Vol.:(0123456789) 1 3 J. Inst. Eng. India Ser. D https://doi.org/10.1007/s40033-024-00664-1 ORIGINAL CONTRIBUTION Synthesis and Investigation on Mechanical Properties of Hybrid FRP Composite Using Taguchi Technique Giridhar S. Kulkarni 1  · N. G. Siddeshkumar 1  · C. Durga Prasad 2  · B. Latha Shankar 3  · C. R. Aprameya 4  · Prashant Patane 5  · Udayshinha Dilip Deshmukh 6  · Chandan Prasad 7   Received: 30 December 2023 / Accepted: 8 February 2024 © The Institution of Engineers (India) 2024 Abstract In this work, hybrid fiber-reinforced plastic (FRP) composites consisting of glass fiber-reinforced plas- tic (GFRP) reinforced with resin epoxy and liquid silicone rubber with fine aluminum powder (particle size range 50–54 microns) or fine silica powder (particle size range 5–10 microns) are made using the hand layup technique. The composites are then prepared in a compression molding machine. Temperature, pressure, and other process factors are optimized in addition to the tensile stress. The mechani- cal characteristics of the fabricated composites, such as tensile stress, flexural stress, and impact strength, will be investigated using SEM images of the damaged surfaces. The result reviles that the most important variable is found to be temperature, and ANOVA is used to optimize the ten- sile test procedure parameters. Three critical process factors were optimized: pressure, temperature, and duration; these were 100 kg/f (980 N), 500 °C, and 40 min. Under the iden- tical ideal process parameters of pressure 100 kgf (980 N), temperature 500 °C, and duration 40 min, the combination of 0.6F + 0.32E + 0.04SR + 0.04SP yields the maximum tensile and flexural stresses. Combining silicon rubber with GFRP led to an increase in impact stress, which peaked in the 50% GFRP + 42% LY556 (Resin) + 4% SR + 4% Al Pow- der combination at the same optimal processing parameters of 100 kg/cm 2 (980 N), 500 °C, and 40 min. Keywords Hybrid FRP composites · Alumina · Silica · Hand layup · Mechanical · Wear Introduction Today’s researchers have been influenced by the expanding demand for the application of fiber-reinforced composite materials in science and engineering [1, 2]. The existing approach of creating hybrid fiber-reinforced composite materials to near-net shape is unsatisfactory if the component is not also subjected to secondary machining operations like milling, drilling, and other comparable processes. The most common machining method used by industries is drilling. On the other hand, drilling fiber-reinforced plastic (FRP) results in problems such as tool flank wear, surface finish/ roughness, fiber pullout, burr height, and others [3–6]. Glass fiber-reinforced plastic (GFRP) is the most frequently used material in structural and non-structural applications in engineering fields like automotive, aerospace, marine, and others because of qualities like light weight to high strength, resistance to corrosion, good fatigue resistance, low thermal conductivity, and resistance to microbial and chemical assaults [7–10]. For structural reasons, hybrid * C. Durga Prasad durgaprasi71@gmail.com 1 Department of Mechanical Engineering, Channabasaveshwara Institute of Technology, Tumakuru, Karnataka 572216, India 2 Department of Mechanical Engineering, RV Institute of Technology and Management, Bengaluru, Karnataka 560076, India 3 Department of Industrial Engineering and Management, Siddaganga Institute of Technology, Tumakuru, Karnataka 572103, India 4 Department of Mechanical Engineering, Government Polytechnic College, Ballari, Karnataka 583101, India 5 Department of Mechanical Engineering, Dr. Vishwanath Karad MIT World Peace University, Kothrud Pune, Maharashtra, India 6 Tata Consultancy Services, Bengaluru, Karnataka, India 7 Department of Mechanical Engineering, National Institute of Technology, Jamshedpur, India