Int. J. Materials and Product Technology, Vol. 60, No.

1, 2020 73

Study on mechanical properties of fabricated hybrid

natural fibre polymeric composites

Rajendra Kumar
Mechanical Engineering Department,
Government Polytechnic, Firozabad,
Uttar Pradesh, India
Email: [email protected]

Ravi Pratap Singh*

Department of Industrial and Production Engineering,
Dr. B.R. Ambedkar National Institute of Technology,
Jalandhar, Punjab, India
Email: [email protected]
Email: [email protected]
*Corresponding author

Ravinder Kataria
School of Mechanical Engineering,
Lovely Professional University,
Jalandhar, Punjab, India
Email: [email protected]

Abstract: In the current work, an effort has been made to fabricate the natural
fibre hybrid polymeric composites using two natural fibres, i.e., shisham wood
powder, and rice husk. The injection moulding process is employed to fabricate
the different three polymer composites by varying the and fibre size, and fibre
weight %. These three fabricated composites have been named as; hybrid-filler
polypropylene composites which are separately containing wood powder and
talc, rice husk powder and talc, and a mixture of wood powder, rice husk
powder and talc. These fabricated specimens are further tested for their tensile,
flexural, and impact properties. The experimental results have revealed that the
fabricated polymeric composites can successfully be employed to produce
stable and strong hybrid polymeric composites for their further industrial
applications. The microstructure study of the tested samples has also been
undertaken to study the behaviour of the material.

Keywords: composites; husk; hybrid; microstructure; moulding; natural fibres;

rice husk; wood.

Reference to this paper should be made as follows: Kumar, R., Singh, R.P. and
Kataria, R. (2020) ‘Study on mechanical properties of fabricated hybrid natural
fibre polymeric composites’, Int. J. Materials and Product Technology,
Vol. 60, No. 1, pp.73–91.

Copyright © 2020 Inderscience Enterprises Ltd.

74 R. Kumar et al.

Biographical notes: Rajendra Kumar is currently working as a Lecturer in the

Department of Mechanical Engineering, Government Polytechnic, Firozabad,
India. He obtained his PhD in the area of ‘Polymeric Composite Fabrication’
from the Department of Mechanical Engineering, I.K. Gujral P.T.U. Jalandhar,
Punjab, India. His areas of research are as follows; polymers, composites,
optimisation methods, and micro-structure analysis. He has published several
research articles in different journals and national/international level
conferences.

Ravi Pratap Singh is an Assistant Professor in the Department of Industrial and

Production Engineering at Dr. B.R. Ambedkar National Institute of
Technology, Jalandhar, Punjab, India. His broad areas of research are as
follows: advanced machining methods, rotary ultrasonic machining, ceramics,
and composites. He has published about 35 research articles throughout the
several SCI/Scopus indexed journal, including national/international level
conferences. Currently, there are two masters and three doctoral research works
going on under his supervision. He is also a life member of IIIE, Mumbai, and
SCIEI, LA, USA. He has awarded as a Young Scientist in Mechanical
Engineering in VIRA-2019 awards.

Ravinder Kataria is working as an Associate Professor in the School of

Mechanical Engineering at the Lovely Professional University, Phagwara,
Punjab, India. He obtained his PhD in the area of Ultrasonic Machining from
the Department of Mechanical Engineering, National Institute of Technology,
Kurukshetra (Haryana), India. He received his BTech in Mechanical
Engineering from the Kurukshetra University, Kurukshetra (Haryana) and
MTech in Mechanical Engineering (Industrial and Production Engineering)
from the National Institute of Technology, Kurukshetra (Haryana), India. His
areas of research include non-traditional machining, composite materials,
ultrasonic machining and conventional machining. He is also academically
engaged with the editorship and reviewer ship with the several SCI/Scopus
indexed journals from last 4–5 years.

