Experimental Analysis of Mechanical Behaviour of Poly Vinyl Chloride (PVC) Plastic Welded Through th

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 11, 2016 | ISSN (online): 2321-0613

Experimental Analysis of Mechanical Behaviour of Poly Vinyl Chloride (PVC) Plastic Welded through the Fabricated Experimental Set-up for Hot Air Welding Md Shakibul Haque1 Inayat Hussain2 Gaurav Agarwal3 Khwaja Moeed4 Mohd Anees Siddiqui5 1,2,3,4,5 Department of Mechanical Engineering 1,2,3 Invertis University, Bareilly 4,5Integral University, Lucknow Abstract— The present work is based on the motivation to bring the technique of hot air welding so as to weld plastic materials such as poly vinyl chloride (PVC) etc. As the hot air welding is an environment friendly joining process.

Through this paper an initiative is taken to introduce this recent technology of hot air welding in the workshop level because hot air welding of plastics is not common in general. In the present work, we have fabricated hot air welding setup for exploring and sharing such a nice invention to humanity given by Robert. C. Reinhardt in 1940. An initiative has been taken to fabricate low cost setup of hot air welding because the actual machine of hot air welding is very expensive and costly. The experiment was performed on the fabricated setup and the samples of PVC plastic were successfully joined through hot air welding technique. After successful joining, the welded samples were tested for tensile strength, hardness and cross breaking load (bending test) and it was found that the samples were safe after the testing which shows the reliability of welded joint and opens the door for young minds to work further on this technique.

Key words: Poly Vinyl Chloride (PVC), Welding of PVC plastic, Hot air welding set-up, hardness, cross breaking load and tensile strength of PVC plastic I. INTRODUCTION Hot air welding is a welding technique, invented by Robert.

C. Reinhardt in 1940. [1] He reported that weld groove and weld rod were heated with hot air stream until they soften sufficient to fuse, then the welding rod is pressed into the groove.[2] Hot air welding is one of the external heating methods[4,5,6]. This method is environment friendly joining process In the present work, we have fabricated low cost setup of Hot air welding by using different equipments for exploring the concept and application of hot air welding for joining the thermoplastic parts such as PVC pipes, water tank etc. After successful fabrication of experimental set-up welding has performed and welded samples are tested for ultimate tensile strength, hardness and cross breaking load.

Mahmood Alam et al. find the maximum tensile strength of 3.92MPa.[3]

A. Diaphragm Pump: The diaphragm pump is used for the purpose of air flow at high pressure. The figure of diaphragm pump which is used in this set-up is shown in figure 1.

Fig. 1: Diaphragm Pump The specification of this pump is given in table-1 B. Hot Air Gun: Suction & Discharge ½ inch Air Inlet ¼ inch Max Flow 2×104 mm3/sec Weight 3 Kg Table 1: Specifications of pump The second major part of developed welding setup is hot air gun which is very important for welding of plastics. In this gun an element is provided for heating the air passes through inner part of the gun. The detailed figure of hot air gun and their layout are shown in figure 2 and 3.

Fig. 2: Hot air gun details

II. FABRICATION OF HOT AIR WELDING SETUP The fabrication steps are discussed in this section of the report. The developed setup has following major parts 1) Diaphragm Pump 2) Hot Air Gun 3) Nozzle 4) Regulator Unit 5) Temperature Indicator (with thermocouple)

Fig. 3: Hot air gun with thermocouple

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Experimental Analysis of Mechanical Behaviour of Poly Vinyl Chloride (PVC) Plastic Welded through the Fabricated Experimental Set-up for Hot Air Welding (IJSRD/Vol. 3/Issue 11/2016/017)

C. Nozzle: There are different types of nozzles which are used in the hot air gun. The specification of the nozzle which is used in this welding setup is given in table 2.

Nozzle diameter 5mm Material of nozzle Stainless steel cross section at inlet and Uniform outlet of the nozzle Table 2: Specifications of Nozzle

Fig. 4: Nozzle attached in hot air gun D. Regulator Unit: Regulator unit is provided for accuracy and controlled variation of process parameters (Air Flow, Air Temperature). The detailed figure of regulator unit is shown in figure 5.

Fig. 5: Regulator Unit

Fig. 7: Fabricated welding setup Power input 230V Power consumption 550W Pump Diaphragm Pump 100°C-480°C(rotary Temperature knob adjustment) Air flow rate(Maximum) 2×104 mm3/sec Round nozzle Nozzle 5mm(diameter) Table 3: Specifications of Developed Welding Setup III. FABRICATION OF SAMPLE HOLDING DEVICE FOR PLASTIC WELDING SET-UP The sample holding device for welding set-up is fabricated with the help of metal sheet. The details are given in table 4.

Parts Details Base 150×120×10 mm3 Jaw-1 50×12×1 mm3 Jaw-2 50×12×1 mm3 Nut-bolts (4 Nos.) Table 4: Details of Sample holding device The detailed figure of fabricated sample holding device is shown in figure 8.

E. Temperature Indicator (With Thermocouple): For welding of PVC, temperature is very important parameter. So it is very important to see the temperature of hot air which is adjusted by the knob. The attachment of digital temperature indicator with thermo couple is provided. Thermo-couple is attached to the nozzle from where the hot air comes out so that the temperature of hot air is visible in digital indicator.

