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Design and Analysis of Carbon Fiber 300–Kevlar Hybrid Composite Bumper for Enhanced Impact Resistance in Automobiles

Authors:
S. Soundararajan, R. Venkatachalam, M. Anil Kumar, V. Kondusamy, S. Gokul, S. Rajkumar

Addresses:
Department of Automobile Engineering, K.S.R. College of Engineering, Tiruchengode, Namakkal, Tamil Nadu, India. Department of Mechanical Engineering, Sagi Rama Krishnam Raju Engineering College, Bhimavaram, Andhra Pradesh, India. Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore, Tamil Nadu, India. Department of Mechanical Engineering, Institute of Technology, Hawassa University, Hawassa, Sidama Region, Ethiopia.

Abstract:

The extremely important design challenge is the vehicle's safety. Both active and passive approaches help to provide the vehicle's safety. One of the passive ways to guard the passengers is a bumper. By properly constructing the bumper, which prevents unexpected collisions, one can significantly enhance the vehicle's safety. Most research on polymer composite bumpers has concentrated on single-fibre reinforcement; hybrid composites have proven to offer higher performance than single reinforcement. Because hybrid composites have the in-built qualities of both fibres, the final composite's strength increases. This work uses Kevlar fibre in addition to carbon fibre to build a bumper. Using finite element analysis, the model was subjected to crashworthiness testing. The model was first created with 3D modelling tools and then exported to FEA analysis. Structural integrity, impact energy absorption, and deformation all show that the CF 300-Kevlar composite bumper beats traditional single-fibre composite bumpers. Simulations of finite element analysis (FEA) confirmed the experimental results and demonstrated that hybrid reinforcement significantly enhances crash performance. Among other benefits over conventional metal and single-fibre composite bumpers, the CF 300-Kevlar hybrid composite bumper is lightweight, durable, and environmentally friendly.

Keywords: Carbon Fibre; Flexural Strength; Impact Strength; Elastic Stress; Elastic Strain; Hybrid Composites; Impact Energy; Energy Absorption; Structural Integrity; Vehicle's Safety; FEA Analysis.

Received on: 02/10/2024, Revised on: 13/12/2024, Accepted on: 27/01/2025, Published on: 05/06/2025

DOI: 10.69888/FTSSM.2025.000406

FMDB Transactions on Sustainable Structures and Materials, 2025 Vol. 1 No. 1, Pages: 35-44

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