copper-ABS for Fused Deposition Modeling (FDM) Feedstock

This paper presents of Polymer Matrix Composite (PMC) as feedstock used in Fused Deposition Modelling (FDM) machine. This study discussed on the development of a new PMC material by the injection molding machine. The material consist of copper powder filled in an acrylonitrile butadiene styrene (ABS), binder and surfactant material. The effect of metal filled in ABS and binder content was investigated experimentally by the Melt Flow Index (MFI) machine. Based on the result obtained, an increment of copper filled in ABS by volume percentage (vol. %) effected on melt flow index results. With highly filled copper in PMC composites increase the melt flow index results. It was concluded that, the propensity of the melt flow allow an internal force in PMC material through the injection molding and FDM machine.