an experimental study to evaluate the mechanical ...no.5(2020)/146-160.pdfrefrigerated lorries at...

Journal of Mechanical Engineering Research and Developments

ISSN: 1024-1752

CODEN: JERDFO

Vol. 43, No. 5, pp. 146-160

Published Year 2020W

146

An Experimental Study to Evaluate the Mechanical Properties and

Durability of Frozen Car Body Walls Using Composite Polyester -

Fiberglass with Sandwich Structure

Minh Quang Chau*, Cao Nguyen Khang Chau, Xuan Khoa Huynh

Industrial University of Ho Chi Minh City, Ho Chi Minh City, Vietnam

*Corresponding Author Email: [email protected]

ABSTRACT: This paper focuses on presenting the results obtained from theoretical calculations, practical tests,

and simulations. The calculations using mathematical models have been published in related documents. The

process is performed according to this sequence: structures analyzing, selecting mathematical models, and

proceeding with Matlab software. Verifying studies are conducted by experimental methods of the above

factors. Random sampling, testing, empirical analysis of results. Mechanical behavior including bending,

tension, and bending deformation of the wall structure is achieved through simulation. The results obtained

show a good correlation between the calculated and determined by experiment and simulation. Specifically, the

wall strength parameters of tensile stresses are 93.05 MPa for calculation and 99.73 MPa for experiments,

similar, the elastic modulus is 1769.4 MPa and 2830.33 MPa, respectively. The compressive stress is 2.54 MPa

and the bending strain obtained from the calculation is 19.51mm. In this paper, the author has calculated the

tensile stress σk, compressive stress σn, elastic modulus E, and bending strain ∆. At the same time, the general

formula for such factors is also given to help enterprises be more flexible in changing and modifying

components to suit the requirements of the given durability.

KEYWORDS: Composite polyester, frozen car, the durability of walls, fiberglass, sandwich structure

INTRODUCTION

The demand for refrigerated trucks is rising. Vietnam is currently a potential market for trucks in general and

refrigerated vehicles in particular. Importers seek to bring brand new refrigerated vehicles to Vietnam from

South Korea and China but prices are too high. In response to the localization policy of transport industry

products, domestic companies such as Quyen Auto, Thaco, Tuong Huy Pacific Isotherms...focus on producing

refrigerated lorries at more affordable prices. To have a standard refrigerated lorry, the traditional materials are

expensive, the weight is heavy, so the sandwich composite material is the best choice [1].

Composite materials are made of two or more different materials, creating new materials with superior

properties compared to the original materials when they work separately. Most composite materials are

combined by the metal, ceramic and polymer [2]. However, today people are interested in synthetic composites.

The most common are reinforced materials made of fiberglass, epoxy, or polyester. Fiberglass-reinforced

composites are not durable, flexible, or hardened with carbon fiber-reinforced composites but on another hand,

fiberglass-reinforced composites are cheaper [3][4].

Composite materials are divided into four main groups, including particle-reinforced composite, fiber-reinforced

composite, structural composite, and nano-type composite. Particle-reinforced composite materials have a

uniform dispersion phase [5], fiber-reinforced composite materials depend on the length and fiber arrangement,

while structural composite is multi-panel, a multi-layer form made by combining itself according to different

structural options [6]. Particularly, the nanocomposite materials have the dispersion phases at the nanometer

level. This project focused on the composite layer structure materials (sandwich) and panels. Composite

reinforced by continuous and discontinuous fiberglass on polyester substrates [7]. Continuous fiberglass is

Woven roving, while discontinuous fiberglass is chopped. Both types of fiberglass are E-glass types [8].

