<p>Recent years polyester-based composites are used in several industries such as aerospace, automotive, construction and medical because of their high strength-to-weight ratio, durability, and corrosion resistance but low mechanical and tribological properties. To improve the above mentioned properties, various particles are added to the polyester. Numerous researchers have incorporated various reinforcements with polyester matrix have been investigated. However, polyester based composites reinforced with nano silica produced from sugarcane bagasse were not addressed so far. Hence, in this study bagasse ash is rich in silica (SiO₂), is the waste from the combustion process and only a small quantity of bagasse ash is utilized as pozzolan in concrete, and a considerable quantity is left unused due to its high carbon and crystallite content is mostly disposed of as landfill. Desired properties of polyester composite was obtained with proper composition of nano silica as reinforcement for better tribological performence. Experiments based on face centred composite rotatable design were carried out to study the effect of various input parameters, viz. normal load, sliding speed and weight% of reinforcements. The adequacy of the developed empirical models has also been tested by the analysis of variance test. The findings revealed that the rate of wear rises with normal load and sliding speed. However, as the weight% of HNT and silica grows, the wear rate reduces. Wear mechanism maps were generated to study the impacts of control parameters, including sliding velocity and normal load. The various wear characteristics of the worn hybrid nanocomposites composite surfaces were analyzed using scanning electron microscope (SEM).</p>