Structural Optimization and Fatigue Performance Evaluation of a Hybrid Carbon–Glass Fiber Reinforced Epoxy Composite Modular Swing Arm for Lightweight Electric Two‐Wheeler Applications

ABSTRACT This paper presents the research on designing and optimization of a lightweight modular swing arm made of a hybrid carbon‐glass fiber reinforced epoxy composite which is to be used in electric two wheelers. It was made using vacuum ‐assisted resin infusion (VARI), producing a fiber volume fraction of about 58% and a content of less than 2% voids. To enhance interlaminar toughness and fatigue strength, nano‐silica particles (as high as 2 wt%) were added to the epoxy matrix. Progressive tensile strength values were observed between 420 MPa (baseline) and 575 MPa in the 2 wt% modified composite with SiO ₂ and interlaminar shear strength was also improved by 30–48 Mpa. The approach of the analysis of the structure at rest demonstrated that the maximum deformation was reduced in 4.8 mm with the baseline structure to 3.1 mm in case of the optimized structure, and the first natural frequency was improved from 42 to 57 Hz, which showed the improvement of the stiffness and dynamical stability. Fatigue testing indicated that there was an improvement in endurance between 4.5 × 10 ⁵ cycles and 1.15 × 10 ⁶ cycles. Multi‐objective optimization process was able to establish an optimal design that attained a weight reduction of 35%–40% without compromising of structure, which validated the viability of nano‐enhanced hybrid composite to support lightweight electric mobility applications.