It is estimated that the annual world car production rate will reach 76 million vehicles per year by 2020. New regulations such as the EU End of Life Vehicles (ELV) regulations are forcing car manufacturers to consider the environmental impact of their production and possibly shift from the use of synthetic materials to the use of agro-based materials. Poor mechanical properties and certain manufacturing limitations currently limit the use of agrobased materials to non-structural and semi-structural automotive components. The hybridization of natural fiber with glass fiber provides a method to improve the mechanical properties over natural fibers alone. This research is focused on a hybrid of kenaf/glass fiber to enhance the desired mechanical properties for car bumper beams as automotive structural components with modified sheet molding compound (SMC). A specimen without any modifier is tested and compared with a typical bumper beam material called glass mat thermoplastic (GMT). The results indicate that some mechanical properties such as tensile strength, Young's modulus, flexural strength and flexural modulus are similar to GMT, but impact strength is still low, and shows the potential for utilization of hybrid natural fiber in some car structural components such as bumper beams.
Application of natural fibre composites is going to increase in different areas caused by environmental, technical and economic advantages. However, their low mechanical properties have limited their particular application in automotive structural components. Hybridizations with other reinforcements or matrices can improve mechanical properties of natural fibre composite. Moreover, geometric optimizations have a significant role in structural strength improvement. This study focused on selecting the best geometrical bumper beam concept to fulfill the safety parameters of the defined product design specification (PDS). The mechanical properties of developed hybrid composite material were considered in different bumper beam concepts with the same frontal curvature, thickness, and overall dimensions. The low-speed impact test was simulated under the same conditions in Abaqus V16R9 software. Six weighted criteria, which were deflection, strain energy, mass, cost, easy manufacturing, and the rib possibility were analyzed to form an evaluation matrix. Topsis method was employed to select the best concept. It is concluded that double hat profile (DHP) with defined material model can be used for bumper beam of a small car. In addition, selected concept can be strengthened by adding reinforced ribs or increasing the thickness of the bumper beam to comply with the defined PDS.
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