1 Introduction

The word called as – ‘composite’ is not a new term to us. The composite material is the
mixture of two dissimilar materials to meet certain properties from each material on these
own base material. The mechanical characteristics of composites differ according to the
combination of matrix and reinforced material used (Fahim et al., 2012). The natural
fibres are usually employed as reinforcement for polymer materials, which have also
added great value to the field of automotive industries (Bax and Mussig, 2008).
Environmental, social, and economic benefits to design ‘green’ automotive elements are
major benefits of such composites (Zhun et al., 2013; Alves et al., 2010; Biswas, 2010;
Saheb and Jog, 1997; Schut, 1999).
Agricultural and biomass-based composites products are eco-friendly and these
composite-based products reduce greenhouse gas emission in the comparison of
petroleum-based materials (Vaisanen et al., 2017; Maldas et al., 1988; Venkateshwaran
et al., 2012; Wambua et al., 2003). Polypropylene (PP) material is well known for its
high-temperature sustainable working and finer tensile strength (Qui et al., 2000).
 Study on mechanical properties 75

With a view to create a balance among the environmental awareness, characteristics

of the green composites, cost-effectiveness, and compositional assortment and design of
hybrid composites perform significant role (Najafi, 2013; Zhun et al., 2013). Hybrid
composites materials provide high tensile strength and impact resistance properties
(Navas et al., 2015; Leong et al., 2004). Jawaid et al. (2011) studied the hybrid
nano-composites with PP/clay/wood flour by melting compounding was prepared and
mechanical properties investigated. The mechanical and thermal properties of wood flour
and talc-filled polylactic acid composite were also investigated successfully. The talc
powder has been added to the composite for the purpose to provide high thermal stability
and stiffness (Jawaid et al., 2013). There is a good improvement in the mechanical
properties of hybrid (wood flour/talc PP) composites (Atiqah et al., 2014; Sapuan et al.,
2003). Studies have reported that the improvement in mechanical properties depends on
the fibre loading, the particle size of the fibre, volume fraction, and the chemical structure
of the coupling agents (Nunna et al., 2012; Yahaya et al., 2016; Yu et al., 2016; Lee et al.,
2008; Singh et al., 2018). Hybrid composite using banana/sisal fibres and thermosetting
resin have been reported to be prepared experimentally, and the tensile strength, and its
modulus have been observed to be in good agreement (Singh and Singhal, 2016a, 2016b,
2016c; Singh et al., 2010; Adhikari et al., 2012).
With a view of above discussion, the current research study has been attempted to
fabricate and study the three kinds of natural fibre composites, namely hybrid-filler PP
composites [possessing wood powder (WP) and talc], hybrid-filler PP composites
[containing rice husk powder (RHP) and talc] and hybrid-filler PP composites [having of
a mixture of wood powder, rice husk powder (WPRHP) and talc]. The fabrication of
these said composites has been achieved by using injection moulding (IM) technique.
These fabricated specimens have also been tested for several mechanical properties. As
per the available detailed literature on the present work, it was observed that there have
been investigations reported to mostly study the effect of fibre sizes of very low order or
smaller (i.e., 0.15–0.70 mm). Therefore, in order to study the effect of medium and
bigger/larger ranged fibre sizes on the considered mechanical properties, in the present
research, it has been attempted to use the fibre sizes of 0.30 mm and 1.180 mm for the
fabrication of natural fibre polymer composites. The aim of the present study is to
investigate the tensile, flexural and impact properties of different developed composites
with the variation of fibre weight percentage and fibre size to find suitable composites.

2 Experimental work

2.1 Materials
PP pellets have been employed for the research study, as shown in Figure 1. The supplied
PP was having density as; 0.9 gm/cc and melt flow index as; 3.2 g/10 min. Filler
materials, WP (saw-dust), and rice husk were also collected those usually get wasted in
industries. The particle size of used WP and rice husk were ranged from 150 µm–4,750
µm (or, 0.150 mm–4.750 mm). The talc powder used for sample preparation is shown in
Figure 2.
76 R. Kumar et al.

2.2 Filler treatment

After collection of rice husk, it was kept in big plastic bags and then rice husk has been
prepared for the physical and chemical treatments. The physical handling of the rice husk
(as in Figure 3) was made by washing thoroughly tap water with 2–3 times and then keep
it drying for 24 hours in sunlight in June month at 40–45°C.

