M. Nithiyakumar Lecturer, Department of Textile Technology, SSM School of Textile and Management, Erode. mnithiyakumar@gmail.com D. Gopalakrishnan Lecturer, South Indian Institute of Fashion Technology, 229 A, Sathya Moorthi Road, Ramnagar, Coimbatore – 641 009, textilesamurai@rediffmail.com

Due to their outstanding properties, such as light weight or high strength and rigidity, fiber-reinforced composite materials have been widely used in a number of technical applications. However, due to the increase in environmental awareness and the requirements of the legislature, the manufacture, use, and dismantling of traditional composite structures, which usually use synthetic fiber materials such as glass, carbon or aramid, are considered more strictly. For this reason, replacing traditional synthetic fiber materials with natural fibers has become an emerging field of interest and development in polymer science and industrial applications. Although it has obtained ecological benefits, for example, the later products will have a small impact on the environment during the formation, use and disposal period, but this strategy will bring further technical and economic benefits. In order to improve the performance and durability of wood structures, fiber reinforced polymer (FRP) composite materials are increasingly used as wood reinforcement materials. At present, the application of wood reinforcement is mainly focused on the use of FRP strips or fabrics to bond to wood components. In this highly competitive world, engineers must find high-performance natural composite structures. To help, there are so many computer-aided engineering tools being used. ANSYS 9.0 is one of the successful finite element modeling software. It is very flexible to design and analyze composite models. In this work, three coconut shell fiber reinforced wood boards were obtained from the manufacturer. They have three different thicknesses and three types of layer configurations. The tensile stress, deflection and density values ​​are studied. Five different models were developed using ANSYS 9.0 software, and the tensile stress and deformation behavior were analyzed. Input data such as density, Young's modulus, shear modulus, and poison ratio are given to construct the model. Among the five models, two models are phenolic jute and coconut shell fiber reinforced wood composite materials. In these models, a layer of wood is eliminated. There is a very large difference in tensile stress values ​​between the original plate and the developed model. But the deformation characteristics of the two are the same. It is found that the obtained model has many manufacturing defects, and the results of ANSYS 9.0 are theoretical values. By considering these aspects, it can be correlated with the result value. According to ANSYS 9.0, jute reinforced composites show good tensile stress improvement at lower thicknesses. Adding jute reinforcement can eliminate a layer of wood, which is beneficial to reduce weight and improve aesthetic value.

It can be seen from the figure that the load is distributed to all layers and the entire area. The edges are well grasped and there is no deformation. So these layers did not bend, only elongation occurred. These figures clearly show that the deformation is controlled by the composite energy of the material. Even if these layers are divided into separate layers, their movement or tendency to separate is still controlled by the next layer. These numbers can be divided into two groups. Model 1 and Model 2 are regarded as one group, and the rest are another group. That is, the layer separation of model 1 is the same as that of model 2. But in the other three models, the layers are not separated separately. Since they are thicker than the previous two models, they will not deform too much. The tensile stress of model 4 is between model 3 and model 5. The deformations of these three models are the same. 4 is slimmer than model 5, but has the same performance. Due to the jute non-woven material, this smoothness has a good aesthetic value and a smooth surface, and the weight is therefore reduced. So it is easier to deal with. Jute fiber is cheaper than wood. Therefore, the cost will be greatly reduced. In summary, a satisfactory thing is that the elimination of wood materials saves more time for putting greens. Conclusion In this study, three types of coconut shell fiber-reinforced wood plywood with different thicknesses were obtained from the plywood manufacturer, and the bending tensile stress test was performed on them. Calculate the actual and theoretical density values ​​of the board. Then, five calculation models were developed using ANSYS 9.0 finite element software package, and the tensile stress was studied. The following conclusions can be drawn from the above research. 1. The tensile stress value of the plate increases with the increase of the thickness. The deflection decreases as the thickness increases. 2. The density value is much lower than the average value. 3. The porosity of all boards is above 35%. This indicates that the non-woven material has poor impregnation to the resin. Due to this failure, the mechanical properties of the board are affected, which results in poor tensile stress values. 4. In the five calculation models, the tensile stress increases as the thickness increases, and the deflection also increases. 5. The jute-containing board is very hard, and the deflection decreases as the thickness increases. 6. Although the tensile stress value of the calculated model is incomparable with the real plate, the deformation trend of the two models is the same. Therefore, mechanical behavior may be relevant. 7. It is recommended to add a phenolic jute layer to make the board more rigid and eliminate a layer of wood. A higher level of mechanical properties can be obtained with a smaller thickness. With this suggestion, eliminating wood will lead to cost reductions. Smoothness gives higher aesthetic value and ease of operation.

