Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today's industrial problems.

• Keywords
• curved composite frame, optimized winding procedure, roving winding, straight helix, toroidal helix, torus, winding angle,
• Publication type
• Journal Article MeSH

The enhancement of fuel economy and the emission of greenhouse gases are the key growing challenges around the globe that drive automobile manufacturers to produce lightweight vehicles. Additionally, the reduction in the weight of the vehicle could contribute to its recyclability and performance (for example crashworthiness and impact resistance). One of the strategies is to develop high-performance lightweight materials by the replacement of conventional materials such as steel and cast iron with lightweight materials. The lightweight composite which is commonly referred to as fiber-reinforced plastics (FRP) composite is one of the lightweight materials to achieve fuel efficiency and the reduction of CO2 emission. However, the damage of FRP composite under impact loading is one of the critical factors which affects its structural application. The bumper beam plays a key role in bearing sudden impact during a collision. Polymer composite materials have been abundantly used in a variety of applications such as transportation industries. The main thrust of the present paper deals with the use of high-strength glass fibers as the reinforcing member in the polymer composite to develop a car bumper beam. The mechanical performance and manufacturing techniques are discussed. Based on the literature studies, glass fiber-reinforced composite (GRP) provides more promise in the automotive industry compared to conventional materials such as car bumper beams.

• Keywords
• automotive bumper beam, glass fiber, impact energy: energy absorption, mechanical design, polymer matrix,
• Publication type
• Journal Article MeSH
• Review MeSH

The crashworthiness of composite tubes is widely examined for various types of FRP composites. However, the use of hybrid composites potentially enhances the material characteristics under impact loading. In this regard, this study used a combination of unidirectional glass-carbon fibre reinforced epoxy resin as the hybrid composite tube fabricated by the pultrusion method. Five tubes with different length aspect ratios were fabricated and tested, in which the results demonstrate "how structural energy absorption affects by increasing the length of tubes". Crash force efficiency was used as the criterion to show that the selected L/D are acceptable of crash resistance with 95% efficiency. Different chamfering shapes as the trigger mechanism were applied to the tubes and the triggering effect was examined to understand the impact capacity of different tubes. A finite element model was developed to evaluate different crashworthiness indicators of the test. The results were validated through a good agreement between experimental and numerical simulations. The experimental and numerical results show that hybrid glass/carbon tubes accomplish an average 25.34 kJ/kg specific energy absorption, average 1.43 kJ energy absorption, average 32.43 kN maximum peak load, and average 96.67% crash force efficiency under quasi-static axial loading. The results show that selecting the optimum trigger mechanism causes progressive collapse and increases the specific energy absorption by more than 35%.

• Keywords
• axial load, composite tube, crashworthiness, energy absorption, finite element model, hybrid composites,
• Publication type
• Journal Article MeSH