Volume 2, Issue 6, June – 2017 International Journal of Innovative Science and Research Technology ISSN No: - 2456 – 2165 IJISRT17JU86 www.ijisrt.com 207 Fabrication, Evaluation and Optimization of Tensile Characteristics of Waste Plastic Reinforced Polymer Composite Sakthi Balan G,* Asst. Professor/Mech, K.Ramakrishnan college of engineering, Trichy, TN, India E-mail: sakthibala33@gmail.com Renold Elsen S, Asst.Professor/Mech, MIET engineering college, Trichy, TN, India E-mail: renoldelsen@gmail.com Rajesh P.V, Asst.Professor /Mech, Saranathan engineering college, Trichy, TN, India E-mail: pvrajeshmech73@gmail.com Abstract- The objective of this work is to investigate the Tensile properties of Non recyclable waste plastics particulate reinforced unsaturated polyester composite. Waste plastic particulates of particle sizes 1, 2, 3 mm were embedded into the unsaturated polyester resin to produce a composite. The specimens were made at 20, 30 and 40% weight percentages of the particulate filler in polyester matrix. Tensile tests were conducted on prepared samples of the composite material as per ASTM standards. Hand layup process was used for composite making. In this work the process parameters such as percentage composition of filler, percentage of catalyst addition (Methyl Ethyl Ketone Peroxide) and particulate size were defined by Taguchi method. The influence of the process parameters on tensile properties of the composite was optimized and regression equation was also formed using ANOVA. For the optimization process, MINITAB 17 software is utilized. The results showed that the tensile strength of the composite with 30% waste plastic reinforcement, 1.2% catalyst addition and 1mm particulate size was maximum. The composite could be considered for applications in areas were a better tensile and light weight material is required. Also this can be a good solution for converting waste plastics into useful products without any toxic emissions which are the main sources of air pollution [1] [6]. Keywords: Unsaturated polyester resin; Hand layup method; Methyl ethyl ketone peroxide (MEKP); Taguchi method; Non recyclable waste plastics. I. INTRODUCTION Plastic is a material consisting of wide range of synthetic or semi- synthetic organics that are malleable and can be molded into diverse shapes. Plastics can be divided into thermoplastics and thermosetting plastics as shown in figure 1. Thermoplastics do not undergo any chemical change in their composition when heated and can be molded many times. Thermosetting plastics can be shaped once; after that its shape cannot be changed. In the thermosetting process, a chemical reaction occurs that is irreversible. Mostly the thermoplastics are recyclable, while thermosetting plastics cannot be recycled. The properties of plastics which affect the environment are as follows: It has very slow rate of degradation, it take 500 to 600 years to decompose based on the type of plastic. Since its degradation rate is much slower, the plastic waste thrown to the land will block the water passages, drainage and it will not allow the rain water to penetrate inside the ground. If we burn the plastics, it will release enormous amount of toxic gases like nitrogen oxides, sulphur dioxide, volatile organic chemicals (VOCs), dioxin, carbon monoxide, carbon di oxide, etc. To inhale dioxin or to be exposed to its fumes can cause cancer, impotence, asthma, allergies and even death [2] [5]. It also affects the water bodies like, rivers, lakes, ponds, seas and oceans and affects the species living in that. During recycling the plastics should be sorted out very carefully, since mixing of plastics make them non recyclable next time and the plastics after separation, gets melted and then extruded and pelletized to make another new product which also needs energy [3] [4]. So the eco friendly way is to reuse the plastics. Mostly the non recyclable plastics such as BPA (Bisphenol A), polycarbonate, polystyrene, polyvinyl chloride (more toxic), polylactide, nylon, butadiene, styrene which are used to make water pipes, insulation, clothing, furniture, toys, packaging foams, drinking cups, DVDs, frames, water bottle caps, water cans, etc are taken for reinforcement at required percentage and the composites are fabricated using hand layup process. Fig. 1. Types of plastics II. MATERIALS AND METHODS A. Matrix material: Mostly polymer-based composite materials, such as fiberglass, carbon fiber, and Kevlar, include at least two parts, the substrate and the resin. The matrix material is a resin. The catalyst used is MEKP (methyl ethyl ketone peroxide). If peroxide is added with the resin, it decomposes to generate free radicals, which initiate the curing reaction. The curing agent used was a cobalt octoate which act as a hardener. In this work the polyester resin is taken in three different compositions such