The use of composite materials with the layered structure is increasing in both civil and industrials. Nowadays,

composite materials are no longer exclusive to some countries but have grown widely. Lui et al. [9] studied the

dynamic performance of Sandwich of beams with lattice core. Experimental results of the different core

mailto:[email protected]

An Experimental Study to Evaluate the Mechanical Properties and Durability of Frozen Car Body Walls Using Composite Polyester -


147

structures are under the same impact of water pressure; the core has a Y-shaped structure withstand higher

forces [10]. Rizk et al.[11] studied Sandwich's structure in wind turbine blades. This study introduced the

transition from using conventional materials to using composite structures with layer structure to increase length

and reduce weight. Jishi et al. [12] conducted a studying model to determine the deformation when applied by

external forces to trucks made of composite materials [13]. The results show the change of deviation of the

surface layer and core in the radial direction at four different times (0.2ms, 0.4ms, 0.6ms, and 0.8ms). Wang et

al. [14] conducted empirical research to determine the parameters of softcore in the sandwich composite. With

the 4-point force method as shown below, the panel is subjected to a certain limit and gradually destroyed. In

general, the studies focus on composite panels with a honeycomb core, strong ribs in the form of hexagons or

triangles, or homogeneous soft cores. Studies are mainly done on Divinycell H100 or E-Glass / Vinyl Ester

materials [15]. However, studies on Polyester - fiberglass materials with composite panel structure (sandwich

panel) with the core of PU foam, reinforced by ribs connected with the distance between the ribs is 300 mm are

not much, especially with the application of these materials to the improvement of the mechanical properties and

durability of refrigerant truck container structures.

Vietnam is a dynamic market for the development of refrigerated trucks made of composite materials, but no

one has calculated the durability for this material and the product was tested only. The fact that each product

must be tested before sold is very detrimental in modern business times. In a time of market economy, the

sooner the product goes to market, the more advantages it takes [16]. Therefore, the product takes two months to

wait for results, in addition to losing the competition, it also wastes storage, wasting waiting time [17]. Polyester

- fiberglass composites with layered structure have been widely used in the automotive and aerospace industries

[18][19]. The application of polyester-fiberglass composite materials to the manufacture of the refrigerated truck

body is a big challenge in terms of durability, but if it can be solved, the benefit of greatly reduced truck weight

and enhances the ability to retain heat due to the core made from PU foam [20].

In this paper, the authors focus on the study of the refrigerated trunk wall with a body wall of 45mm or more in

thickness and ribbed links, arranged in parallel, Z-shaped, Z-shaped heads and feet linked in turn to the surface

layer and the bottom layer, separated by a distance equal to 300mm. The sandwich structure of the frozen car

body walls, together with its components (surface layer, ribs), are made of Polyester-based composite material,

reinforced with fiberglass. Combining simulation and empirical research to evaluate the mechanical properties

of the walls of refrigerated vehicles (tensile stress (σk), compressive stress (σn), compression modulus (E), and

the bending strain (Δ) of the panel in laboratory conditions).

MATERIALS AND METHODOLOGY

Experimental process

Samples fabrication

Because the ribbed panel is arranged parallel and 300mm apart, the sampling will only take place where the ribs

are interlinked, and the tendon will run along with the test piece, creating an I form samples. The number of

samples for each test is 08 samples.

Jigs Manufacturing

To perform the bending test, firstly, apart from the machine, the jig is an indispensable part. Figure 1 shows an

axonometric view drawing of the jig.

The Bending Test Process

The steps to be taken include: Using a dimension gauge to ensure that the sample is manufactured to the

standard; Record the sample sizes, as well as the spacing of supports; Set the test speed; Provide compressive

force until the test specimen is destroyed; Record the resulting compression force corresponding to the

displacement, the compressive force corresponding to the deformation, respectively; The measuring instrument

is an Insize caliper, the tolerance is 0.02mm.

With the implementation of sample testing steps by ASTM D638-02a, the LLOYD LR30K tensile testing

machine [21]. The sample size data is measured by an Insize caliper with an accuracy of up to 0.02mm. Traction

speed set at 5mm/minute. During the sample drag, the Max load [N], Break load [N], Max Ext. [mm], Slope

[N/mm] are the results automatically recorded and displayed on the screen.



148

From the above parameters, strength σ and elastic module E will be calculated as follows:

][MPaA

F=

(1)

Accordingly, on the screen of the testing machine are: σ is Strength, F is Max load, A is the cross-sectional area

of the test piece and is equal to Thickness x Width of the product.

The modulus of elasticity of an object is determined by the slope of the stress-strain curve in the region of

elastic strain.

][MPaA

lSlopeE

=

(2)

Where A is the cross-sectional area of the test piece (l x w). The slope is the slope of the stress-strain curve in an

area of elastic strain.

