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Journal of Polymer & Composites Original Research Special issue

Design and Analysis of Honeycomb Rear Door Map Pocket by Application of Finite Element Method

  1. Pramod Ram Wadate Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune
  2. Deepak Dhondge Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune
  3. Rahul Bachute Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune
  4. Pritee Purohit Department of Mechanical Engineering, Army Institute of Technology, Pune

Abstract

In modern automobiles, the door trim plays a vital role in both functionality and occupant safety. It integrates various convenience features such as armrests, power window switches, and map pockets, while also contributing to crash energy absorption during side impacts. In such collisions, the occupant's body typically contacts the door trim, making its design and material selection critical for minimizing injury through controlled deformation and energy dissipation. This research focuses on enhancing the crashworthiness of a rear door map pocket by analysing its response to impact using simulation and experimental methods. A 3D model of the map pocket is developed using SolidWorks and evaluated through Finite Element Analysis (FEA) in ANSYS Workbench 21, using a falling steel ball impact scenario as per industry standards. To improve energy absorption and reduce reactive forces, the conventional material is replaced with 3D-printed ABS featuring a honeycomb structure. Denting (compression) tests on a Universal Testing Machine (UTM) were used for experimental validation, followed by a comparative analysis of simulation and experimental outcomes to assess performance. The findings aim to guide the development of safer, lightweight automotive components, with recommendations for future improvements.

Keywords

References (17)

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