Cost‐effective manufacturing process for the development of automotive from energy efficient composite materials and sandwich structures

Abstract

The advanced composite materials are increasingly being used in the automotives for their ultralight physical properties and super strong mechanical properties. This research examines the cost‐effective single‐step liquid resin infusion manufacturing process for developing all composite car body as the generally used sheet molding compound manufacturing process is highly capital intensive. Three different scaled down models of the Eco car were developed focusing on minimal weight and air drag coupled with aesthetics. Structural design and analysis was carried out using the Pro/E and Ansys tools. The Pro‐E model was scaled up to generate computer‐aided drafting drawings for tool development. Different stations were marked on the model and sliced virtually for development of pattern. Moreover, the mold was manufactured from carbon and glass/polyester composites for prototype manufacturing of the car body. This involved manual placement of desired number of carbon layers as preform on female side of the mold. The vacuum sucked the resin through a number of carefully selected entry ports which ensured effective resin distribution and impregnation. Polycarbonate wind shield was thermoformed in the convection oven according to streamlined geometry of car body and hinged. The car body was integrated with the compatible floor panels and accessories. The crumble zone shock absorber in the bumper was manufactured using successive layers of nomax honeycomb and polyvinyl chloride rigid foam to dampen the accidental shock. The car performed remarkably well in the Eco marathon race held at Malaysia, 35:97–104, 2014. POLYM. COMPOS., 2013. © 2013 Society of Plastics Engineers

Challenges in Compression Testing of 3D Angle-Interlocked Woven-Glass Fabric-Reinforced Polymeric Composites

“…Specimens and tab panels for 2D and 3D FRPC are manufactured through vacuum infusion technique to achieve uniform resin distribution and less void content [47,48]. Epoxy resin, 'Huntsman LA5052', having Araldite 5052 and Aradur 5052 mixed in 100:38 by weight, was used for the infusion process.…”

Impact Loading Performance of Polymer Foam Core Aluminium Sandwich Panels

“…Global warming is seen as one of the most significant problem of recent times. One of the main reasons for this is the CO 2 emissions caused by vehicles in traffic [1,2]. For these reasons, researchers and automotive industry companies have carried out various studies to reduce emissions.…”

Modelling the deformation of continuous fibre-reinforced thermoplastics subjected to hygrothermal loading

“…11 This is especially relevant for the cost sensitive automotive industry. 12–14 FRPs are mostly composed of thermoset- or thermoplastic matrices with a large thermoset majority. 15,16 Composites with thermoplastic matrix systems offer shorter cycle times and are an interesting alternative.…”