Figure 1. The bending jig drawing

Simulation process

To meet the requirements set out from the beginning of the topic, a simulation of the behavior of the product

under force is necessary. Ansys APDL 15.0 software was used to simulate the bending of the panel to describe

the process and behavior of the test piece.

Simulation process of dragging the component layers of panel

To perform the simulation, we firstly declare the reference by selecting Structural in the Preference and Element

Type sections in the Preprocessor in Figure 2 and Figure 3.



149

Figure 2. Declaration of references

Figure 3. Select the type of detail

Then, declare the properties of the material as shown in Figure 4. With the elastic surface modulus is Efc =

1769.4 [MPa] and the Poisson factor is νfc = 0.35. After declaring the material, draw the geometric structure of

the cross-section of the test piece in sections as shown in Figure 5, draw the test piece in the modeling section.

Next, continue meshing for the simulation object as shown in Figure 6.



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Figure 4. Material definition

Figure 5. The shape of the test piece



151

Figure 6. Meshing the test sample

Enter the pulling force obtained from the equation Ffc_pull = σ × A = σfc_pull × b × t, where A, b and t are the area,

width, and thickness of the sample, respectively; σfc_pull is the surface tensile stress; dragging in the direction Ox,

the direction towards the machine. At the same time, we have to fix one end of the sample by selecting ►

structural ►displacement, choosing on keypoint. To solve the problem with the parameters entered, select

solve► current LS ► then select the Ok button to appear in the window as shown in Figure 7. To get the

problem results as well as the necessary data, the result type display need to be selected. Figure 8 is the result of

pulling a composite surface test specimen 3mm thick, 13mm wide, and 50mm long. The stretching display on

the computer is 2.28mm.

Figure 7. Solving the problem with parameters defined



152

RESULTS AND DISCUSSION

Analyzing and processing experimental data

The experimental test results are summarized in Table 1. The table consists of three types of samples that have

tried are surfacing, surfacing with tendon and tendon layer. In the surfacing layer type, there are three sets of

samples, each consisting of five randomly cut pieces from the finished plate and standardized measurement [22].

The surfacing with the tendon layer is the same. Particularly, the tendon layer has only one sample set.

Table 1. Tensile test results data

* Measuring equipment: Lloyd LR 30K. The test piece is 50mm long

Test

piece

name

No.

Thick

-ness

(mm)

Wide

(mm)

Max

Load (N)

Slope

(N/mm)

Strength

(Mpa)

Modulus

(MPa)

TB

Strength

(MPa)

TB

Modulus

(MPa)

