Enactment of Fiber Reniforced Hybrid Epoxy Composite for Passenger Car Bumper Beam

: These days, fuel economy and emission petrol control of passenger vehicles are two critical challenges. The most effective approach to improve fuel efficiency with the front and rear parts of a vehicle are equipped with bumpers, which are crucial in low-speed collisions because they serve as low-speed energy absorbers. Sacrificing safety is to employ fiber reinforced composite materials in the body of cars. The fascia is a major element that is designed to absorb abrupt or impact loads that are imparted to automobiles either purposefully or accidentally. The objective for the incorporation of the bumper is when a collision suspends a vehicle to abrupt or impact loads, it is employed to absorb crash energy and is beneficial again for safety of the driver passengers as well as for the vehicle. In this work, a novel composite bumper beam which will be made of hybrid (natural and synthetic) fiber epoxy composite material embedded with multi walled carbon nanotubes to improve the bending stiffness. The major goal of the current investigation is to determine the impact of nano carbon tubes on the mechanical characteristics of jute/glass/epoxy hybrids and banana/glass/epoxy hybrids. The samples manufactured using a hand layup method and a variety of stacking sequences. Experimentations for three quasi-static 3-point bending test as well as fracture toughness will be conducted. Also, water absorption capability in reinforced materials will be measured. Based on the results, the bumpers are proposed for the Indian

These are usually stronger and harder. Composite materials provide characteristics and are multifunctional material systems not obtainable from any discrete material.

Classification of composites:
Composites are categorized into four groups on the basis of matrix material. They are: i.Composite Metal Matrix ii.Ceramic Matrix Composite iii. Composite Polymer Matrix

Bumper:
In the context of cars, the term "fascia" typically refers to the front or rear bumper cover, or the plastic panel that covers the area between the hood and the windshield. It is also sometimes used to describe the dashboard or instrument panel in the interior of the car. The fascia of a car is usually designed to be aerodynamic, stylish, and protective. It can be made of various materials, such as plastic, fiberglass, or carbon fiber, and may be painted to match the color of the car's body. The fascia also includes openings for headlights, fog lights, grilles, and other features that help to enhance the car's appearance and functionality. Additionally, some car manufacturers may use the term "fascia" to refer to the entire front or rear assembly of the car, including the bumper cover, grille, and other components as shown in fig. 1. It is a piece of material that is long, thin and flexible, like a length of thread. Fiber Polymers may be pulled into long filaments with a length to width ratio of at least 100:1 Fiber comprises of natural and artificial fiber.

Fibrous composites:
Composites with short fiber reinforcement consist of a matrix that is strengthened by a phase separation in the manner of discontinuous fibers that have a diameter of 100 inches and a length of 100 inches. They fall under category a) Composites with unpredictable fiber direction. b) Composites having desired fiber orientation. Long-fiber reinforced composites have a matrix that is strengthened by an evanescent phase made of continuous fibers.
i.Fibers are oriented in a single direction. ii.Fibers oriented in two directions (woven).
As part of this research work we have done lot of literature survey meanwhile it was helpful us to do move work forward and corresponding literature as mentioned below. Pathania (2019) et al. The density is lesser in E-glass i.e 1983 kg/m 3 and Tensile strength is 490 Mpa where as steel density is 7850kg/m 3 and tensile strength is 520 Mpa. E-Glass Epoxy fibre also showed well results rather than steel. And the cost of the bumper beams can be reduced by more than 50%.
Moghaddam (2011) et al. A commercial short-fiber composite bumper made of GMT material (glass fibre epoxy) with a mechanical spring is designed under frontal impact test. It is revealed that by utilizing this mechanical energy absorber the bumper is able to convert about 80% of kinetic impact energy to spring potential energy and release it to environment in the low impact velocity. Davoodi (2010) et al. y enhancing the impact property, a hybrid of kenaf/glass fibres might be used in vehicle structural elements like the bumper beam. Additionally, by enhancing the structural design parameters, the impact property may be enhanced.