References 1. Bledzki. AK, Gassan. J., 1999, "Composite materials reinforced with cellulose-based fibers", Advances in Polymer Science, pp. 221 – 274 2. Carlos Gonz´alez, Javier LLorca, "Multi-scale modeling of fracture in fiber-reinforced composite materials" , 3. Dieter H. Mueller, Andreas Krobjilowski, "New Discovery of the Properties of Natural Fiber Reinforced Composites", Journal of Industrial Textiles, Vol. 33, No. 2—October 2003, pp 111-130 4. Gregg A. Ambur, Gerald G. Trantina, "Predicting the Failure of Thermoplastic Composites", Mechanical Design; April 20, 1989; 61, 8; ProQuest Science Journal, pg. 91 5. Jang-Kyo Kim, Yiu-Wing Mai, 1998, "Engineering Interface in Fiber-Reinforced Composites", Elsevier, New York 6. James E. Mark, 1999, "Polymer Data Handbook", Oxford University Press, London 7. Julio F. Davalos, "Characterization of the Bonding Interface of Wood Fiber Reinforced Polymer Composites", The 3rd International Conference on Advanced Engineered Wood Composites, July 10-14, 2005, Bar Harbor, Maine, USA 8. Kimberly Kurtis, "Polymer and Fiber Reinforced Materials" Polymer Composites", CEE 3020 Building Materials, Georgia Institute of Technology 9. Minjie Chen; Chao Yingwan; Zhang Yong; Yinxi Zhang, 2005, "Short glass fiber reinforced PP composite Fiber orientation and mechanical properties of materials", Polymers & Polymer Composites, 13, 3, ProQuest Science Journals 10. Michael W. Reed, Robert W. Barnes, Anton K. Schindler, Hwan-Woo Lee, "Concrete bridges that maintain traffic Fiber-reinforced polymer reinforcement", ACI Structural Journal 11. Parikh. DV; Squid. TA; Swani. APS; Blanchard. EJ, "Thermoformed automotive composites containing kenaf and other cellulose fibers", Journal of Textile Research; August 2002; 72, 8; ProQuest Scientific Journal, pg. 668 12. Rizov.V; Hamia T; Reinhardt. A; Friedrich K. 2005, "No Continuous long glass fibers strengthen the fracture toughness of polypropylene: a method based on numerical prediction of fiber orientation in injection molding", Polymer and Polymer Composites; 13, 2; ProQuest Science Journals, p. 121 13. Sanjay K. Mazumdar, 2002, "Composite Material Manufacturing-Material, Product and Process Engineering", CRC Press, London 14. Sudhakaran Pillai. M., Vasudev. R., 2001, "Coconut Fiber in Agricultural Textiles Application in technical textiles", International Symposium on Technical Textiles 15. Torres. FG; Diaz. R M., 2004, "The Morphological Characteristics of Natural Fiber Reinforced Thermoplastics (NFRTP) Processed by Extrusion, Compression, and Rotational Molding" , Polymers and Polymer Composites, 12, 8; ProQuest Scientific Journal, Pg. 705 16. 1991, "Materials", Machine Design, 63, 13, ProQuest Journal, p. 7. 790 17. www.naturaindia.com 18. www.tifac.org.in 19. Hull. D, Klein. TW, 1996, Introduction to Composite Materials", Cambridge University Press, Cambridge

