29 January 2011

FRP RADIATOR GRILL


FRP RADIATOR GRILL



SUBMITTED BY

AJESH.A











CONTENTS


v INTRODUCTION

v OBJECTIVE

v FRP RAW MATERIALS

v FRP TECHNOLOGY

v MANUFACTURING PROCESS

v PODUCTION PROCEDURE

v PRODUCTION FLOW CHART

v COMPARISON WITH OTHER RADIATOR GRILL

v COST ANALYSIS

v PLANT LAYOUT

v CONCLUSION

v REFERENCE




INTRODUCTION

   
Reinforcing plastic matrix with high strength fibre material result in production of what is called fibre reinforced plastic. FRP’S have outstanding properties such as high strength to weight ratio and excellent corrosion resistance and are easy to fabricate. A wide variety of articles are made by the fibre reinforcing process. A remarkably high strength to weight raio is the main feature. Attracting space craft designers. Elegance light weight and corrosion resistant quqlities make it suitable material in a salt water application. Corrosion resistance property of the reinforced plastic is fully utilized when they are employed in huge quantities.


        Different type of Radiator grills are available in the market. But the price of those are very high. FRP Radiator grill has light weight, good finish etc. More over the manufacturing process is simple and it need less manufacturing material.


OBJECTIVE


To produce an FRP Radiator grill

Colour                     :   Black
 
No. of layers           :    2

Weight of product  :     1.650 gm



F R P RAW MATERIALS

1.    POLY ESTER RESIN

2.    M E K P

3.    COBALT NAPHTHANATE SOLUTION

4.    GLASS FIBRE

5.    POLY VINYL ALCHAHOL


A precut glass cloth or mat is then laid over the glass  cloth. Rollers are used to press the glass cloth on the resin uniformly and also remove the air entrapped air bubbles. Alternate layers of resins and glass cloths are laid in a similar sequence until the required thickness is build up. The whole set up is then cured eieher at the ambient on elevated temperature. After curing is completed the reinforced plastic material is thus trimmed and is removed from the mould and subjected to trimming and finishing.



MANUFACTURING PROCESS



The first step in the production of FRP based Radiator grill is cleaning the mould and wax paste to avoid scratches and for surface smoothness. Mould releasing agent PVA applied using sponge. PVA is a water soluble polymer. So mould releasing easy.
After PVA drying gelcoat is applied using laminating brush. For the production of FRP based Radiator grill general purpose resin is used. The gelcoat in the ratio of 1 kg resin for 100 gm of pigment.
It is stirred thoroughly and mixed with Cobalt Naphthanate and MEKP. Gel coat is applied whole of the mould surface with a brush. After that required size fibre adhered to the gelcoat surface by applying resin compound using laminating brush. Process is repeated to get the required thickness and allowed to setting the product.
                        
            Usually within half an hour moulding become cured. Then the product is released from the mould using water with force. 


COMPARISON WITH OTHER RADIATOR GRILL


FRP BASED
CLAY BASED
Light weight
      High weight

Low cost

       High cost
Easy processability
   Processing is complicated
No painting and polishing
required
  Painting and polishing 
   required





APPLICATION

It is used for Automobile purposes.

    

COST ANALYSIS
               
INGRADIENTS
QUANTITY
COST
Glass fibre
100 gm
8.00
Polyester resin
200 gm
18.00
MEKP
3 ml
2.00
Cobalt Naphthanate
5 ml
4.00
PVA
5 ml
3.00
Sand paper 1 sheet
1
3.00
Cotton waste
1
2.00
TOTAL

40.00
          


REQUIREMENTS

         Labours          2 Person

         Mould             1


CONCLUSION

        In modern life FRP based products are more useful. This is used for a variety of application. This is a development of plastic product. Compared to another manufacturing process of plastic products it has more advantages.


    

REFERENCE

    
FRP technology by R.G Whetherhead

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