Low Velocity Drop-Weight Impact of Flax–Glass Hybrid Composites for Application in Automotive Components: Numerical Modelling and Experimental Analysis

This study focuses on the behavior of hybrid polymer composites made from glass fiber and natural fiber-based flax fabric when subjected to low velocity drop-weight impacts. With the rise in the utilization of composites in structural components in various industries like the marine, aerospace and automotive industries, it is of paramount importance to study the effects of low velocity drop-weight impacts and their damage assessment on the composites. Low velocity drop-weight impacts can occur due to a tool falling on a composite part or due to an impact with a small object. The experimental tests were carried out according to ASTM standards with a drop-weight impact testing machine. Simulations were done to replicate the tests using explicit finite element software LS-DYNA. The experimental tests were carried out on samples of thickness ~2.5 mm and the energy at impact was 50 J. Upon comparing the experimental results, it was seen that an error percentage in the deformation varied between a minimum of 3.32% and a maximum of 8.93%, and the maximum force at impact varied between a minimum of 0.06% and a maximum of 17.14%. The variations between the experimental and simulated values can be attributed to the presence of voids or other defects that would have inadvertently crept in while making the composite. Additionally, composite laminates lined with a layer of EPS (expanded polystyrene) foam were tested and compared with composite laminates which were not lined with the foam. An improvement in the performance of the composite laminates lined with the EPS foam was observed.