(Microsoft Word - 74- 83 \335\321\314 \343\315\341) Al-Khwarizmi Engineering Journal,Vol. 13, No. 1, P.P. Mechanical Properties Investigation Different Parameters Variations Department of Electromechanical (Received 30 May 2016; accepted 7 September 2016) https://doi.org/10.22153/kej.2017.09.001 Abstract The main objective of this research is to light unman air vehicle (UAV). The mechanical properties, weight and cost are the basis criteria of fiber volume fraction, fillers and type of fiber selection. Finite element method was used to investigate the stress distribution on addition to estimate the maximum stress. An experiments plan has been designed to get the data on the basis of Taguchi technique. The most effective parameters at noise ratio (S/N), main effect and analysis predicted results are very close. It was found that t followed by filler content and then the fiber volume fraction roving + unidirectional carbon) fiber, 7.5% good mechanical properties, high safety factor, acceptable cost, and offers weight savings on average by 40% percent as compared to aluminum alloy. Keywords: Mechanical properties, composite material, 1. Introduction In aero engineering applications, the to weight ratio and cost are the main factor influence the selection of material [1,2]. Composite materials are well known excellent combination of high structural stiffness and low weight [3,4]. Nowadays, the vehicle (UAV) air frame use 70% composite materials. Whereas Boeing 787 composite materials in airframe and primary structure. This approach offers weight savings compared with the conventional aluminum designs [5]. Composites material are composed of fibers and matrix. The main source of strength and reinforcement is fibers, while matrix hold the fibers together in shape with the of stresses transfer between the fibers prevent formation of new surface flaws and Khwarizmi Engineering Journal,Vol. 13, No. 1, P.P. 74- 83 (2017) Properties Investigation of Composite Material Under Different Parameters Variations Farag M. Mohammed Electromechanical Engineering/ Universityof Technology Email: drfaragmahel@yahoo.com (Received 30 May 2016; accepted 7 September 2016) https://doi.org/10.22153/kej.2017.09.001 is to design and select a composite plate to be used in fabricating The mechanical properties, weight and cost are the basis criteria of fiber volume fraction, fillers and type of fiber with three levels for each were considered to optimize the composite plate inite element method was used to investigate the stress distribution on the wing at cruise An experiments plan has been designed to get the data on the basis of Taguchi at the process to be find out by employing L9 (3 3 ) orthogonal array nalysis of variance (ANOVA). The results show that, the experimental was found that the type of fiber is the most effective parameter on the plate selection fiber volume fraction. The best parameters combinations are 7.5% graphite filler and 30% fiber volume fraction). This combination provides , high safety factor, acceptable cost, and offers weight savings on average by 40% percent as echanical properties, composite material, polyester, Taguchi technique. s, the strength the main factors influence the selection of material [1,2]. Composite materials are well known for their combination of high structural stiffness he unman air vehicle (UAV) air frame use 70% composite Boeing 787 use 50% composite materials in airframe and primary offers weight savings as conventional aluminum are composed of he main source of strength matrix make with the ability between the fibers [6]. Matrix of new surface flaws and abrasion by isolates the fibers from one another able to deform under applied load stress [7]. Matrix holds fibers required shape, but the fibers improves mechanical properties. Qahtan [8 physical and mechanical properties of materials polymer matrix with10% weight fraction. It is found that, the fraction effects on the properties of composite materials. Monika et al [9] had result presents that the failure of the tension specimens happens at the ends of section and the curved region begins Whereas, Farag and Drai [10], mechanical and tribological behavior of glass polyester composite system under the effect graphite filler contents. It was