Tribological and surface roughness behaviors of glass sphere-filled PP composites

Purpose This study explores the tribological properties and surface roughness of glass sphere-reinforced polypropylene (PP) composites. Drilling tests were conducted using various drill bits (HSS, TiN-coated HSS, carbide), feed rates, and cutting speeds, with experiments designed via the Taguchi L27 orthogonal array. Design/methodology/approach The experimental design for drilling tests and surface roughness measurements was made using the Taguchi L27 (33) orthogonal array. Surface roughness measurements were carried out using a MarSurf VD 140 Profilometer Model (Mahr Metrology in Germany) device. Data obtained from drilling tests and surface roughness measurements were analyzed using analysis of variance (ANOVA) and signal-to-noise (S/N) ratio analysis. Findings ANOVA and signal-to-noise (S/N) ratio analyses revealed that drill bit type significantly impacts surface roughness, accounting for 61.70% of the variation. Increasing feed rates raised surface roughness, while higher cutting speeds reduced it. Carbide drill bits yielded the lowest surface roughness values. Regression analysis indicated a high predictive accuracy for the model (R2 = 89.72). The optimal parameters for achieving minimal surface roughness were identified as a carbide drill bit, 0.05 mm/rev feed rate, and 25 m/min cutting speed. Originality/value The results obtained reveal the potential of glass sphere reinforced PP composites in industrial applications. This study will contribute to the existing literature by enabling further research on the friction and wear behaviors of glass sphere reinforced PP composites, revealing the potential of these materials in tribological applications.