Design and Structural Analysis of Glass Fiber Reinforced Composite for Two-Wheeler Mudguard

Abstract

The increasing demand for sustainable and lightweight materials in the automotive industry has led to the exploration of reinforced composite materials. This study focuses on the design and structural analysis of a glass fiber reinforced composite mudguard for automotive applications. The mudguard was designed and simulated using ANSYS software to evaluate its performance under real-world conditions. A finite element model of the mudguard was created with a quadratic order element, and a mesh convergence study was conducted to ensure correct simulation results. The boundary conditions were applied, with fixed support at the fastener slots and a load of 1500N applied perpendicular to the surface of the mudguard. A comparative study was carried out by simulating the same model with different materials. The simulation results showed a maximum deformation and a significant maximum equivalent stress, showing that the glass fiber reinforced composite mudguard exhibits excellent mechanical strength and stiffness. This research highlights the potential of glass fiber composites in enhancing automotive safety and efficiency while contributing to weight reduction. A sustainability analysis of E-glass was conducted, and the results were summarized in a dedicated sustainability report. The findings provide a foundation for further research and sustainable practical implementation of glass fiber composites in automotive engineering.

Introduction

The automotive industry is prioritizing sustainability by adopting lightweight and eco-friendly materials. Glass fiber-reinforced polymers (GFRP) have emerged as a viable alternative to metals and plastics due to their strength, durability, and lower environmental impact. Historically, composite materials date back to 1200 AD (e.g., Mongolian bows) and gained prominence during WWII. Today, they are widely used in automotive and aerospace sectors.

GFRP offers benefits like high impact resistance, recyclability, and cost-effectiveness compared to carbon fiber. It is increasingly used in automotive parts such as bumpers, chassis, and passenger cells, as seen in models from BMW, Lexus, Mercedes-Benz, and others.

The study focuses on designing a mudguard using GFRP, aiming for weight reduction without compromising durability. Reducing vehicle weight improves fuel efficiency in combustion engines and energy efficiency in electric vehicles.

A literature review shows composites have 4–6 times the tensile strength of metals and offer design flexibility. A 43% fiber volume fraction is ideal for enhancing impact strength. GFRP's mechanical properties include a tensile strength of 0.08 GPa and a Young’s modulus of 25 GPa.

Experimental Charpy impact tests were conducted on GFRP specimens of varying diameters to evaluate their performance, following modified ASTM D6110 standards. Results showed GFRP has superior impact resistance compared to traditional materials like ABS (13.57 kJ/m²).

Conclusion

The research scope and applications of composite materials are ever-expanding, and through this study and the simulation of working environment of the GFRP automotive part (i.e., a mudguard) using the Finite Element Method FEM was conducted. The impact analysis conducted in Charpy impact tester demonstrated that the glass fiber-reinforced polymer GFRP composite provides significant advantages in terms of impact resistance, structural integrity, and weight reduction compared to conventional materials like metals and plastics ABS. The ANSYS simulation results demonstrate the glass fiber composite mudguard\'s excellent impact resistance, exhibiting minimal deformation of 7.99 mm and a maximum stress of 328.16 MPa, thereby showcasing its potential as a durable and reliable material for automotive applications. Furthermore, the study highlights the potential of GFRP composites in automotive applications, particularly in lightweight structural components that require a balance between strength and flexibility. The reduced weight contributes to improved fuel efficiency and lower emissions, aligning with the automotive industry\'s sustainability goals.

References

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Copyright

Copyright © 2025 Hareesh Kanth S, Melavasal Pandian D, Vinayagamoorthi M A. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.