Figure 1 Polypropylene (see online version for colours)

Figure 2 Talc powder (see online version for colours)

Crushing machine was employed to crush the dried husk of rice, and further converted
into RHP, as shown Figure 4. WP is a saw-dust, i.e., the waste of saw mills and produce
abundantly in India (as in Figure 5). In the present research work, WP of shisham tree (as
a name is known in India) has been used.
Both fibre powders (WP and RHP) were washed separately by normal water for 3–4
times in order to remove dust and other excess materials. For the chemical handling, the
WP and powder of rice husk immersed distinctly in 6% NaOH solution (as in Figure 7)
for 12 hours. The treated fibres were washed by tap water directly through 3–4 times to
remove excess NaOH. After chemical treatment, WP and RHP powders were allowed to
 Study on mechanical properties 77

dry in an oven at 110°C for 24 hours for removing fully moisture content and then stored
in air tight containers separately with marking of fibre type and size.

Figure 3 Rice husk before crushing (see online version for colours)

Figure 4 Rice husk after crushed and treated (see online version for colours)

Figure 5 WP after treated (see online version for colours)

78 R. Kumar et al.

Based on the detailed literature work, two fibre sizes have been used for the fabrication
purpose in current work. For this persistence, the sieves analysis according to IS: 460-
1962 (as exemplified in Figure 6), has been conducted. Sieving is a simple and
convenient method of separating particles of different sizes. Sieves with distinct types of
holes were employed for the arrangement of WP and RHP fibre size. There are seven
different sieves are used for the separation of fibre size from the raw fibres. The
separation ranges from 150–4,750 µm of the sieve analysis is presented in Table 1.
Diameter ranges of both fibres 300 µm and 1,180 µm (0.3 mm and 1.18 mm) are used.

Figure 6 Sieving analysis machine (see online version for colours)

Figure 7 Fibre treatment in NaOH solution (see online version for colours)

Table 1 WP and RHP fibre size range after sieve analysis

WP and RHP fibre size range

Fibre size range in micrometer (mm)
4.75 3.35 2.36 1.18 0.60 0.30 0.15
 Study on mechanical properties 79

3 Composite sample preparation

3.1 Mixing and compounding

From Table 2, it is clear that the fibre loading is varied from 10, 20, 30 weight percentage
and talc powder 10 weight percentage is fixed for all composites samples while PP
proportion is varied from 80 to 60 wt. % accordingly for all composites to make one
hundred percent weight of composites composition for sample making. The three hybrid
composites that consists of, WP + talc + PP is called as; WPPP, RHP + talc + PP is called
as; RHPPP, and WP + RHP + talc + PP is called as; WPRHPPP composites. Without
using any reinforcing material, the first sample of PP is prepared for the comparison with
other fabricated composites properties.
The compounding is carried out with a twin screw extruder. The extruder barrel
temperature is varied in six zones from feeding to die zones (temp. ranges between 190 to
240°C). Compounds were blended at a screw speed of 50 rpm and melting pressure of the
extruder was fixed at 3 MPa. After the melting process, PP comes out through dyes. The
mixtures of fibre compositions were fed into the extruder through a hopper according to
composite formulations, as represented in Table 2. The twin extruder operating
conditions are illustrated in Table 3.
Table 2 Composite formulations for PP composites (percent by weight) with fibre size (µm)

Rice husk Talc Natural

Exp. Composite Wood powder PP wt.
powder content powder fibre size
no. sample code content wt. % %
wt. % wt. % (µm/mm)
1 PP100 0 0 0 100 0
2 WP10 10 0 10 80 300/0.3
3 WP20 20 0 10 70 300/0.3
4 WP30 30 0 10 60 300/0.3
5 RHP10 0 10 10 80 300/0.3
6 RHP20 0 20 10 70 300/0.3
7 RHP30 0 30 10 60 300/0.3
8 WP5RHP5 5 5 10 80 300/0.3
9 WP10RHP10 10 10 10 70 300/0.3
10 WP15RHP15 15 15 10 60 300/0.3
11 WP5RHP5 5 5 10 80 1,180/1.180
12 WP10RHP10 10 10 10 70 1,180/1.180
13 WP15RHP15 15 15 10 60 1,180/1.180

Table 3 Twin screw extruder operating conditions

Melting pressure (MPa) 3

Screw rotation speed (RPM) 50
Screw temperature (°C) 190, 200, 210, 220, 230, 240
80 R. Kumar et al.

