Dry-sliding wear analysis and prediction using response surface method and fuzzy logic for Kota stone dust–fly ash–epoxy hybrid composites

Abstract

This paper reports on the utilization of waste Kota stone dust and fly ash as filler materials in polymeric resin for the development of a new class of hybrid composite. Epoxy is taken as polymeric resin for the fabrication of different sets of hybrid composites. The fabricated samples are tested for their physical, mechanical, and dry-sliding wear properties. An experimental investigation shows the density, void contents, and water absorption rate increase as a linear function of fillers content. Mechanical testing is performed to evaluate the tensile, compressive, flexural, and hardness properties. From the experimentation, it is observed that the mechanical properties under investigation improve with the addition of either of the fillers. The maximum tensile strength obtained is 33.6 MPa, whereas flexural strength increases to 63.96 MPa resulting in an appreciable improvement. The compressive strength improves to 102.39 MPa and hardness reaches a Shore D number of 84. Sliding wear tests are performed as per the L₁₆ array based on the response surface method (RSM) using pin-on-disk apparatus. It has been observed that filler content, sliding velocity, sliding distance, and normal load in the declining sequence are significant in affecting the wear rate. Furthermore, the wear rate of composites is predicted with the help of response surface method and fuzzy logic within the experimental domain, and the results are compared with the outcomes reported in some of the existing literature. The study of worn composite surfaces using a scanning electron microscope resulted that the formation of wear tracks, grooves, craters, cavities, wear debris, etc. are some of the dominant mechanisms causing wear loss. As a result of our research, gainful utilization of wastes like Kota stone dust and fly ash for preparing polymer composites has opened up.