A

SYNOPSIS

ON

“Experimental investigation of the crashworthiness performance

of laminated composites using Plastic bike’s wind shield and
woven carbon fiber mat”
BY

MR. ABHIJEET PRAKASHRAO SABLE

M. TECH (DESIGN ENGINEERING)

REGISTRATION NO-19271209

UNDER GUIDANCE OF

PROF. S.H.PATIL

MECHANICAL ENGINEERING DEPARTMENT

GOVERNMENT COLLEGE OF ENGINEERING, KARAD.

(An Autonomous Institute of Government of Maharashtra.)
2020- 2021

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 SYNOPSIS

1. Name of the course: DESIGN ENGINEERING

2. Name of the student: SABLE ABHIJEET PRAKASHRAO

3. Name of Guide: Prof. S.H.PATIL

4. Name of Co-Guide: -

5. Ref. Letter of Guide: -

6. Proposed title of dissertation: “Experimental investigation of the

crashworthiness performance of laminated composites using bike’s Plastic
wind shield and woven carbon fiber mat”

7. Relevance-
7.1 Introductions- Crashworthiness is the ability of a vehicle to protect its occupants
during an impact/accident. Crashworthiness plays a key role in energy absorption and hence
in vehicle accidents, also Crashworthiness concerns the safety of a vehicle during a car
accident, not crash prevention. In vehicle accidents, the dissipation of crash forces is of high
importance to save lives and protect assets. Depending on the nature of the impact and the
vehicle involved, different criteria are used to determine the crashworthiness of the structure.
Several criteria are used to assess crashworthiness prospectively, including the deformation
patterns of the vehicle structure, the acceleration experienced by the vehicle during an
impact, and the probability of injury predicted by human body models. Injury probability is
defined using criteria, which are mechanical parameters (e.g., force, acceleration, or
deformation) that correlate with injury risk.
To define crashworthiness, car companies must conduct extensive crash testing to
identify potentially injurious car defects. These tests chiefly concern how the force of a
collision affects the occupant of a vehicle. 
Car accidents are among the major causes of mortality in modern society. In the
automotive industry, safety is one of the main design considerations. When there is a
progressive collapse of the vehicle structure during a frontal crash, two basic requirements
should be fulfilled for preventing death or serious injury to the occupants.

 The first requirement ensures that occupants do not sustain injuries caused by
high inertia forces and material used.

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  Occupants are not clamped by the car structure during the crash event. To fulfill
this requirement, the deformation of the passenger compartment needs to be
limited.
This project is all about the first requirement of crashworthiness testing parameter i.e.
“High inertial force and material” used. Aluminium, Steel, rubber, plastics, fiber and are four
commonly utilized commodities found in cars, this project deals with laminated composites
of plastic and carbon fiber.

7.2 Motivation- Most of the parts in automobile vehicle are made from plastic fiber material
like mudguard, wind shield, mirror case, bonnet, when accident takes place then destruction
in plastic parts occurs. Therefore it is necessary to make plastic material enough hard so that
it cannot break easily in accidents, by using carbon fiber as reinforcement material.

8. Literature review-

8.1 Samer Gowid, Jamil Renno et.al, - Crashworthiness plays a key role in energy
absorption in vehicle accidents. The energy absorption capacity of laminated composite
materials is heavily investigated in the industry due to their low cost, corrosion
resistance, and high strength to weight ratio. Thus, this paper experimentally investigates
the effect of the addition of woven fiber laminates and fiber steel sandwich laminates on
the strength and energy absorption capacity of PVC polymer tubes. The sandwich‐
structured composite is formed from two woven glass‐fiber composite layers with a steel
layer in between. Four normal and hybrid reinforcement configurations are proposed,
evaluated, and compared to the benchmark unreinforced tube. The crashworthiness
characteristics of the reinforced composite tubes were identified using quasi‐static axial
compression tests. The crushing parameters, in terms of load–displacement response,
load‐carrying capacity, Specific Energy (SE) absorption capability, and Crush Force
Efficiency (CFE) were determined for each sample. Moreover, Scanning Electron
Microscope (SEM) analysis was carried out to investigate the microstructures, which
clearly indicate the fractured surfaces. The results show that the tube reinforced with a 1
mm steel layer sandwiched between 2 layers and 4 layers of woven glass‐fiber has the
highest SE and CFE of 14 J/g and 0.91, respectively, while the tube reinforced with 7
layers of glass fiber layers only has the highest Initial Peak Load (IPF) of 139.36 kN.

