Experimental Investigation of Biodiesel Blends on Performance and Emission Characteristics of Diesel Engines

Abstract

Lightweighting of automotive structures requires materials that can reduce mass without creating unacceptable losses in stiffness, strength, impact resistance, or occupant protection. This methodology paper presents a finite element analysis (FEA) framework for evaluating fibre-reinforced composite materials as substitutes for conventional steel in load-bearing automotive components. A representative B-pillar/side-frame reinforcement is adopted as the numerical case study, while the workflow is also applicable to bumper beams, roof rails, cross-members, and energy-absorbing members. The procedure combines geometry preparation, orthotropic lamina definition, laminate lay-up selection, mesh-convergence assessment, static and low-speed impact loading, progressive failure evaluation, and mass-constrained optimization. Steel, glass-fibre-reinforced polymer (GFRP), quasi-isotropic carbon-fibre-reinforced polymer (CFRP), and an optimized CFRP laminate are compared using component mass, maximum displacement, peak reaction force, energy absorption, and composite failure index. Representative numerical results from the defined model indicate that the optimized CFRP concept can provide approximately 73% mass reduction relative to the steel baseline while maintaining comparable global stiffness and a failure index below unity. The study emphasizes that reliable composite FEA depends on correct fibre orientation, mesh objectivity, damage parameters, contact definitions, and experimental calibration. The proposed workflow therefore provides a structured basis for early-stage lightweight automotive design before expensive prototype and crash-testing campaigns.