This study investigates the sliding wear behaviour of epoxy composites reinforced with cenosphere nanoparticles using response surface methodology and finite element method. Epoxy composites with varying cenosphere nanoparticle content (0 wt.‐% ‐ 10 wt.‐‐O%) were fabricated and subjected to dry sliding wear tests under different loads (10 N ‐ 30 N), speeds (0.9 m/s ‐ 2.7 m/s), and distances (400 m ‐ 1200 m). Response surface methodology was employed to design experiments and analyze the influence of process parameters on wear rate. Analysis of Variance results revealed that cenosphere content and velocity had significant effects on wear rate, with cenosphere content being the most influential factor. The wear rate increased with increasing velocity and decreasing cenosphere content. Finite element method simulations were performed using ANSYS 18.R1 Workbench to predict the stress distribution, deformation, and material loss in the wear‐affected zone. The combination of response surface methodology and finite element method provides valuable insights into the sliding wear performance of these lightweight, sustainable polymer composites and highlights the potential of these advanced statistical and computational tools in the design and development of high‐performance materials for various applications.
Singh et al. (2026) studied this question.