Experimental Characterization and Finite Element Analysis of Jute and Glass Fiber Reinforced Epoxy Composite Material for Structural Automotive Components.

Abstract

Using of fiber-reinforced composite materials is rapidly advancing in the automotive and aerospace industries due to their superior properties, including lightweight, high strength-to-weight ratio, high impact strength, corrosion resistance, design flexibility, and dimensional stability. Traditionally, vehicle bodies have been constructed from heavy metals like steel, increasing vehicle weight and fuel consumption. This study focuses on enhancing the mechanical properties of Jute/Glass Fiber reinforced epoxy composites for automotive body applications. The research evaluates tensile, compression, impact, and flexural strengths of unidirectional jute and glass fiber composites by varying fiber weight ratios, orientation angles, and stacking sequences. Experimentation followed ASTM standards, and the composite car bonnet was designed and analyzed using Classical Laminate Theory and optimization via Opti-Struct in Altair Hyper Mesh 2019. Results indicated that a 50/50 weight ratio of jute to glass fibers with unidirectional orientation offered the best mechanical properties. Additionally, incorporating ±45° fiber orientations enhanced impact strength in both lateral and transverse directions. The bonnet design optimization led to a 67% weight reduction compared to conventional steel bumpers, resulting in an average fuel savings of 0.0034 L/100 km. Thermal analysis using FEM Ansys showed that the composite bonnet had lower thermal conductivity and heat flux, with higher temperature distribution at the edges due to constraints. The thermal stress remained within safe limits, indicating no immediate failure risk. In conclusion, the hybrid composite material with Jute/Glass fibers can effectively replace traditional steel Bonnet, offering significant weight reduction and fuel efficiency improvements without compromising safety.