found graphite filler content increases Al-Khwarizmi Engineering Journal Composite Material Under in fabricating wing skins of The mechanical properties, weight and cost are the basis criteria of this selection. The to optimize the composite plate at cruise flight condition in An experiments plan has been designed to get the data on the basis of Taguchi orthogonal array, signal to he experimental and the on the plate selection, parameters combinations are ((E-glass woven . This combination provides , high safety factor, acceptable cost, and offers weight savings on average by 40% percent as abrasion by isolates the fibers from one another, able to deform under applied load and distributive fibers to maintain the improves the matrix 8] investigated the physical and mechanical properties of composite materials polymer matrix with10% weight the particle volume properties of composite had an experimental the failure of the tension ends of straight gage region begins transition. demonstrated the mechanical and tribological behavior of glass- under the effect of was found that with the increases up to 7.5%. The Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 75 mechanical and tribological properties behavior improved. Since, the mechanical properties, weight and cost are the main parameters that effect on the composite material selection. Taguchi technique and multiple regression models can be used to optimize these parameters. Drai et al [11] using Taguchi approach to investigate the mechanical and tribological behavior of glass-polyester composite material under different filler content. It is found that the additives parameter have the highest influence. Farag, Drai and Hussam [12], demonstrate the influence of graphite filler content on the sandwich panel glass-polyester deflection and deformation behavior subjected to low velocity impact by using Taguchi technique, and show that the mass has the main influence on the deflection, whereas the graphite filler is the dominate parameter influence on the deformation. Taguchi method is a powerful tool to design a high quality system and has been widely used in engineering analysis. Moreover, Taguchi method uses a special design of orthogonal array to demonstrate the entire parameters effects through a small number of experiments. Therefore, the time required for the experimental investigations is significantly reduced, and it is effective in the investigation of the multiple factors effect on the performance, as well as to study the influence of individual factors to determine which factor has more influence, which one less [13,14,15]. The main objective of this work is to design and select a composite plate to be used in fabricating wing skins of a light UAV. To investigate the influence of fiber volume fraction, filler and type of fibers on the composite plate selection parameters. An experiments plan has been designed to get the data on the basis of Taguchi technique in a controlled way. 2. Unman Air Vehicle Specifications The UAV is a small short range tactical vehicle which is used for reconnaissance and surveillance missions. It operates in Iraq weather. designed with high aspect ratio wing, twin tail boom layout and a 3 hp power engine. Equipped with auto-pilot system and it can flight fully autonomous with the programmed flight track. The UAV specifications are shown in Table.1. Table 1, Specification of UAV. Length 2 m Wingspan 3 m Airfoil NACA 0012 Chord 0.35 m Height 1.25 m Maximum Speed 100 km/h Cruise Speed 50-60 km/h Ceiling 1000 m Maximum Range 50 km Max Takeoff Weight 30 kg Navigation Mode GPS 3. Experimental Test Material: materials used are resin, fiber, filler and a hardener (Methyl Ethyl Kenton Peroxide) at room temperature. Resin is unsaturated polyester (UP). Fibers are; E-glass woven roving (Eg) and Unidirectional carbon (UC). Fillers are graphite (G) and aluminum (AL) powders. The physical and mechanical properties for these raw materials are listed in tables 2, 3 and 4. Table 2, Physical and mechanical properties of (UP) resin [16]. Properties Value Density 1268 kg/m 3 Tensile strength 50 MPa Modulus of elasticity 3 GPa Elongation 2.5% Barcol hardness 40 Table 3, Physical and mechanical properties of fiber: a- E-glass woven roving [17]. Properties Value Density 2580 kg/m 3 Tensile strength 3450 MPa Modulus of elasticity 72 GPa Poisson’s ratio 0.22 b- Unidirectional carbon [18]. Properties Value Density 1790 kg/m 3 Tensile strength 3900 MPa Modulus of elasticity 230 GPa Poisson’s ratio 0.2 Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 76 Table 4, Physical and mechanical properties of filler: a- Aluminum powder [19]. Properties Value Density 2700 kg/m 3 Tensile strength 60 MPa Modulus of elasticity 71 GPa Thermal conductivity 247 w/m.