Surface

layers

MTN-

1 2.5 13.4 3695.0 1910.0 118.9 2211.1

100.53 2809.09

MTN-

2 2.6 13.7 3623.0 2878.0 108.8 4310.6

MTN-

3 2.5 13.3 3417.0 1867.0 110.6 3027.0

MTN-

4 2.5 13.5 3456.0 1958.0 112.6 3211.5

MTN-

5 2.5 13.4 3424.0 1825.0 110.1 2929.1

MTL-4 2.1 12.7 3333.0 1142.0 125.2 2153.1

MTL-1 2.5 12.7 3061.0 1719.0 105.7 2941.0

MTL-3 2.5 12.9 3945.0 2203.0 132.8 3713.6

MTL-5 2.6 13.0 3118.0 1867.0 99.8 3013.4

MTL-2 2.5 13.1 3396.0 1811.0 105.5 2787.2

MTL-6 2.5 13.4 2637.0 2013.0 78.3 2964.7

MTL-9 3.3 12.9 3845.0 2187.0 93.1 2651.1

MTL-

11 3.3 13.3 2880.0 1678.0 67.1 1947.8

MTL-

10 3.5 12.9 3428.0 2213.0 77.5 2481.9

MTL-

12 3.6 13.4 2879.0 2116.0 59.9 2172.2

MTL-7 3.6 12.7 4138.0 1747.0 90.0 1900.1

MTL-8 3.9 12.9 5681.0 2485.0 111.7 2442.6

Surface

layers -

tendon

linking

MXL-

1 2.6 12.8 3002.0 1917.0 98.5 3119.9

88.25 2631.54

MXL-

2 2.8 12.6 4193.0 2425.0 118.8 3412.6

MXL-

3 2.6 13.1 3997.0 2046.0 117.2 3003.6

MXL-

4 2.6 13.0 5174.0 2237.0 151.4 3278.5

MXL-

5 2.6 13.2 3080.0 1821.0 91.6 2714.0

MXL-

6 2.7 13.1 4814.0 1957.0 136.5 2807.5

MXL-

7 4.2 12.8 2727.0 2269.0 50.7 2128.2

MXL-

8 3.7 12.5 2567.0 2454.0 55.0 2626.3

MXL- 3.7 13.8 2547.0 1985.0 50.6 1963.3



153

9

MXL-

10 3.6 13.7 3273.0 2351.0 66.8 2389.2

MXL-

11 3.5 12.8 2974.0 2442.0 67.2 2745.4

MX-1 3.6 12.8 3735.0 2505.0 83.7 2817.8

MX-2 3.6 13.4 4248.0 2234.0 90.7 2378.4

MX-3 3.6 12.5 2904.0 1932.0 72.5 2417.7

MX-4 3.6 13.3 3525.0 2272.0 75.5 2423.8

MX-5 3.6 13.2 4110.0 1434.0 91.9 1615.6

Tendon

linking

layers

Ga1 1.6 13.0 1795.0 1013.0 87.3 2466.7

84.31 2851.25 Ga2 1.9 13.1 1742.0 1234.0 76.9 2719.0

Ga3 1.9 12.8 1765.0 1185.0 85.7 2842.2

Ga4 1.6 13.2 1708.0 1072.0 87.8 2748.6

Through observing each data in Table 1, we see that the values in the second sample set including MXL-7,

MXL-8, MXL-9, MXL-10, MXL-11 of ribbed surface associated with the max load value are 2727; 2567; 2547;

3273; 2974, respectively. These values are relatively uniform but lower than the other two sets of samples. This

could be because the material used in the sample is less or less qualified, or it may also be caused by a non-

standard cut. The simplest way to test a sample is to observe the fracture of the sample after the test. After

verifying the accuracy of the empirical data, the results obtained are shown in Table 2.

Table 2. Data after verification of data accuracy

* Measuring equipment: Lloyd LR 30K. The test piece is 50mm long

Test

piece

name

No.

Thick

-ness

(mm)

Wide

(mm)

Max

Load (N)

Slope

(N/mm)

Strength

(MPa)

Modulu

s (MPa)

TB

Strengt

h (MPa)

TB

Modulu

s (MPa)

Surface

layers -

tendon

linking

MXL-

1 2.6 12.8 3002.0 1907.0 98.5 3129.9

102.57 2730.86

MXL-

2 2.8 12.6 4193.0 2415.0 118.8 3422.6

MXL-

3 2.6 13.1 3997.0 2056.0 117.2 3013.6

MXL-

4 2.6 13.0 5174.0 2247.0 151.4 3288.5

MXL-

5 2.6 13.2 3080.0 1831.0 91.6 2724.0

MXL-

6 2.7 13.1 4814.0 1987.0 136.5 2817.5

MX-1 3.5 12.8 3735.0 2506.0 83.7 2807.8

MX-2 3.5 13.4 4248.0 2237.0 90.7 2388.4

MX-3 3.3 12.5 2904.0 1934.0 72.5 2407.7

MX-4 3.5 13.3 3525.0 2272.0 75.5 2433.8

MX-5 3.4 13.2 4110.0 1436.0 91.9 1605.6

As shown in Table 1, the Max load value of the white surface test result is not uniform. Uneven test results are

due to many different reasons. These may include machines, people, methods, materials, environments, and

measuring instruments. Therefore, it is necessary to screen the results after sample testing. To refine the results,

we use the method of eliminating errors in experimental planning. Today, there is much statistical software

support but in this study, we use Statgraphics software. The surface layer has all 17 sets of data, input the max

load value into the software, choosing the 95% confidence level using the variance analysis function. Results

after screening are shown in Table 3, Table 4, and Table 5.

Table 3. Data of surface layer after screening with 95% confidence

* Measuring equipment: Lloyd LR 30K.



154

Test

piece

name

No.

Thick-

ness

(mm)

Wide

(mm)

Max

Load

(N)

Max

Ext.