The cutter machine was used to transformed the extruded product into pallet form, as
shown in Figure 8. The composite preparations are arranged as per the proportion of mass
in %, and the fibre size. Virgin PP pellets are first fed from the main feeding hopper at
the end of IM machine to fabricate PP specimens. The WPPP or RHPPP or WPRHPPP
pellets material is fed in 70–90 tonne electronic IM machine. All the injection parameters
are shown in Table 4. The coupling agent known as Silane (S-69) is added (1% by
weight) in the mixture for the purpose of good bonding of fibre in a PP matrix.

Figure 8 Compounding pallets of composites (see online version for colours)

Table 4 IM parameters

Injection pressure (MPa) 5

Screw rotation speed (RPM) 40
Cycle time (sec) 30
Nozzle temperature range (°C) 149, 171, 200, 240
Mould temperature (°C) 50

3.2 Testing of mechanical properties

The tensile and flexural properties have been measured using the universal testing
machine, (make: Instron, USA-3382), at a cross-head speed of 50 mm/min. Tensile
specimens (as reflected in Figure 9) with the dimensions of 68.20 × 12.70 × 3.18 mm3 is
moulded from the IM machine. The tensile tests have been performed in accordance with
standard ASTM D-638 employing a standard testing set-up, as shown in Figure 10. The
flexural specimens (as reflected in Figure 11) with dimension 50.00 × 12.40 × 3.30 mm3
are moulded from the IM machine. The tests for flexural characteristics were carried out
with a cross-head speed of 1.50 mm/min, as shown in Figure 12. The flexural properties
have been measured in three-point bending tests.
The impact test specimens of the developed composites and PP were prepared
through the cutting the half-length of the flexural testing specimen. The preparation of
impact test specimens with the dimensions of 25.00 × 12.40 × 3.30 mm3 has been carried
out. The notch over the sample to be tested was prepared very carefully to attain the
notch depth of 2.5 mm, and notch angle of 45°, by using the manual notch cutter, as
shown in Figure 13. The impact test with notched specimens is shown in Figure 14. The
 Study on mechanical properties 81

impact test was performed in the accordance of ASTM D-256 standard. The impact test
results are noted directly from the digital screen of Izod impact tester. For all the three
tests, experiments have been performed at ambient conditions and three specimens are
tested for each formulated polymer.

Figure 9 Tensile specimen before and after testing (see online version for colours)

Figure 10 Tensile testing loading arrangement (see online version for colours)
82 R. Kumar et al.

Figure 11 Flexural specimen before and after testing (see online version for colours)

Figure 12 Flexural testing arrangement (see online version for colours)

 Study on mechanical properties 83

Figure 13 V-Notch manual cutter (see online version for colours)

Figure 14 Impact specimens (see online version for colours)

4 Results and discussion

4.1 Tensile properties

All the obtained experimental results of hybrid filled PP composites for different
properties are presented in the Table 5. The tensile strength and tensile modulus of the
WPPP composite lie in the range of 32.39–36.48 MPa, and 950–1,022 MPa, respectively.
The variation of tensile strength and tensile modulus for different types of hybrid filled
PP (WPPP, RHPPP, and WPRHPPP) composites and the virgin PP has been represented
in Figure 15, and Figure 16, correspondingly.
It has been perceived that the tensile characteristics of the WPPP hybrid polymer
increased up to 10% of the volume fraction then gets decreased up to a certain limit and
then further gets increased (from 32.39 MPa to 33.21 MPa) as the volume fraction
increased. Higher wt. % (20% to 30%) which offers proper bonding in the fabricated
polymeric composites can be revealed as the reason for this attained improvement in
tensile properties. The tensile modulus for the WPPP hybrid composite, first gets
increased up to 20% volume fraction, then decreased (1,079 MPa to 1,022 MPa).
84 R. Kumar et al.

