Simulation, fabrication and mechanical characterization of a jute–epoxy biocomposite hubcap for automotive applications

Abstract

This study presents the design, numerical simulation, fabrication, and mechanical characterization of an automotive hubcap manufactured from a jute fabric-reinforced epoxy biocomposite. The hubcap geometry was designed in SolidWorks and analyzed using finite element simulations under static, centrifugal (2546 rpm), and thermal (130 °C) loading conditions representative of service environments. The component was fabricated by compression molding using a two-part silicone mold derived from a 3D-printed master. Mechanical testing of jute–epoxy laminates revealed a tensile strength of 25.97 MPa, a tensile modulus of 2.47 GPa, a flexural strength of 69.41 MPa, and a flexural modulus of 1.08 GPa. Finite element results showed low deformation (maximum 0.058 mm under static load and 0.031 mm under centrifugal load) and Von Mises stresses below 9.5 MPa, corresponding to safety factors above 2.7. Under thermal loading, the maximum stress reached 52.3 MPa with a displacement of 0.138 mm, identifying temperature as the most critical condition. The fabricated hubcap exhibited a low mass of 239 g, representing an estimated weight reduction of 30–40% compared to conventional plastic alternatives. These results confirm the feasibility of jute-based biocomposites for lightweight, non-structural automotive applications with improved environmental performance.