̊C practical size 75 µ m b- Graphite powder [19]. Properties Value Density 1780 kg/m 3 Tensile strength 40 MPa Modulus of elasticity 11.7 GPa Thermal conductivity 118 w/m.K practical size 100 µ m Experimental design: Three parameters that (fiber volume fraction, filler and type of fiber) were considered with three levels for each, to optimize the composite plate mechanical properties, cost and weight. Table 5 shows these parameters with their levels. Taguchi technique to experimentation gives a regular way to collect data, interpret and analyze to satisfy the study objective. Selection of control factors is the most important stage in the experiment design. therefore, take care in choosing a suitable orthogonal array and control parameters with their levels, to get combination of optimum level [20, 21]. To study the impact of parameters in this work, L9 (3 3 ) orthogonal design has been used as shown in table 6. Specimens Preparation: specimens were manufactured by dry hand layup technique. Unsaturated polyester resin was mixed with the hardener in ratio 100:2 by weight. The powders filler was mixed with known amounts of unsaturated polyester resin. The stacking procedure of fiber-polyester composites was constructed by placing fiber ply one above other with resin mixed well to spread between plies using mold of (250x250x20) mm. The fiber orientation of unidirectional carbon was made with [0/90/0/90], whereas for (Eg+UC) was made by [Eg/0UC/Eg/90UC]. The whole assembly was pressed by (0.3 MPa) then released and allowed to cure for a 6 days at room temperature. The product is a composite plate. The plates are cut into the appropriate dimensions using a tipped cutter, and then machining it by using a vertical milling CNC machine to manufacture a tensile tests specimens according to ASTM D 638-3 [22]. While, Charpy impact test specimens were performed according to ISO 179 [23] as shown in fig.1. These specimen’s details are shown in table 6. Tensile test done using LARYEE tensile test machine, with 1000 kg applied load and (2mm/min) strain rate. While, Impact test done using LARYEE Charpy impact test machine. Tests carry out in laboratory of Material Eng. Dept./University of Technology. -a- -b- Fig. 1. Experimental test specimens: a- Tensile test specimens. b- Charpy impact test specimens. Table 5, Parameters with their levels. Parameters Symbol Levels of Parameter Level- 1 Level- 2 Level- 3 Type of fiber A Eg UC Eg+UC Filler B 0% 5%AL 7.5%G Fiber volume fraction C 27% 30% 33% Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 77 Table 6, Experimental plan using orthogonal array L9. Exp. No. Parameters and level Type of fiber- A Filler- B Fiber volume fraction - C level value level value level value 1 1 Eg 1 0% 1 27% 2 1 Eg 2 5%AL 2 30% 3 1 Eg 3 7.5%G 3 33% 4 2 UC 1 0% 2 30% 5 2 UC 2 5%AL 3 33% 6 2 UC 3 7.5%G 1 27% 7 3 Eg+UC 1 0% 3 33% 8 3 Eg+UC 2 5%AL 1 27% 9 3 Eg+UC 3 7.5%G 2 30% 4. Results and Discussion Aerodynamic forces: The aerodynamic loading under the cruise flight conditions can simply be defined as, the load acting on the aircraft will be equivalent to the weight of the structure. Lift load on the aircraft structure is normally distributed as 80% on wings and remaining 20% on the fuselage [24]. Since, the aircraft take-off weight under design is 30kg. Therefore, the total load acting on the wings will be equal to (300 × 0.8 = 240N). The load acting on each wing will be 120N. Since, the aerodynamic load is applying on the center of pressure of wing located at ¼ chord from leading edge. Using finite element method (ANSYS-11 software) to investigate the effect of (120N) on the wing. The results represent the von Misses stress distribution shown in fig. 2, and it is found that the maximum stress is 40 MPa. Experiment results: After preparing all the nine specimens for each test. Experimental tests were conducted use tensile test machine and Charpy impact test machine. Each experiment was repeated three times and then compute the average value. The Modulus of elasticity, Fracture toughness, and tensile strength are the mechanical properties that investigated here. The experimental results for each specimen with their calculated density was listed in table 7. The density of a composite material can be calculated using [25]. ρc = ∑ Vi ρi = V1.