8.2 Malepati Vineeth Choudary. Balasubramanian et.al, -The most noteworthy use of
composite materials is seen in structural components for air craft’s. In this investigation,
a laminate of glass fiber reinforced with stainless steel wire mesh is used. Corrosion
resistance, less elongation at high tension and high flexibility are the features of stainless
steel fiber. The mechanical properties of the laminates were strengthened with steel wire
mesh and studied for their performance. Tensile, compressive and flexural tests were
carried out on glass fiber/stainless steel hybrid composites to understand the behavior of
the composite. Three-point bend test was carried out on those specimens to evaluate the
flexural strength and flexural modulus. It has been observed that the reinforcement of
stainless-steel wires has significant impact on the mechanical properties of the
sandwiched laminates.

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8.3 N. Mahaviradhan, S. Sivaganesan et.al, -Many research works were carried out in
the field of material science; these researches show that the composite materials are
better than the conventional materials due to their enhanced mechanical properties. The
recent manufacturing trends, Aluminium based composite materials are popular in most
of the application like automotive, aircraft, military, and others. The carbon fiber
reinforced aluminum metal matrix composites are highly potential materials for
aerospace and electronics industries. In the present work, an open die casting method is
used to fabricate the AA 6061 based composite material. The AA6061 is used as a base
metal, and the uncoated continuous long spool-type pitch-based carbon fibers are used as
reinforcement. The carbon fibers were placed in the format with two-levels of weight
percentage 5% and 10%; the carbon fibers were reinforced with a certain distance with
AA6061 Aluminium alloy; the composite is fabricated with the help of an electric
furnace. The composite’s mechanical properties were studied by the various mechanical
tests and they were compared with the base alloy of AA6061. The morphological
characteristic was studied by the SEM images, which exhibit the uniform distribution of
carbon fibers in the composite material.

8.4 Patryk Jakubczak, Jarosław Bienias, Magda Drozdziel et.al, - Impact resistance
is one of the basic properties of thin-walled coating structures that is of vast importance
in the aerospace industry. Being able to absorb the energy of impact force, having
resistance to puncture and being able to limit internal damage to the structure affect the
continued load capacity of the component. Current aerospace designs utilize composite
and hybrid materials. The work compares the low-velocity impact resistance of carbon
fibers-reinforced polymer, Aluminium carbon reinforced aluminum and hybrid titanium
carbon laminates. In the assessment measurable, experimental and analytic evaluation
criteria for the phenomenon of impact and the reaction of the material to this type of
load, based on diverse physical foundations were utilized. It was demonstrated that a
laminate based on titanium layers has at least two times higher impact resistance than
Aluminium based laminate, and at least six times greater impact resistance than its
conventional carbon-epoxy equivalent.

8.5 Şahin Yavuza, Mehmet Mert İlmanb et.al, - In this paper, different approaches of
the modeling techniques for the single-link uniform cross-sectional shape manipulators
are presented. Three different materials of manipulators which are epoxy-glass and
carbon-fiber for the composite manipulators and the steel manipulator are considered for
both the simulation and the experimental analyses. Three different modeling techniques
which are solid, beam and shell models are used for both manipulators. Modeling
procedures are conducted in ANSYS Workbench and transient analyses are performed in
order to investigate and compare the accuracy of the modeling approaches with the
experiments. The results show that vibration responses of three modeling approaches
have well matched with the experimental results. Comparing the analysis times, the solid
modeling takes considerably higher time than the beam and the shell modeling. It is
concluded that beam and shell modeling are appropriate for the modeling and faster
obtaining transient results for all material types of manipulators. Since the solution times
of shell and beam modeling are close to each other, the manipulators can be modeled as
beam or shell model if the manipulator has uniform cross-sectional geometry. For non-
uniform cross-sectional geometry of the manipulators, it can be suggested that the shell
modeling is more appropriate for modeling technique while it is impossible to model the
non-uniform cross-sec Table 5 Elapsed time and RMS comparison for the different case
scenarios of steel manipulator, Tonal geometry as beam model.

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8.6 Huan-Chang Tseng* , Rong-Yeu Chang, Chia-Hsiang Hsu et.al,- Fiber reinforced
polymer (FRP) composites offer exciting new possibilities for the green automotive
industry, owing to their excellent mechanical properties, advantageous weight reduction
and economical fuel consumption. In practice, accurately predicting fiber orientation is a
critical issue in causing anisotropy in the mechanical properties of the FRP parts.
Recently, an objective fiber orientation model, iARD-RPR (Improved Anisotropic
Rotary Diffusion model combined with a Retarding Principal Rate model) proved
significant in the field of fiber suspension rheology. Using state-of-the-art injection
molding simulations, we therefore used the iARD-RPR model to explore the fiber
orientation changes for various fiber components in regard to fiber length (short and long
fibers) and fiber type (glass and carbon fibers). Under an extreme condition of higher
fiber concentration and longer fiber lengths, a thicker core region and a narrow shell are
always found in a typical orientation pattern of injection molded FRT parts. More
importantly, these predicted orientation distributions provided to micromechanical
material modeling computation of mechanical properties aid in the discussion on the
reinforcing ability of short/ long fibers and glass/carbon fibers based on the numerical
simulation results. Comparisons with experimental data are also presented herein.

