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Design and Fabrication of Composite Bumper for Light Passenger Vehicles

The fuel efficiency and emission gas regulation of passenger cars are two important issues in these days. The best way to increase the fuel efficiency without sacrificing safety is to employ fiber reinforced composite materials in the cars. Bumper is the one of the part having more weight. In this paper the existing steel bumper is replaced with composite bumper. In this work the design and fabrication of composite bumper made up of glass fiber reinforced polymer is carried out by which weight of the bumper can be reduced. Fabrication of composite bumper is carried out by hand layup process by using E- Glass/ Epoxy bidirectional laminates. Composite bumper is analysed and Charpy impact tests are carried out. Compared to steel bumper, the composite bumper is found to have 64% higher factor of safety and 80% less in cost. From the fabrication it was found that the weight reduction of 53.8% is achieved using composite material without sacrificing the strength.