RESEARCH ARTICLE A comparative analysis of the abrasion wear characteristics of industrial wastes filled glass/polyester composites based on the design of experiment and neural network Subhrajit Ray 1 | Arun Kumar Rout 2 | Ashok Kumar Sahoo 3 1 Department of Mechanical and Electrical Engineering, CAET,OUAT, Bhubaneswar, India 2 Department of Production Engineering, VSSUT, Burla, India 3 School of Mechanical Engineering, KIIT deemed to be University, Bhubaneswar, India Correspondence Subhrajit Ray, Department of Mechanical and Electrical Engineering, CAET, OUAT, Bhubaneswar, India. Email: subhrajitmech@gmail.com Abstract This article presents the abrasion wear behaviour of different industrial wastes filled glass/polyester composites. Two types of fillers such as fly ash and gran- ite dust are chosen with different weight proportions along with polyester and glass fiber for fabricating the composite using hand layup route. Abrasion wear properties of the developed composites are studied in the dry sand abrasion wear test rig as per the ASTM-G-65 standard. The experiments were conducted based on Taguchi design. Between the two fillers, granite filled composite showed better abrasion resistance property as compared with fly ash. Normal load and filler content are found to be the most influential factor for the abra- sion loss of the composites followed by abrading distance and sliding velocity. The results are predicted using neural network and also compared with the experimental and regression model data. Abraded surfaces are examined by the SEM to ascertain the different wear mechanisms responsible for abrasion loss of material. KEYWORDS design of experiment, industrial wastes, neural network, three-body abrasion 1 | INTRODUCTION In earlier days, polymer matrix composites found their importance in various engineering sectors due to their advanced, such as, higher modulus and high specific strength. The polyester resin was widely used for its envi- ronmental resistance, adhesive strength, good electrical insulation, high chemical, water-resistance, and low shrinkage property. However, only the matrix shows poor sliding resistance due to its lower impact strength and toughness. Therefore, the addition of reinforcement in the neat resin provides higher load carrying capacity, enhanced wear resistance, low density, low vibration, and increased mechanical properties [1] . Carbon, glass, and Kevlar fibers are generally reinforced in the resin to improve their strength, toughness, and adequate toughness. Reinforcement of fiber in the resin improved the physical and mechanical properties of these composites and makes it suitable to be used as structural and other engine components [2] . Glass fibers are preferred over carbon or kevlar fibers due to their low cost and high strength. The desired properties of the composite materials can be achieved by a judicious combination of fibers and fillers in tailor mode for tribo- logical applications [3] . Polymer composites are frequently used in many tribological situations like mineral carrying pipes, gears, ship hulls, chute liners, turbine blades, aero- space, electrical contact brushes, automotive parts in day- to-day applications [4] . The stiffness, specific strength, and lightweight of fiber and matrix are the intrinsic properties that stand responsible for selecting the suitable tribo- resistant material. Wear is considered as the major Received: 8 July 2020 Revised: 23 September 2020 Accepted: 23 September 2020 DOI: 10.1002/pc.25836 Polymer Composites. 2020;1–15. wileyonlinelibrary.com/journal/pc © 2020 Society of Plastics Engineers 1