8.7 K. Karthik ⇑ , D. Rajamani, A. Manimaran, J. Udayaprakash et.al,- Composites

made of synthetic fiber combined hybrid composites are find many industrial
applications. Due to high strength to light weight ratio, higher modulus significantly
reduced cost. In this research, composite fiber in woven mat form is added to matrix
element with varying stacking sequences of symmetrical laminates. Four various hybrid
laminate composites having glass, kevlar and carbon fibers are the reinforcements in
varying stacking sequences are produced using hand lay-up technique followed by
compression molding. The mechanical strength of the produced composite is evaluated.
Experimental results found that composite having stacking sequences of Carbon-Kevlar-
Carbon Kevlar- Carbon (C-K-C-K-C) has the highest value of tensile strength 385.09
MPa respectively. Scanning Electron Microscope (SEM) is used to examine the
morphology of fractured surface of hybrid composites during testing. SEM images
revealed that hybrid composite with C-K-C-K-C had less defects on its fractured surface
compared to other counter parts of the hybrid composites.

8.8 Yushun Zhao, Fuhua Xue , Linlin Miao, Chao Wang, Chao Sui, Qingyu Peng
Xiaodong Hea et.al,- Carbon nanotubes (CNTs) are regarded as the next generation of
one-dimensional super-strong Nano materials due to their extraordinary mechanical
properties. Recently, much attention has been dedicated into super-strong CNT-based
fibers resulting from twisting operation. However, the roles of a promising compression
operation on the mechanical enhancement mechanisms of CNT fibers (CNFs) are not
clear. Especially, the combined twisting-compression effect has not been known. In this
work, with using coarse-grained molecular dynamic simulation method, the tensile
mechanical properties and mechanical enhancements of randomly-distributed CNT fibers
(RDCNFs) were studied. It was found that the mechanical performances of such
RDCNFs could be significantly improved by increasing CNT length or decreasing initial
bending degree of CNTs. Furthermore, both specific strength and specific modulus can
be effectively tuned by twisting and compressing operations, where self-locking and

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unhitching mechanisms of CNT knots play critical roles. On the other hand, following
theoretical guidance, a super strong CNF with the maximum specific strength up to 296
mn/tex (~6.8 GPa) was designed and fabricated. This work provides a theoretically and
experimentally support to design super-strong CNT-based fibers and lays a foundation
for their future applications.

8.9 Esfandiar Pakdel * , Sima Kashi, Russell Varley, Xungai Wang et.al,- Carbon
fibre reinforced composites (CFRC) continue to play a key role in the growth and
development of many weight sensitive industries. However, their proliferation has raised
increasing concerns regarding the required practices and strategies to deal with these
expensive engineered structures at the end of their life cycle. This has brought into focus
the need to develop more sustainable and efficient recycling solutions for these products.
Similarly, the necessity of managing dry carbon fibre scraps generated during the
manufacturing process of CFRC has attracted more attention in recent years. This review
article provides an overview on recent advances in recycling CFRC as well as processing
dry carbon fibre scraps. Influential parameters, advantages, drawbacks, and possible
environmental impacts of the main technologies of processing CFRC waste including
mechanical, thermal (pyrolysis and fluidised bed), and chemical (solvolysis and low
temperature chemical processing) will be evaluated. Their potential effects on
mechanical characteristics and surface chemistry of fibres are assessed. Moreover, recent
processing methods of dry and semi-finished carbon fibre scrap are also reviewed.
Specific attention is paid to the recent developments in producing hybrid yarns and
nonwovens made of waste carbon fibre. The methodologies developed in this area, their
processing conditions, as well as other important findings are discussed. This review
paper provides a valuable platform for researchers and decision makers working in the
field of carbon fibre by providing a clearer picture on the options available to recycle
CFRC, and the methods of developing value-added products using waste carbon fibre.

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 9. Gaps in Literature Review-
a. In above research paper Laminated coating of carbon fiber, glass fiber, and jute
fiber mostly takes place on metals only.
b. Lack of information related with manufacturing of laminated composite, and
resins.
c. Researchers have not studied on bikes plastic wind shield as base material and
composed with carbon fiber mat as laminated reinforcement material.
d. And whenever accidents happens in vehicle plastics parts gets scratches and
easily destructed, so it is necessary to do analysis on plastic parts using carbon
fiber mats as laminated reinforcement.