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1. Introduction Composite material is a magical material with light weight, high strength-to-weight ratio and rigidity. It has made great progress in replacing traditional materials such as metal and wood. These materials are a combination of two or more individual materials, aiming to achieve superior performance/performance compared to each material. Due to the flexibility to choose various combinations of fiber-reinforced materials and resin matrix, these materials provide some significant advantages for metals in many structural applications. Reinforcing fiber is the main load carrier of composite materials, and the matrix component transfers the load from fiber to fiber. The choice of the best reinforcement form and material depends on the performance requirements of the finished part [13]. Biocomposite materials are natural fiber composite materials, defined as composite materials composed of biodegradable natural fibers as reinforcement and biodegradable or non-biodegradable polymers as a matrix [7]. The advantages of natural fibers over traditional reinforcing fibers (such as glass and carbon fibers) are their low cost, low density, high toughness, acceptable specific strength, enhanced energy recovery, recyclability, and biodegradability. Biocomposites derived from natural fibers and traditional synthetic thermoplastics or thermosetting plastics are very environmentally friendly because the matrix resin is not biodegradable. However, these biocomposites can maintain a balance between economic and environmental issues in various industrial applications such as automobiles, construction, and consumer products. In order to improve the performance and durability of wood structures, fiber reinforced polymer (FRP) composites are increasingly used as wood reinforcement materials [7]. At present, the application of wood reinforcement is mainly focused on the use of FRP strips or fabrics to bond to wood components. Nowadays, coconut shell plywood and coconut shell plus waste rubber wood decorated with oriented jute are widely used. Phenolic is used as the matrix material. Two types of composite panels have been developed, namely, coconut shell fiberboard (jute + rubber wood + coconut shell fiber) as a substitute for plywood and natural fiber reinforced board (jute + coconut shell fiber) as a substitute for medium density fiberboard. These natural materials have all the characteristics required for general-purpose boards and can be used to replace wood or MDF boards for partitions, false ceilings, surface panels, roofs, furniture, cabinets, wardrobes, etc. [17]. Today, engineers must design closer to material limits to meet cost and weight requirements. In the safety design close to the material failure point, the engineer must be able to define when and where the failure occurs. However, determining the point of failure and failure mode requires accurate characterization of mechanical performance. Unfortunately, although this type of data is available for most isotropic materials, these data are only now collected for anisotropic composite materials [14]. In recent years, computer simulation is becoming an attractive method for predicting the load distribution and failure of composite materials. The introduction of a finite element commercial software package can optimize the design to reduce material costs and production time. Among these software packages, ANSYS 9.0 is a successful computer-aided engineering tool that can be used to analyze the behavior of composite materials. 2. Method 2.1 Obtaining Coir Fiber and Jute Fiber Reinforced Wood Boards Using phenol formaldehyde as the matrix, three different thicknesses of coconut fiber, jute and rubber wood composite boards were obtained from the coconut fiber board manufacturer. Natural hard fibers, such as coconut shell fibers and jute impregnated with phenolic resin, are used to make these boards. Although the MDF replacement board is made only of jute and coconut husk fiber bonded with phenolic resin, the coconut husk fiber board is made of jute, coconut husk fiber and rubber wood waste. A very thin layer of jute fiber impregnated with phenolic resin is covered as a finish to enhance the aesthetics and provide a smoother wood. The basic process involved in manufacturing the coconut shell fiber layer includes forming a non-woven mat of coconut shell fibers (the fiber ends are facing up to provide rigidity), spraying the mat with phenolic resin, and hot pressing the sheet in a multi-daylight hydraulic press to press the sheet with a heating system. Then trim to the desired size. The density of the layer can vary with the pressure used. According to the density, the coconut shell fiber composite material can be used as particle board, plywood, medium density fiberboard or hard board [17]. 2.2 Testing of composite panels 2.2.1 Bending tensile stress

The maximum tensile stress and bending deflection of the composite material were tested on Amsler's universal wood testing machine. The machine is set to 400 kg range. The valve is closed. A zero adjustment was made on the dial. Measure the size of the cross-section of the sample. Measure the distance between the center and the bracket. The specimen is placed symmetrically on the holder. Apply the load slowly and continuously until the specimen fails. Record the maximum load and maximum deflection at failure.

2.3 Development of computational compound model The computational compound model is developed with ANSYS 9.0 finite element software package. The developed model is deformed by applying a load, and the tensile stress and deflection are analyzed. 2.3.1 ANSYS 9.0 uses this CAE tool to analyze to determine the stress distribution and material deformation in the composite layer. The finite element method is a series of numerical techniques used to solve boundary value problems, initial value problems and eigenvalue problems. The basic process of finite element is to divide the domain into multiple (or) elements, use the equation governing the problem of each element as a function of selected values, and solve for these values. After completing this operation, refer to the element equation to obtain the appropriate solution variable for the problem. Dimensional factors such as density, Young's modulus, shear modulus, poison ratio and thickness are considered.