ρ1 + V2.ρ2 + … + Vn. ρn …(1) Where: ρc: density of composite material. ρ1, ρ2, ρn: density of each constituent. V1, V2, Vn: volume fraction of each constituent. Fig. 2. von Misses stress distribution on wing. Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 78 Table 7, Experimental results and their signal-to-noise ratio. Exp. No. Modulus of Elasticity Tensile strength Toughness Density GPa S/N dB MPa S/N dB MPa√m S/N dB Kg/m 3 S/N dB 1 2.612 8.339 129 42.212 16.570 24.386 1622.24 -64.202 2 5.201 14.322 174.53 44.837 19.633 25.860 1733.2 -64.777 3 8.340 18.423 201.40 46.081 21.456 26.631 1739.36 -64.808 4 14.373 23.151 315.21 49.972 26.750 28.546 1424.6 -63.074 5 23.639 27.473 480.49 53.634 32.192 30.155 1511.86 -63.590 6 24.401 27.748 500.84 53.994 34.047 30.642 1447.34 -63.211 7 14.425 23.182 240.74 47.631 20.892 26.400 1570.61 -63.921 8 12.247 21.761 357.24 51.059 26.306 28.401 1587.19 -64.013 9 16.307 24.247 467.32 53.392 30.146 29.585 1581.5 -63.981 Signal to Noise Ratio (S/N): Signal to noise ratio measures sensitivity of the quality investigated to those uncontrollable factors (error) in the experiment. Using “bigger is better” quality characteristic for mechanical properties investigation, while “smaller is better” used for density analysis to get high strength/weight ratio. The following logarithmic equation used to perform S/N ratio analysis [26]. 1. “bigger is better”, �⁄ = −10 ����� �1� � 1 ��� � ��� � … 2" 2. “smaller is better”, �⁄ = −10 ����� �1� � ��� � ��� � … 3" Where: n is the observations number. yi is the data observed. For all nine experiment readings, the S/N ratios were calculated and listed in table 7. From table 7, it can be seen that, experiment number 6 has the largest mechanical properties S/N ratio. The parameters combination with their level in this experiment is A2B3C1. Whereas experiment number 4 show the smallest density value, and the parameters combination with their level is A2B1C2. According to the results of combinations generated from orthogonal array. The optimum levels were predicted by estimating the control factors for different three levels. The control factors levels were determined and listed in table 8. Fig. 3 shows the distributions of average S/N ratios. Where the goal for mechanical properties is “bigger is better”, from fig. 3 it can be noticed that, the optimal parameters combination with their levels is A2B3C3, equivalent to (carbon fiber, 7.5%G filler and 33% fiber volume fraction), which get a higher characteristic of modulus of elasticity, tensile strength and toughness. While A2B1C1 is the optimal parameters combination with their levels for density to get “smaller is better”, that equivalent to (carbon fiber, 0% filler and 27% fiber volume fraction). Table 8, Average signal to noise ratio of different parameter levels. Parameter Symbol Average of S/N (dB) of different parameter levels Max - Min optimum level Level - 1 Level - 2 Level - 3 Modulus of Elasticity Type of fiber A 13.6948 26.1239 23.0635 12.4291 A2B3C3 Filler B 18.2242 21.1850 23.4730 5.2487 Fiber volume fraction C 19.2827 20.5734 23.0261 3.7433 Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 79 Tensile strength Type of fiber A 44.3768 52.5332 50.6942 8.1564 A2B3C3 Filler B 46.6049 49.8434 51.1558 4.5509 Fiber volume fraction C 49.0883 49.4006 50.1153 0.3122 Toughness Type of fiber A 25.6257 29.7810 28.1284 11.7167 A2B3C3 Filler B 26.4442 28.1386 28.9524 4.2933 Fiber volume fraction C 27.8097 27.9969 28.0185 1.3471 Density Type of fiber A -64.5957 -63.2918 -63.9718 11.7167 A2B1C1 Filler B -63.7325 -64.1266 -64.0002 4.2933 Fiber volume fraction C -63.8088 -63.9441 -64.1065 1.3471 Underlined value represents the optimum level. Fig. 3. Main effect graph. Analysis