However, in case of RHPPP, and WPRHPPP hybrid polymers, it has been observed that
the tensile strength is very high up to 10 wt. % loading of fibres, but then started
decreasing with the increase in filler loading. It has also been revealed that, the little
decrement in tensile modulus with increasing of fibre size. The results of the tensile
properties for the hybrid composites have been observed as excellent (36.26 MPa and
1,204 MPa) as compared to the pure PP material (35.60 MPa and 550 MPa).

Figure 15 Tensile strength of the different type of composites (see online version for colours)

Figure 16 Tensile modulus of different type of composites (see online version for colours)

4.2 Flexural properties

For PP, the flexural strength and flexural modulus results have been attained as; 41.27
MPa, and 1,415 MPa, respectively (as reflected in Table 5). From Table 5, it can be
revealed that, for the WPPP composite, flexural strength and modulus get varied between
48.95–50.72 MPa, and 2,370–3,756 MPa, respectively.
 Study on mechanical properties 85

Table 5 Experimental obtained results of PP and developed PP-based composite

Tensile Tensile Flexural Flexural Impact

Exp. Material and
strength modulus strength modulus strength
no. compositions
(MPa) (MPa) (MPa) (MPa) (J/m)
1 PP100 35.60
2 WP10 36.48 950 48.95 2,370 15.78
3 WP20 32.39 1,079 50.72 3,221 18.67
4 WP30 33.21 1,022 50.40 3,756 17.09
5 RHP10 34.49 962 52.41 3,456 16.41
6 RHP20 32.20 985 48.12 2,289 19.37
7 RHP30 32.10 1,092 43.47 2,644 16.49
8 WP5RHP5 36.26 944 50.88 2,525 17.01
9 WP10RHP10 33.61 1,024 48.92 2,718 18.55
10 WP15RHP15 31.97 1,088 48.49 3,671 17.21
11 WP5RHP5 33.47 804 50.72 2,309 18.07
12 WP10RHP10 32.62 1,012 51.99 2,738 17.18
13 WP15RHP15 35.26 1,204 47.24 3,385 16.92

Figure 17 Flexural strength of the different type of composites (see online version for colours)

The variation of the flexural strength and flexural modulus for different types of hybrid
filled PP composites (WPPP, RHPPP, and WPRHPPP), and PP is exemplified in
Figure 17, and Figure 18, correspondingly. It is observed that the flexural strength of the
hybrid WPPP composite
(up to 20 wt. %) increased up to a certain limit then further gets negligibly decreased
(from 50.72 MPa to 50.40 MPa). The prepared WPPP samples with enhanced fibre
loading, has revealed to possess improved flexural strength. In addition, for the hybrid
WPRHPPP composite, the flexural strength revealed to get improved as filler size
incremented (up to 1,180 µm). While comparing between PP and the different developed
composites, for the later ones, the flexural strength is observed to be improved. However,
for the case of flexural modulus, it has been found that, for the hybrid WPPP composite,
86 R. Kumar et al.

with an intensification in the loading of fibres, the flexural modulus gets increased (from
2,370 MPa to 3,756 MPa), whereas for the hybrid RHPPP, it first gets decreased (from
3,456 MPa to 2,289 MPa) and then slightly gets increased (from 2,289 MPa to
2,644 MPa). For the hybrid WPRHPPP polymers, the flexural modulus gets augmented
(from 2,525 MPa to 3,671 MPa) with an improved loading of fibres. The flexural
characteristics have been reported to get improved for the hybrid WPRHPPP composite
as compared to the other fabricated hybrid composites.

Figure 18 Flexural modulus of different fabricated composites (see online version for colours)

Figure 19 Impact strength of several fabricated composites (see online version for colours)

4.3 Impact strength

Figure 19 is illustrating the comparative results obtained for the impact strength of
fabricated hybrid polymeric composites for the present work. The obtained result of
impact strength for PP is 21.7 J/m, however with the variation of fibre loading in the
WPPP composites, the impact strength lies in the range of 15.78–18.67 J/m. Similarly,
for the RHPPP composites, the impact strength reported to lie in the range of
16.41–19.37 J/m, however, for the WPRHPPP composite, it lies in the range of
 Study on mechanical properties 87