ANSYS is a complete FEA software package that engineers around the world use in almost all engineering fields: • Structures • Heat • Fluids, including CFD (Computational Fluid Dynamics) • Electrical/Electrostatics • Electromagnetics The reasons why ANSYS is selected for analysis are as follows:

Various modules of ANSYS, such as: ANSYS Multiphysics, ANSYS Mechanical, ANSYS Professional and ANSYS FLOTRAN

Solving fracture mechanics problems involves performing linear elastic or elastoplastic static analysis, and then using specialized post-processing commands or macros to calculate the required fracture parameters

ANSYS allows us to model composite materials using special elements called layered elements. Once the model is built using these elements, any structural analysis (including nonlinearities such as large deflection and stress hardening) can be performed. 2.3.2 Composite material modeling Composite materials are more difficult to model than isotropic materials such as iron or steel. Since each layer may have different orthotropic material properties, special care needs to be taken when defining the properties and orientation of each layer. In this section, we will focus on the following aspects of building a composite model: • Choosing appropriate element types • Defining hierarchical configurations • Specifying failure criteria • Following modeling and post-processing guidelines 2.3.3 Development of theoretical models in this work , Developed five models to analyze composite panels. They are constructed with the following configuration and arranged one by one. Type 1 (M1): 3 layers (2 phenolic coconut husk fiber + 1 wood) Type 2 (M2): 5 layers (2 phenolic coconut husk fiber + 1 wood + 2 phenolic jute) Type 3 (M3): 5 layers (3 Phenolic Coir + 2 Wood) Model 4 (M4): 7 Layers (4 Phenolic Coir + 3Wood) Model 5 (M5): 7 Layers (3 Phenolic Coir + 2 Wood + 2 Phenolic Jute) The following table 2.1 shows each layer The thickness of the model and the total thickness of the model.

The models M1, M3, and M5 are constructed based on the obtained layer configuration of the composite board. The other two models, M2 and M4, were developed using a new layer configuration, which is contained in a thin layer of phenolic jute. Table 2.2 below shows the input data required to build the layer. The software package will use these specifications to calculate the mechanical properties of the model when it deforms under an applied load.

Coir fibers and jute nonwovens impregnated with phenolic resin are considered isotropic materials. Because of the different mechanical properties with the grain direction, wood is considered to be an orthotropic material. 3. Results and discussion The three types of composite panels obtained were tested for bending tensile stress in Amsler's universal wood testing machine. The load range is set at 0 – 4000 N. The plate is deformed and the tensile stress is calculated. The density and void ratio of the board are also calculated using the formula mentioned in section 2. In the ANSYS software package, five models have been developed, as shown in Table 2.1. Among them, three models were developed based on the obtained board configuration, and two models were developed with new layer combinations, including thin-layer phenolic jute. These five models were deformed due to applied load and analyzed with ANSYS software. The results obtained are compared with actual values. 3.1 The performance of the coconut shell fiber reinforced wood composite board 3.1.1 The thickness of the board The composite material has three different thicknesses. Table 3.1 below shows the layer details of the board.

3.1.2 The bending performance of the developed composite material The tensile stress and deflection values ​​of the composite panel tested on the Amsler universal wood testing machine are shown in Table 3.2.

It can be clearly seen in Table 3.2 that the tensile stress increases with the increase in thickness, while the deflection decreases. But the tensile stress of plate 3 is increasing sharply. The deflection is lower than other plates, and the tensile stress during bending is directly related to the deflection. Compared to plate 3, plates 1 and 2 are thinner materials. They have one and two layers of wood. So the sample is flexible and can be bent freely. B3 consists of three layers of wood, the Young's modulus value of wood is about 16 GPa. Therefore, B3 is very hard and will not bend easily. Therefore, it can withstand heavy loads with small deflection. 3.1.3 Density of composite board The actual density, theoretical density and porosity of composite board are calculated according to the formula given in Section 2, and the values ​​are shown in Table 3.3.

The density of the obtained board is not uniform, which is very different from the theoretical value. The porosity of all panels exceeds 35%. This indicates that the material is not properly impregnated into the resin. The density of all materials used in the board is above 1.2 g/cc, including resin, and the density of the board should be at least 1.2 g/cc. As the density increases, the void percentage will be 15. This gap difference leads to poor bonding with wood and fiber, which in turn affects the strength value [19]. If this fault is eliminated, the strength will be greatly improved. From the above discussion, it can be seen that the composite board is not properly reinforced by the fibers. 3.2 Evaluation of Ansys9.0 calculation model Five models with different thicknesses have been developed in the ANSYS 9.0 software package. Layer configuration is discussed in Section 2. The model deforms due to the applied load. The tensile stress and deflection are shown in Table 3.4.