of Variance (ANOVA): ANOVA is a statistical method in which used for predicting the individual interactions of all control parameters. In this research, ANOVA used to analyze the influence of fiber volume fraction, filler and type of fiber on the mechanical properties and density of composite material plates. In the analysis, to measure the corresponding effects on the quality characteristics, use the percentage distributions of each control parameter [27]. Table 9, present the mechanical properties and density results using ANOVA analysis. From these results it can be found that the significant parameter is the type of fiber, followed by filler and then the fiber volume fraction. The type of fiber contributions to mechanical properties and density are exceed 70% and 80% respectively. a- a-Modulus of elasticity b-Tensile strength c-Toughness d-Density Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 80 Table 9, ANOVA results of mechanical properties and density. Parameters Sum of Squares (SS) Degree of Freedom (df) Mean Squares (MS) F value Contribution (%) Modulus of Elasticity Type of fiber 251.6187 2 125.8094 54.7421 78.76 Filler 41.5502 2 20.7751 9.0397 13.01 Fiber volume fraction 21.6940 2 10.8470 4.7197 6.79 Error 4.5964 2 2.2982 1.44 Total 319.4594 8 100.00 Tensile strength Type of fiber 109.8185 2 54.9092 78.1765 76.09 Filler 32.9210 2 16.4605 23.4355 22.81 Fiber volume fraction 0.1796 2 0.0898 0.1279 0.12 Error 1.4048 2 0.7024 0.97 Total 144.3238 8 100.00 Toughness Type of fiber 26.260 2 13.130 104.590 72.05 Filler 9.8244 2 4.9122 39.1281 26.95 Fiber volume fraction 0.1137 2 0.0568 0.4528 0.31 Error 0.2511 2 0.1255 0.69 Total 36.4501 8 100.00 Density Type of fiber 2.5516 2 1.2758 692.407 87.04 Filler 0.2429 2 0.1215 65.9229 8.29 Fiber volume fraction 0.1333 2 0.0667 36.1732 4.55 Error 0.0037 2 0.0018 0.13 Total 2.9315 8 100.00 5. Confirmation Test The optimum combinations parameters of processes with their levels were found using Taguchi technique. But the optimum combinations did not match any experiment from experiments in orthogonal array. Therefore, it is necessary to confirm results of Taguchi technique with experimental results for the optimum combinations. The mechanical properties and density values at the optimum condition were predicted through use the optimum process parameters level [28]. The optimum combination parameters of mechanical properties are (A2B3C3), in which equivalent to (carbon fiber, 7.5%G filler and 33% fiber volume fraction). Whereas the optimum combination parameters of density are (A2B1C1), that represent (carbon fiber, 0% filler and 27% fiber volume fraction). The S/N ratio of optimum combination process parameters can be predicted using the following equation [21]: '()* = '+ + � '� − '+" - ��� … 4" Where: '()*: predicted S N⁄ ratio. '+: Total mean of S N⁄ ratios. '�: mean S N⁄ ratio at optimum levels. <: number of main design parameters that affact the quality characteristics. The predicted results were listed in table 10. Tensile and Charpy impact test specimens then prepared for the optimum combination parameters, and experiments of (tensile test and Charpy impact test) had been done for mechanical properties, while its density was estimated. The results are shown in table 10. The results show that, the experimental and the predicted results are Farag M. Mohammed Al-Khwarizmi Engineering Journal, Vol. 13, No. 1, P.P. 74- 83(2017) 81 very close, with error not exceed 7.5%. This verify that the experiment result is correlated with the predicted result. From experiments and Taguchi technique analysis, turns out the optimum combination parameters. Without refer to the cost, but the cost is one of the most important factors that influence the selection of materials in engineering applications. The cost of unsaturated polyesters is approximately the same for all samples, as well as the cost of additives are very few in comparison with the fiber cost. Therefore, it will be a focus on fiber as an effective parameter in the selection. It is necessary to optimize between the cost, weight (density) and mechanical properties. The combination parameters (carbon fiber, 7.5%G filler and 33% fiber volume fraction), gives higher mechanical properties with a very agreement