17.01–18.55 J/m. When the fibre size gets changed, i.e., 1,180 µm, the impact strength of
hybrid WPRHPPP composite has been observed to vary from 16.92–18.07 J/m. The
results demonstrate that, with the 20 wt. % loading of fibres, the impact strength of the
WPPP composite is getting increased and then decreased consecutively.
In addition to this, the impact strength of RHPPP composite is revealed to increase up
to 20 wt. % loading of fibres, and thereafter diminished significantly. It has been seen
that, with a rise in the filler loading weight %, the impact strength is improved for the
developed hybrid WPRHPPP composite. In comparison with the obtained results for
impact strength, the comparative performance of the hybrid filled PP composites with the
virgin PP composites has been revealed as not so superior as it has been observed in case
of flexural and tensile properties.

5 Microstructure analysis of tested samples

The microstructure analysis [with the aid of scanning electron microscopy (SEM)
analysis] of the tested pieces with impact and flexural testing has also been undertaken.
Figures 20 and 21 are depicting the micro SEM graphs of the work sample for
experiment number 7 at 1,000× and 3,000×, correspondingly after performing the impact
test.

Figure 20 SEM image after the impact test (exp. no. 7, at 1,000×) (see online version for colours)

The removal of a few larger portions from the workpiece is revealed from the images.
This sudden strike of the test hammer over the notch can be the valid reason for this
aspect (as reflected in Figure 21). The failure is the completely brittle type, and
microstructure images are also showing the sharp edges portions over the SEM images
which further confirm the brittle mode of failure. There is no plastic mode deformation of
the workpiece revealed form the microstructure.
Figures 22 and 23 are depicting the micro SEM image of the work sample
corresponding to experiment number 3 (at 100× and 3,000×), and experiment number 11
(at 1,000× and 2,000×), correspondingly, for the flexural test. The SEM images are
clearly exposing the bending behaviour of the material contents. The pattern followed by
88 R. Kumar et al.

the work grains has also been observed through these images. At some portion of the
tested samples, pull-out of the WP particles has been observed (as exemplified in Figure
22).

Figure 21 SEM image after the impact test (exp. no. 7, at 3,000×)

Figure 22 SEM images before and after the flexural test (exp. no. 3, at 100× and 3,000×)
(see online version for colours)

Figure 23 SEM images for the flexural test (exp. no. 11, at 1,000× and 2,000×)
(see online version for colours)
 Study on mechanical properties 89

Though, the organised sample for this trial has exposed to retain better flexural strength.
No presence of cavities has been observed at most of the SEM of top surface, between
the matrix particles and fillers (as shown in Figure 23) which demonstrate the decent
interfacial closeness between the materials.

6 Conclusions

The major inferences drawn from the present study as;

• The tensile strength gets improved for the hybrid filled PP composites (WP, and
RHP) as compared to the other developed hybrid filler PP composites. For the tensile
modulus of RHPPP and WPRHPPP composites, the tensile modulus get increased as
filler loading get improved. The small decrement in the tensile modulus (with an
increase in fibre size) has also been revealed from the experimental results.
• The flexural strength (for WPPP composites) has been observed to get first increased
up to 20 wt. % increased and then decreased. However, for the RHPPP, and
WPRHPPP composites, the flexural strength has revealed to get decreased with the
filler loading. At the same fibre loading, the flexural strength of WPRHPPP
composite is enhanced than for several distinct prepared samples. Therefore, it can
further be concluded that a fine improvement in flexural characteristics of the
developed hybrid polymers has been divulged than the virgin PP.
• The impact strength of the fabricated polymers has been found maximum at 20 wt. %
of the fibre loading. However, with the increment of fibre size, maximum impact
strength has been perceived at 10 wt. % loading of fibres. For all the conducted tests,
the hybrid WPRHPPP composites have reflected quite fine and resembling
properties to that of for the WPPP and RHPPP composites.
• The removal of a few larger portions from the work surface has been revealed from
the SEM micrographs for impact test. The failure is of completely brittle type, and
the microstructure images have shown the sharp edges portions over the SEM
images which further confirm the brittle mode of failure. The pull-out consequence
of fibre under the impact testing circumstances can be seen as the most possible
reason for these sharp regions. However, for the flexural test, very few cracks and
depleted edges regions have been revealed out from the microstructure images.

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