Fabrication, Characterization, and Machining of Polypropylene/Wood Flour Composites

Wood polymer composites (WPCs) are considered as one of the highly competent classes of hybrid composite materials having potential applications in automotive, furniture, and construction industry. In this present study, fabrication of PP-g-MA compatibilized PP-wood flour composites was accomplished utilizing melt blending extrusion. The extruder was operated at a temperature profile of 180–210 °C. Wood flour, prior to its incorporation in polymeric material, was sieved to get fine wood flour particles. Compression-molded specimens of composites were characterized for their morphological attributes and for the determination of their chemical makeup, mechanical features, and thermal stability. FTIR analysis determined the chemical makeup of WPCs. Thermogravimetric analysis revealed the thermal stability of composites at temperature higher than 280 °C. Composites were rated as V2 grade according to their flammability performance. SEM analysis manifested the dispersed state of wood flour in the PP matrix. Mechanical properties manifested the increased stiffness of WPCs owing to increase in loading of wood flour which was associated with the restricted motion of polymer chains imparted by the wood flour particles. Surface topology study of in-hole drilled surface was also carried out by performing machining of WPCs for the analysis of surface roughness as a function of drill speed. Furthermore, the environmental sustainability of WPCs machining was demonstrated, and the reduction in waste generation through drilling of composites was observed.