density of (1478 kg/m 3 ), but higher cost, because the cost of carbon fiber is approach to 20 th times the cost of E-glass fiber. The results of using finite element method showed that, the maximum stress on the wing is 40 MPa. So, from table 7, and the optimum combinations parameters, it can be choosing the combination parameters in which get the required selection. Experiment number 9, present agreement combination parameters for the composite plate selection. This combination provides good mechanical properties, high safety factor, acceptable cost, and offers weight savings on average by 40% percent as compared to aluminum alloy. The parameters combinations of this experiment are ((Eg+UC) fiber, 7.5% G filler and 30% fiber volume fraction). Table 10, Confirmation results characteristic Optimum Parameter Level Experiment Predication Difference (%) Modulus of Elasticity (GPa) A2B3C3 32.644 34.282 4.7 Tensile strength (MPa) A2B3C3 548.627 542.426 1.1 Toughness (MPa) A2B3C3 32.9507 35.646 7.5 Density (kg/m 3 ) A2B1C1 1408.94 1400.700 0.57 6. Conclusions From the results obtained in this work the following can be concluded: 1. The type of fiber is the significant parameter effect on the composite plate selection, followed by filler and finally the fiber volume fraction parameter. 2. The type of fiber parameter contributions on mechanical properties exceed 70%, while on density it is exceed 80%. 3. The optimum combination parameters with their levels of mechanical properties are (carbon fiber, 7.5 Graphite filler, and 33% fiber volume fraction). Whereas, the optimum combination parameters of weight are (carbon fiber, 0% filler, and 27% fiber volume fraction) 4. The agreement combination parameters with their levels are ((Eg+UC) fiber, 7.5% Graphite filler and 30% fiber volume fraction). This combination provides good mechanical properties, high safety factor, acceptable cost, and offers weight savings on average by 40% percent as compared to aluminum alloy. 7. References [1] Torenbeek, E., “Synthesis of Subsonic Airplane Design”, Delft University Press, The Netherlands, 1982. [2] David J. Peery and Azar J., “Aircraft Structures”, McGraw-Hill Book Company, New York, 1982. [3] Anand F. and Bharat K., “Design and Analysis of Horizontal tail of UAV using composite materials”, IJCTT, Vol. 4, Issue 7, 2013. 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CHIU, “Bending strength analysis of centrally-debonded composite sandwich beam using Taguchi method”, Hokkaido University Collection of Scholarly and Academic Papers: HUSCAP, 2013. [21] S.R. Chauhan, Anoop Kumar, I. Singh, and Prashant Kumar,” Effect of fly ash content on friction and dry sliding wear behavior of glass fiber reinforced polymer composites - a Taguchi approach”, Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No.4, 2010. [22] ASTM Designation: D 638-03, “Standard test method for tensile properties of plastics”, ASTM international. [23] ISO 179-1982 (E),” Plastics-Determination of Charpy impact strength of rigid material”, International standard. [24] Jr. Anderson,” Fundamentals of Aerodynamics”, third edition, McGraw Hill, New York, 2001. [25] ASTM, "Standard Test Method for Tensile Properties of Fiber-Resin Composites/D3039", 1988. [26] Roy, R.K. ,”A primer on the Taguchi method”, Competitive Manufacturing Series, Van Nostrand Reinhold, New York, 1990. [27] Sandhyarani Biswas, Amar Patnaik and Pradeep Kumar, ”Silicon Carbide Filled Polymer Composite for Erosive Environment Application: A Comparative Analysis of Experimental and FE Simulation Resultsc, Silicon Carbide-Materials, Processing and Application in Electronics Devices, 2011. [28] G. Bhanu Kiran1, Suman K. N. S., Mohan Rao N., Uma Maheswara Rao R., ”A study on the influence of hot press forming process parameters on mechanical properties of green composites using Taguchi experimental design”, International Journal of Engineering, Science and Technology, Vol. 3, No. 4, pp. 253-263, 2011. ج ��� ���� ���� ��� 1، ا ��د�13��� ا ��ارز�� ا ������ ا� ،83-74 )2017( 83 ��� �� � ���اد ا ��!�"#!�� ��ا�� ��&���%���� ا ��اص ا ��'% ج ��� ���� ا*6%&5! ا*4#.3*23"! /01/ ا*(.-,! ا*#()و&"#%$"#"! drfaragmahel@yahoo.com -7(8*ا:*#4)و$9 ا: ��(� ا ص 3اا*Lا4W<-ت . 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