(mm)

Slope

(N/mm

)

Streng

th

(MPa)

Modul

us

(MPa)

TB

Streng

th

(MPa)

TB

Modulu

s (MPa)

Surface

layer

sample

MTN-1 2.52 13.40 3695.00 2.52 1810.0

0 118.86

2911.0

9

99.84 2730.45

MTN-2 2.64 13.65 3623.00 2.57 2898.0

0 108.78

4350.5

7

MTN-3 2.52 13.32 3417.00 2.75 1877.0

0 110.57

3036.9

8

MTN-4 2.27 13.54 3456.00 2.61 1968.0

0 112.64

3201.4

8

MTN-5 2.52 13.41 3424.00 2.71 1835.0

0 110.06

2949.1

0

MTL-4 2.10 12.68 3333.00 2.94 1152.0

0 125.17

2163.1

4

MTL-1 2.28 12.70 3061.00 2.52 1709.0

0 105.71

2951.0

3

MTL-3 2.50 12.92 3945.00 2.67 2213.0

0 132.76

3723.5

8

MTL-5 2.60 13.02 3118.00 2.56 1877.0

0 99.78

3003.3

9

MTL-2 2.65 13.14 3396.00 2.67 1801.0

0 105.49

2797.1

9

MTL-6 2.5 13.4 2637 1.7 2003.0 78.3 2974.7

MTL-7 3.6 12.7 4138.0 4.2 1757.0 90.0 1910.1

MTL-9 3.21 12.86 3845.00 3.63 2197.0

0 93.14

2661.0

6

MTL-11 3.22 13.32 2880.00 2.82 1688.0

0 67.15

1967.8

1

MTL-10 3.44 12.85 3428.00 3.01 2203.0

0 77.55

2491.9

6

MTL-12 3.59 13.38 2879.00 2.69 2106.0

0 59.94

2192.1

9

Average 2.6 99.73

2830.3

3

Table 4. Data of green surface layer - associated tendon after screening with 95% confidence


Test

piece

name

No.

Thick

-ness

(mm)

Wide

(mm)

Max

Load

(N)

Max

Ext.

(mm)

Slope

(N/mm)

Strength

(MPa)

Modulu

s (MPa)

TB

Strengt

h (MPa)

TB

Modulu

s (MPa)

Surface

layers -

tendon

linking

MXL-

1 2.58 12.80

3002.0

0 2.28

1907.0

0 98.54 3129.92

102.57 2730.86

MXL-

2 2.80 12.60

4193.0

0 2.27

2415.0

0 118.85 3422.62

MXL-

3 2.60 13.12

3997.0

0 2.70

2056.0

0 117.17 3013.60

MXL-

4 2.62 13.04

5174.0

0 3.17

2247.0

0 151.44 3288.47

MXL-

5 2.55 13.18

3080.0

0 2.60

1831.0

0 91.64 2723.97



155

MXL-

6 2.70 13.06

4814.0

0 3.01

1987.0

0 136.52 2817.48

MX-1 3.50 12.75 3735.0

0 2.06

2506.0

0 83.70 2807.84

MX-2 3.50 13.38 4248.0

0 1.75

2237.0

0 90.71 2388.43

MX-3 3.26 12.52 2904.0

0 2.65

1934.0

0 72.50 2407.68

MX-4 3.52 13.26 3525.0

0 2.68

2272.0

0 75.52 2433.84

MX-5 3.38 13.23 4110.0

0 3.48

1436.0

0 91.91 1605.64

Averag

e 3.0 102.57 2730.86

Table 5. Data linking rib samples after screening with 95% confidence


Test

piece

name

No.

Thick

-ness

(mm)

Wide

(mm)

Max

Load

(N)

Max

Ext.

(mm)

Slope

(N/mm

)

Strengt

h

(MPa)

Modulu

s (MPa)

TB

Strengt

h (MPa)

TB

Modulu

s (MPa)

Tendon

linking

layers

Ga1 1.7 13.0 1845.0 2.9 1119.0 87.3 2476.7

84.8 2711.95 Ga2 1.8 13.1 1792.0 2.6 1266.0 76.9 2729.0

Ga3 1.7 12.8 1815.0 2.5 1217.0 85.7 2882.2

Ga4 1.6 13.2 1818.0 2.2 1133.0 87.8 2758.6

Averag

e 1.6 84.4 2711.6

Analyzing and processing simulation data

The simulation results of the panel layers' stretching process are elongation along the x-axis, they are shown in

Figure 8. Similarly, the simulation results of the plate bending process Width Height Length (b h S) = 75

85 560 is shown in Figure 9.

