read the safety data sheet (SDS) and technical data sheet (TDS)
for the resins that you're using
design and fabricate a 3D mold (~ft2)
and produce a fiber
composite part in it,with resin infusion and compaction
produce test coupons for your composite fabrication process(es)
I extract some important points from both Safety and Technical datasheets of Epoxy Solution we are using to complete oure this week task:
Here are some safety measures and warnings before using this material:
- Causes serious eye irritation
- Causes skin irritation
- Toxic to aquatic life with long lasting effects
- Wear protective gloves
- Wear eye/face protection
- Wash thorougly after handling
- if ON SKIN: wash with plenty of soap and water. If skin irritation or rush occurs: Get medical attention.
- if IN EYES: RInse cautiously with water for several minutes. If eye irritatipon persist. Get medical advice and attention
- Take off contaminated clothing and wash before reuse
here are some safety measures and warnings before using this material:
- Causes serious eye damage
- Causes severe burns and eye damages
- May cause an allergic skin reaction
- Harmful to aquatic life with long lasting effects
- Wear protective gloves/protective clothing
- Wear eye/face protection
- Wash thorougly after handling
- If SWALLOWED rinse mouth
- If IMNHALED Remove victim to fresh air and call a POISON Center or doctor/physician
- if ON SKIN: wash with plenty of soap and water. If skin irritation or rush occurs: Get medical attention.
- if IN EYES: Rinse cautiously with water for several minutes. If eye irritatipon persist. Get medical advice and attention
- Take off contaminated clothing and wash before reuse
- The solution is mixed with 2:1 Ratio
- Mix components thorougly till 10 minutes when it starts heating it is good for nexgt process
- it takes 24 hours to dry
Basically, composites are the combination of some components having different physical and chemical properties, which combine to make a composite , which is stronger than the individual elements.Composites can be natural or synthetic. Wood, a natural composite, is a combination of cellulose or wood fibers and a substance called lignin. To make a composite you need four things:
I design a boat in this week for. I used SolidWorks to design my model and below I mentioned steps:
In start I select TOP plane from solidworks and draw line on it and assign dimensions to the line.
After that I select centerline and assign dimensions to that line
The I Used center 3Point ARC for curve
Design In solidworks
After that I used Right plane for the edge and draw a rectangle on it .
Draw Rectanle
After that I used Top plane and used 3point Arc for curve after applying tis the design looks like this
Draw Curve
after that I applied profiling
Profiling
After some steps The preview Looks like this
Preview
In last I save file as STL to import in vcarve softare.
For this week assignments we are using High Density Foam which has thickness of 50mm. For milling high density foam we are using Shopbot (to understand how to work with Shopbot
VCarve Pro is used to generate G-Code for Shopbot
The steps to generate G-Code mentioned below:
First open VCarve and click on File > Import... and select Import COmponent/ 3D Model ... in a window select .STL file which we made in designing part
Window Pop Up
Design In vcarve
Now click on toolpath and select Rough Machining Toolpath we are using 0.5 inch End Mill drill bit, but it was not present in Tool database so we create New database, settings are shown in picture
Tool For Roughing
Finisihing process is same the bit database is not present so we make with Ball Nose inch diameter other settings are shown in picture
Tool For Finishing
Preview Of Roughing
Tool For Finishing
Previwe Of All design
Preview Of Design
Toolpaths are given to machine for further process and here are the some results
Tool Change
Setting XYZ
Finishing
Final Result
I am using double layer of fabric in my assignment, it makes the surface more hard. The fabric are in arrangement that one layer is set to another with 45 degree of angle.
Final Result
The plastic layer is covered on mold so it safe from Resin and can be use again
Plastic layer
A fabric weighted for finding the quantity of ratio of Resin and Hardner
Mixing Of Material
The ratio of Resin and Hardner is mixed in 2:1 and the total quantity is 3xweight of a material which is 150gm approx
Mixing Of Material
Paste the resin dipped fabric on Mold then again make a layer of plastic on it and squeeze it over surface so it can attain a shape
Cover with plastic
Place a breather and put the whole experiment into air bag which is ued to suck the air and build pressure on composite to attain the shape
Cover with plastic
We wait a day to dry the material and the result was hard like rock
After 24 Hours
Final Result
As a group assignment this week we did mill a very simple test design, a curvy shape in solidworks. Saved it as an .stl to machine it and then we generated tool paths in vcarve as following.. Initially, a new Vcarve file was opened and the dimensions were set according to the size of the model (222 x 101mm). Then by importing the Component/3D model(.sldprt file). Now cutomize your job as following.
The 3D model is being set in the proper plane
In the next step we place the model at center so that the model comes inside the dimesnions we set.
The 3D model is placed at the center
From the toolpath tab, we generate the toolpath for roughing and finsihing.
The roughing is being done with the tool foam roughing 0.5 inch tool which is already added in the tool list
>The preview of model after roughing
>The The preview of model while finishing
The next step was to cut the model on the 40mm foam, the toolpaths were generated and then used in cutting on shopbot.
>shopbot at work of roughing & finishing the model
We are using Jute as the fiber, we already cut the two pices on Laser cutter. The arrangement of the composite is shown below:
>The arrangement of vacum for the model
>The model is being put in the vaccum for curing for at least one dayl
The model was put for curing for the whole day and then the next day, we removed the mold and removed all the extra layers.
The mold is removed and the hardened composite is ready
You may Download thsi Week file from Here
.png)