The same trend is followed in the developed model, that is, the tensile stress gradually increases as the thickness increases. But in the deflection value, firstly, the deflection increases with the increase of thickness. In addition, the above values ​​are re-made into two different sets according to their layer configuration (such as wood and jute), as shown in Table 3.5. Set 1 serves as a list of models developed based on the obtained board. They only contain phenolic coconut shell fiber and wood. They are M1, M3 and M5. The two new models in the second group include phenolic jute with coconut husk fiber and wood. They are M2 and M4. The results show that the deflection value of the first group is higher than that of the second group.

In the above table, the deflection of M3 and M5 is higher than that of M2 and M4. Before starting to analyze Table 3.5, it is necessary to clarify the incomparable difference between the tensile stress value of the actual material and the developed model. The values ​​given in Table 3.4 cannot be compared with the values ​​given in Table 3.2. The following points can be considered to draw conclusions. The first is that natural materials are not homogeneous. It is impossible to obtain the same quality materials in all regions of production, and performance will vary by region and season. But ANSYS 9.0 will consider the material to be homogeneous. The second thing is that the input data values ​​for each layer used to build the model are only taken from the literature. Single-layer properties such as phenolic coconut husk fiber and wood have not been tested. The role of resin and wood is only surface bonding, resin will not enter the wood. In the coir fiber non-woven material, resin plays a vital role. However, it is found in Table 3.3 that the void ratio is greater than 35%. It is an important criterion for the lower mechanical properties of circuit boards. As already discussed, the composite board is not properly reinforced by the fibers. The rigidity and strength of those boards are only due to the wood material. The variation in the thickness of the resulting ply and the discontinuity of the wood layer is also another important criterion for reducing the bending tensile stress. But in the ANSYS 9.0 software package, the above shortcomings are not considered. It can be considered that all layers are homogeneous and tightly packed. These layers are correctly meshed. The mesh transfers the load applied according to the layer details. Therefore, the value obtained from ANSYS 9.0 is purely theoretical. The most important thing that should be considered is the test method of the model. In Amsler's wood testing machine, the sample is simply placed on a support and bent. Therefore, the bending freedom of the sample is greater. They deflect to the maximum limit. This is why the deflection value is higher than the developed model. But in ANSYS 9.0, the edges of the model are firmly grasped and deformed. Therefore, only the elongation of the model occurred, not the bending. Therefore, it is impossible to compare the values ​​of the obtained circuit board and the developed model. But there is a good agreement that the tensile stress value increases with thickness and material configuration. With this protocol, these values ​​can be associated with the real board. Although there are huge differences in stress values, the results obtained from ANSYS 9.0 are only consistent with the various layer configurations we provide. Therefore, it can be considered that these values ​​can be used to modify the real board.

In the analysis in Table 3.4, the deflection increases as the thickness increases. As mentioned earlier, the model is firmly grasped and bent. So these layers are stretched to their limit. For this reason, the model is not deflected like the real model. The maximum deflection is only 8 mm. But in actual boards, thin boards are more flexible, and they are bent to 36 mm. The deflection behavior is divided into two groups. One set is a real board configuration, and the other is a newly designed model. It can be seen that in the first group, the deflection increases as the thickness increases, and in the second group, they are decreasing. In the first group, the materials used are phenolic coir and wood. The Young's modulus of phenolic coconut shell fiber is only 4.3 GPa. The modulus value of wood is as high as 16 GPa in the grain direction. But wood has a disadvantage, that is, the modulus value perpendicular to the grain direction is only 1 GPa. This difference was taken into account in the models developed in the first group. However, in the second group, a wooden layer was eliminated and a phenolic jute layer was included. The modulus value of jute is as high as 40 GPa, and the modulus value of phenolic jute is 7.5 GPa. The modulus value is higher than that of phenolic coconut shell fiber. The elongation rate of coconut husk fiber is as high as 40%. But the elongation of jute is only 1.5%. The introduction of the phenolic jute layer showed a very good improvement in the tensile stress value. By using a jute layer, a layer of wood can be eliminated. Compared with Model 2, the phenolic jute used in Model 4 has a higher thickness. The stiffness of the model will automatically increase. This is the reason why the deflection decreases with the increase of thickness in the second group. Figure 3.1 to 3.10 show the deformation details of the model obtained with ANSYS 9.0. The figure shows the bending behavior of the model. The distribution of stress is represented by different colors. The stress value matches the color on the model layer. The stress level is given below the model.

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