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The present work deals with the crashworthiness behaviour of high-density polyethylene (HDPE) composite against aluminium alloy (Al5022). For the composite reinforcement purpose, 20 wt. % of kenaf or multi-walled carbon nanotube has been considered. HDPE composites have been fabricated using the microwave-assisted compression moulding process, and uniaxial tensile tests have been performed to obtain their mechanical properties. Crashworthiness analyses of HDPE composites have been investigated using ANSYS finite element software, wherein obtained mechanical properties are given as inputs. Numerical investigations are conducted for full, offset, and oblique frontal impact. Crashworthiness of the automotive body panel has been investigated based on deformation of the bumper, kinetic energy of the body panel, and the target body’s reaction force. The results showed that although the HDPE composites’ directional deformation is higher than that of aluminium alloy, these have considerably lower values of deceleration and reaction force during the impact period.

Crashworthiness performance of HDPE-kenaf and HDPE-CNT composite structures