Fig. 8: Sample holding device IV. EXPERIMENTAL PROCEDURE After the successful fabrication of hot air welding set-up, the experiment of hot air welding was conducted on PVC plastic samples Fig. 6: Temperature Indicator with J-type thermocouple The above parts are installed inside a wooden case made of plywood material making arrangement for the position of Digital Temperature Indicator with ThermoCouple, Regulator unit in the front view of the welder. The detailed figure of developed welding setup is shown in figure 7.

Fig. 9: Sample size details

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Experimental Analysis of Mechanical Behaviour of Poly Vinyl Chloride (PVC) Plastic Welded through the Fabricated Experimental Set-up for Hot Air Welding (IJSRD/Vol. 3/Issue 11/2016/017)

Fig. 14: Successful welding of PVC sample Fig. 10: Sample holding

Fig. 15: Two pieces of welded sample for testing

Fig. 11: Starts of hot air welding process.

A. Experimental Specifications: 1) Air flow rate Nozzle dia=5mm Cross-section area of the nozzle(A)= 19.64mm² velocity of hot air (V) = 0.3 m/sec= 300 mm/sec Air flow rate = A×V= 19.64× 300= 5893mm3/sec = 5.893 cm3/sec 2) Welding Temperature Temperature of hot air = 275 °C 3) Welding Speed (WS) Distance travel Welding speed  Time taken to cover the distance

Distance travel = width of the workpiece= 5 cm= 50 mm Time taken to travel the distance= 200 seconds = (WS) 

Distance travel Time taken to cover the distance



50 143

 0.35 mm / s

V. TESTING OF WELDED SAMPLE Fig. 12: During the hot air welding process.

Tensile test have been being conducted on Universal Testing Machine (UTM).

Fig. 13: End of the hot air welding process.

Exp.

Temp (°C)

Air flow Rate cm3/s

1

275

5.893

Fig. 16: Testing of welded sample on UTM UltimateLoad Ultimate Ultimate Welding Speed Strength  CrossSectionArea Load Load mm/s kgf N MPa 0.35 172 1687.32 1687.32/150=11.25 Table 5: Tensile test Result

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Experimental Analysis of Mechanical Behaviour of Poly Vinyl Chloride (PVC) Plastic Welded through the Fabricated Experimental Set-up for Hot Air Welding (IJSRD/Vol. 3/Issue 11/2016/017)

Bending test have been being conducted on Electronic Universal Testing Machines Unitek-9450 and find out the cross breaking load.

Air Cross Welding Temp flow Breaking Exp. Speed (°C) Rate Load mm/s 3 cm /s N 1 275 5.893 0.35 77 Table 6: Bending test Result

3) The welded specimen was safe after the level of three testing, it shows the reliability of the hot air welded joint.

4) The result of tensile strength is 11.25MPa which is far better than Mahmood Alam et al. result of 3.92MPa.[3] 5) The fabricated setup is user-friendly due to easy controlling of air flow, air temperature, welding speed, less weight and portable.

VII. SCOPE OF FUTURE WORK    

The Welding parameters, welding angles and directions can be made variable.

Whole setup can be automated.

A more stable design can be made.

More materials with high melting point can be welded by changing the temperature range.

ACKNOWLEDGEMENT

Fig. 17: Testing of welded sample on EUTM Unitek-9450 Hardness test have been being conducted on ShoreD hardness Durometer and find out the hardness of welded sample.

At this moment of accomplishment, I wish to pay my heartfelt gratitude and sincerest thanks to my guide, Dr. Gaurav Agarwal and Er. Inayat Hussain, department of Mechanical Engineering, Invertis University Bareilly. This work would not have possible without their able guidance, support and encouragement. Under their guidance I have successfully overcome many difficulties and learned a lot.

I am also extremely indebted to Er. Ajitanshu Mishra, HOD, Mechanical Engineering Department, Invertis University Bareilly, for providing necessary infrastructure and resources to accomplish my work. Last but not the least, it goes without saying that I am indebted to a number of friends and well wisher specially who have extended their co-operation and help during this work.

REFERENCES

Exp. 1

Fig. 18: Shore-D hardness Durometer Air flow Welding Hardness Temp(°C) Rate Speed mm/s Shore-D cm3/s 275 5.893 0.35 74.25 Table 7: Hardness test Result VI. CONCLUSION

After successful fabrication of hot air welding setup by following conclusions can be drawn: 1) The thermoplastics like PVC can be successfully welded by using our fabricated setup at workshop level.

2) There is successful joining of two PVC samples without any fumes, harmful gases, radiations, flames, etc.

[1] Reinhardt R.C.,U.S. Patent 2, 22,545: Method of welding thermoplastic materials 1940 [2] Md Shakibul Haque, Manoj Kumar and Adnan Khan, Invertis Journal of Science and Technology, Vol. 8, No. 4, 2015 ; pp. 216-219 [3] Mahmood Alam, Dr. Shahnawaz Alam and Kamran Rasheed; Study And Empirical Modeling Relating Welding Parameters And Tensile Strength of Hot Air Welded PVC Plastic; IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 2 Issue 2, February 2015.

[4] Schwartz M.M., joining of composite matrix materials, ASM International, chapter 2, 35-87 1994 [5] MarczisB., CziganyT,PerodicaPolythechnica ser. Mech.

Eng,(46/2)117-126, 2002 [6] Stokes,V.K.,Joining methods for plastics and plastics composites, An overview, polymer engineering and science (29/19)1989, 1310-1324

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