Parametric appraisal and wear prediction of red brick dust filled epoxy composites using finite element method

Abstract This article proposes the development of a novel polymer composites using non‐conventional materials, specifically constructional wastes such as red brick dust, in different weight percentages (0 wt.‐%, 10 wt.‐%, 20 wt.‐%, and 30 wt.‐%) and their erosion wear characteristics has been studied. Solid particle erosion test equipment is employed to evaluate the erosion wear characteristics of the composites. According to the study, adding red brick dust to epoxy resin enhances its erosion resistance. The influence of input parameters has also been evaluated using Taguchi approach. The results of this experiment show that the most important variables influencing the composites′ wear rate are impact velocity and filler content. The factor combinations A 2 B 4 C 4 D 2 E 3 exhibit the lowest erosion wear. Moreover, a commercial finite element method tool called ANSYS 2019 R2 is utilized to estimate the wear rate of epoxy/red brick dust composites. After that, the experimental and predicted wear rates of the composites are compared, and it is discovered that the two sets of data accord better. Scanning electron microscopy is utilized to examine the eroded composite samples, and the potential wear causes are explored.