The core has better tensile strength than compression due to the tendon bond having higher tensile strength than

compression. This tensile force varies with the thickness of the test piece due to changes in the bending force.

Thus, if the thickness of the panel increased without changing the core properties (increasing the thickness of

the tendon or increasing the number of tendons per unit area), the risk of destroying the core will increase. This

vertical tensile stress of the panel changes inversely with the thickness of the panel. That is, when the plate is

thicker, the tensile stress will decrease because of the surface-layer properties, the core layer does not change,

while the cross-sectional area changes.



156

Figure 8. Simulation results of surface layer elongation, where the tendon is connected

Figure 9. Simulation results of panel bending process (bxSxh) 75x560x85

Assessing the impact of the components

The impact of the components on the surface layer properties

If the components are changed, the elastic modulus will change accordingly. If the weight limit of Mat-type

fiberglass in one square meter is from 0 kg/m2 to 1 kg/m2, the limit of Woven roving fiberglass is from 0 kg/ m2

to 1 kg/m2 and the ratio of polyester compared with the fiberglass from 1.0 to 3.0 times, the result of the elastic

modulus is affected and is shown in Figure 10.



157

Figure 10. Analyzing the influence of components on the elastic modulus

Figure 10. The role of the components on the modulus of elasticity

As the ratio of Mat fiberglass, Polyester ratio increases, the value of elastic modulus decreases, while the role of

Woven fiberglass is the opposite. When increasing the proportion of Woven roving type fiberglass, the value of

elastic modulus increases accordingly. Thus, the role of Woven roving fiberglass form to elastic modulus is

greatest. Figure 10 also shows that a combination of different components will have different impact results.

The value of elastic modulus also depends on the combination of Woven roving fiberglass and Mat-type

fiberglass. When changing these two components, the elastic modulus value is quickly affected. Next is

polyester. As shown in Figure 10, if we want to increase or decrease the elastic modulus of the material, we

should impact on the composition of Woven roving fiberglass or polyester component.

Impact of ingredients on the elastic modulus of the surface layer

Thus, the largest elastic modulus value of Efc when Woven roving fiberglass is the highest ratio, and the

proportion of Mat type fiberglass has the lowest impact.



158

Figure 11. The maximum elasticity modulus of Efc when the Polyester ratio is 1.5 times

Figure12. Value of the largest elastic modulus Efc when the ratio of Polyester is 2 times

CONCLUSIONS

The study solved issues including determination of tensile stress σk, compressive stress σn, elastic modulus E,

and bending strain ∆. At the same time, the experimental results to verify the calculated results. Experimental

data shows that the maximum difference is 6.7% for surface tension, including Mat + Woven roving + Mat,

6.68% for surface tension, including Mat + Woven roving + Mat + Ribs and 0.27% for the tension of Woven

roving layer (ribbed).

• Building a model to simulate the tensile and bending process for specific components of the wall panel, the

result is the deformation behavior and displacement parameters of deflection of 20.11 mm and tensile stress

σk = 95.37 MPa.

• Optimized research for components including Woven roving fiberglass, Mat, and Polyester to the elastic

modulus. The results showed that the value of Elastic Modulus was highest when the Polyester - Mat -

Woven roving ratio was 1.5 - 0 - 0.8.

The practical meaning of the topic is:

• Applying calculation research results in production, helping enterprises be more flexible in changing and

modifying components to meet the requirements of given durability.



159

• The calculation and simulation help to identify and predict the parameters and behavior of materials and

structures.

• Minimize testing costs.

• Identify appropriate structural parameters for specific products according to customer requirements. From

there, building a model of product quality management, calculating quality costs, optimizing product

quality.

• To facilitate the process of calculating and setting up tools and formulas in excel format, when workers

need to enter the necessary parameters, the results will be faster, easier to apply.

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