Design and analysis of polymer matrix composite side impact beam of vehicles

In recent years, with the development in the automotive sector and the increase in the number of vehicles in the world, security problems have come to the forefront as well as environmental problems. Today, the automotive industry focuses on the development of low-fuel-consuming automobiles with high safety levels and low-cost production methods. Appropriate designs for achieving this can be achieved through the use of materials that allow lighter and higher pulsation damping. In the vehicle, weight reduction occurs in the chassis and bodywork area as in every region. With the work done, a decrease in weight and fuel consumption will be achieved on the side impact beams in cars, and on the other hand, a safe structure that is resistant to side impacts has been created. When studies done up to now are examined, metal beams are generally preferred because they are more economical. In recent years composite materials have become more prominent. This is due to the fact that composites are much lighter and stronger than steel materials. Thus, with the development of composite materials technology, it has started to be used more effectively in the automotive industry. In this study, using the honeycomb sandwich structure composite, appropriate beam material selection, sample materials and prototype side impact beam profiles were produced. Carbon fiber reinforced epoxy material on the top surface of honeycomb sandwich structures, Aluminum and Nomex honeycomb was used as core material. Three point bending, tensile and impact tests were applied to the produced test samples. By using different material orientations, the strength, impact, weight etc. parameters of the beam are experimentally examined. By working on two different profiles, C and O side impact beam was produced from carbon fiber reinforced polymer composite material. The produced C profile Aluminum and Nomex honey honeycomb core structure and O profile carbon fiber side impact beams were tested with free weight reduction method from 2500 mm, 2750 mm and 3000 mm heights. Thus, the optimal design of the beams used in cars to prevent impacts to the side beams can be realized. By using alternative composite materials (carbon-fiber reinforced epoxy, polyethylene) on one side, a decrease in fuel consumption and a reduction in fuel consumption will be provided, while on the other hand, a safety structure will be created by increasing the resistance of the side beams against impacts.