10. Proposed Work :

10.1 Problem statement

 Most of the parts in automobile vehicle are made from plastic fiber material like
mudguard, wind shield, mirror case, bonnet. But when accident takes place then
destruction in plastic parts occurs.
 Therefore it is necessary to make plastic material enough hard so that it cannot
break easily in accidents, by using carbon fiber as reinforcement material.
 To study laminated composites and manufacturing laminated composite using
carbon fiber and plastic wind shield.
 To do experiment using UTM machine and tensile machine, and perform analysis
of laminated composite using ANSYS software.

i. 10.2 Objective: This dissertation aims to,

 To manufacture laminated composite material by using carbon fiber and plastic
wind shield of bike.
 To study crashworthiness behavior of laminated reinforced under various analysis
process and condition.
 To find at which force, stress load–displacement response, load‐carrying capacity,
Specific Energy (SE) absorption capability, and Crush Force Efficiency (CFE) of
the laminated wind shield will break by using universal tensile machine, impact
testing machine.
 To know the suitability and crashworthiness of reinforcement using carbon fiber.

10.3 Cost estimation

Sr. no. Component name Quantity Cost
1. Woven carbon fiber 6 550*6=3100 rs
2. Plastic wind shield 10 500*10=5000 rs
3. Epoxy resin 1 1000*1=1000 rs
4. Base coat 1 500*1=500 rs
5. scrub paper 10 25*10=250 rs
6 Brush 2 20*2=40 rs
7. Hair dryer 1 1000*1= rs
Total 10950 rs

11. Work plan-

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 Finalization of topic

Review of literature related to problem

Research gap-Problem statement- Material selection

Collection of data

Manufacturing of laminated composites

Perform experiments as per design of experiment

The analysis of data using ANSYS and MATLAB software

Conclusion

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12. References:

1) Samer Gowid, Elsadig Mahdi Jamil Renno, Sadok Sassi Ghais Kharmanda, Abdallah
Shokry- “Experimental investigation of the crashworthiness performance of fiber and
fiber steel-reinforced composites tubes”, published in 2020 Composite Structures 251
(2020) 112655.

2) Malepati Vineeth Choudary, A. Nagaraja- “Characterization of laminate sandwiched

with stainless steel and glass fiber”. Published in 5 November 2019 Materials Today:
Proceedings.

3) N. Mahaviradhan, S. Sivaganesan-“Experimental investigation on mechanical

properties of carbon fiber reinforced aluminum metal matrix composite”. Accepted 16
September 2020 Composite Structures 251 (2020) 112655.

4) Jakubczak, Jarosław Bienias- “The collation of impact behavior of titanium/carbon,

aluminum/carbon and conventional carbon fibers laminates”. Published in 2020 Thin–
Walled Structures 155 (2020) 106952.

5) Şahin Yavuza,⁎, Mehmet Mert İlmanb, Batuhan Binici Şahin Yavuza,⁎, Mehmet Mert
İlmanb, Batuhan Binici et.al,- “Modeling approach and analysis time comparison of
single-link flexible steel- and epoxy-glass/carbon-fiber composite manipulators”
published in 2020 Structures 26 (2020) 396–405.

6) Huan-Chang Tseng* , Rong-Yeu Chang, Chia-Hsiang Hsu et.al,-“ Numerical

prediction of fiber orientation and mechanical performance for short/long glass and
carbon fiber-reinforced composites Accepted 20 February 2017 published in 2020
Composites Science and Technology 144 (2017) 51e56.

7) K. Karthik, D. Rajamani, A. Manimaran, J. Udayaprakash et.al,-“Evaluation of tensile

properties on Glass/Carbon/Kevlar fiber reinforced hybrid composites” Accepted 2
June 2020 Materials Today: Proceedings.
8) Yushun Zhao , Fuhua Xue , Linlin Miao, Chao Wang , Chao Sui Qingyu Peng ,
Xiaodong et.al,-“ Roles of twisting-compression operations on mechanical
enhancement of carbon nanotube fibers” Accepted 27 September 2020 published in
Dec 2020 Carbon 172 (2021) 41e49.

9) Esfandiar Pakdel *, Sima Kashi, Russell Varley, Xungai Wang et.al,-“Recent progress
in recycling carbon fiber reinforced composites and dry carbon fiber wastes” Institute
for Frontier Materials, Deakin University, Waurn Ponds Campus, Geelong, VIC,
3216, Australia Resources, Conservation & Recycling.

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 UNDERTAKING OF STUDENT

Presented work is my own work, on part of wok had been summited for award of any
degree /diploma at any other university/college

----------------------------------
MR. SABLE ABHIJEET PRAKASHRAO
Mtech (Design Engineering)
Govt. College of Engineering Karad

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Undertaking of Guide :
Information given by student is correct and said facilities are available with the college.
Date: 29-01-2021
Place: Karad, Maharashtra.

------------------------ ----------------------
Signature of Guide Signature of HOD

Prof.S.H.PATIL Dr. R.K SHRIVASTAV

Head of the department (MECHANICAL)

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