Epoxy Resin:
The composites can be laminated using any resin one factor that needs to be taken while picking a resins is its viscosity. Faster lamination is possible with lower viscosity because permanent reinforcement may be included more quickly. Although higher viscosity resins can also be selected, careful preparation would be needed. A prevalent type for the resin is diglycidyl ether of bisphenol A (DGEBA). 24 The deformations and fracture toughness are generally lowered, while the tensile modulus, transition temperature of glass, thermal stability, and chemical resistance are all enhanced. A lot of mechanical and aeronautical constructions employ epoxy resin. Epoxy resin has a number of benefits, including i. Excellent adhesion to metal and glass fibers ii. No volatile substances present while curing. iii. Good chemical and solvent resistance; low shrinkage while curing

Mould:
Typically, a mould is required when employing the lay-up technique to create components in order to position the layer inside or outside and get the desired form. The mould pattern is shown in fig. 2. To retain the flat base of the layup, we did not utilize a mould but rather a tabletop.

Release agent
Prevents resin from sticking to the mould. Here the table top was covered with plastic sheeting toast as the release agent. Some other release agents used in industry are: i. Waxes ii. Spray releases iii. Release films iv. Internal releases (added to gel coat or resin system) Since they can function as contaminants if unintentionally included into the composite layup, release agents are often placed to the composites moulds or equipment in a separate defined area.

Experimental Setup
The combination of different fibers have to be now prepared as per the testing that we have choosen and all the specimens should follow the standards shown in fig. 3.

Specimen Preparation:
Ensure that the work area is clean and free of dust, dirt, and debris. Prepare the mould by applying a release agent to prevent the composite from sticking to the mould. Cutting and arranging materials: Cut the reinforcing fibers, such as fiberglass or carbon fiber, to the desired shape and size. Mixing the resin: Mix the resin and hardener according to the manufacturer's instructions. Thoroughly stir the mixture to ensure that the resin and hardener are evenly distributed.

Applying the resin:
Apply the resin onto the reinforcing fibers using a brush or roller. Ensure that the resin saturates the fibers and that there are no dry spots. Laminating: Add additional layers of reinforcing fibers and resin onto the mold, following the desired sequence and orientation. Use a roller or squeegee to remove any air pockets or excess resin. Curing: Allow the composite to cure according to the resin manufacturer's instructions. This typically involves placing the mold in a temperature-controlled environment to allow the resin to harden.

Demolding:
Once the composite has cured, remove the part from the mold. Carefully peel back the mold to avoid damaging the composite. Trimming: Trim any excess material from the edges of the composite using a saw or other cutting tool.

Mechanical testing:
After fabrication is completed the test specimens were subjected to various mechanical tests as per ASTM standards. The flexural test of composite is carried out using Electronic Tensometer shown in below figures. The flexural test is generally performed on flat specimens. A uniaxial load is applied through both the ends. The ASTM standard test method for flexural properties of hybrid fiber composite has the designations Impact strength measurement is done on IZOD test on the composites using impact strength testing machine. Water absorption test is also performed on the specimens prepared.
Standards for bending test: The standards for specimen do not vary depending on fiber orientation. For the bending test, ASTM D739 specimen standards are taken.
Bending specimen geometry: The specimen configuration does not depend on the direction of the fiber. The fiber may be placed in unidirectional / multidirectional in consideration. The area of the specimen is rectangular. The cross sectional area is also rectangular. The required dimensions of the specimen are represented in table 2.

Flexural testing:
Flexural testing, also known as bend testing or bending test, is a type of mechanical test used to evaluate the bending or flexural strength and stiffness of a material. This test involves applying a force to a sample of the material at a specific distance from its supports or points of restraint. Experimental setup for flexural strength shown in fig. 5.

Impact strength testing:
A mechanical test called an impact analysis is performed to determine whether a product or product can survive rapid loading or shocks loading. Experimental setup for impact strength shown in fig. 6.In this test, an object or material is put to a significant intensity, typically by having a load or a pendulum dropped onto it.

Water absorption test:
Water absorption testing is an important method to evaluate the performance of fiber composites, especially those that are used in environments with high humidity or exposure to water. The test involves measuring the amount of liquid that a material absorbs over a given period of time shown in fig. 7.

RESULT AND DISCUSSIONS:
The Results of impact strength and water absorption rate are discussed as follows

4.1: Flexural Test results:
The break loads observed by performing flexural test on all specimens by using Tensometer represented in following table 3.

4.2: Impact Test results:
Impact strength has been calculated based on impact energy and areas of specimens by using the formula (1) and shown in table 4. Impact Srtength = Impact energy/Area of the specimen (1)   fig .9, among all the above specimens, the Glass-Rami-Rami-Jute-Jute-Glass (S-4) having high impact strength of 6.8 N/mm 2 .

4.3: Water Absorption Test Results:
The amount of water absorbed by the specimen is derived by the formula shown below and tabulated in table 5.