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

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 940 951
    By

    Pramod Ram Wadate,

  • Deepak Dhondge,

  • Rahul Bachute,

  • Pritee Purohit,

  1. Assistant Professor, Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune, Maharashtra, India
  2. PG Student, Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune, Maharashtra, India
  3. Assistant Professor, Department of Mechanical Engineering, Ajeenkya D.Y. Patil School of Engineering, Pune, Maharshtra, India
  4. Associate Professor, Department of Mechanical Engineering, Army Institute of Technology, Pune, Maharshtra, India

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: Hexagonal core structures, composite structures, trapezoidal core structures, finite element analysis, automotive.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Pramod Ram Wadate, Deepak Dhondge, Rahul Bachute, Pritee Purohit. Design and Analysis of Honeycomb Rear Door Map Pocket by Application of Finite Element Method. Journal of Polymer & Composites. 2026; 14(01):940-951.
How to cite this URL:
Pramod Ram Wadate, Deepak Dhondge, Rahul Bachute, Pritee Purohit. Design and Analysis of Honeycomb Rear Door Map Pocket by Application of Finite Element Method. Journal of Polymer & Composites. 2026; 14(01):940-951. Available from: https://journals.stmjournals.com/jopc/article=2026/view=236674


References

  1. Y. Yuhazri1, M.H. Amirhafizan, A. Abdullah Kenaf et. al. Fibre Composites as Promising Green Composites for Automotive Car Door Map Pocket Application IJMME-IJENS. 2018; 18 (02): 15–21p. https://www.researchgate.net/publication/325287917
  2. Y. Yuhazri1, M.H. Amirhafizan, A. Abdullah Potentiality of Utilizing Hybrid Non-woven/woven Fabric Kenaf Fiber Composite for Car Door Map Pocket. 3rd International Sciences, Technology & Engineering Conference 2018 – Material Chemistry; 2018 April 17–18; Penang, Malaysia. AIP Conf. Proc. 2018. (Conference Proceedings) https://doi.org/10.1063/1.5066969
  3. Yuan Liu a, Min Zhou b, Kedong Fu et. al. Optimal Design, Analysis and Additive Manufacturing for Two-Level Stochastic Honeycomb Structure International Journal of Computer Integrated Manufacturing, 2019 32(7), 682–694p https://doi.org/10.1063/1.5066969
  4. Gouri Ghongade, Kota Pavan Kalyan, R. Vaira Vignesh, M. Govindaraju. Design, fabrication, and analysis of cost-effective steel honeycomb structures. Materials Today: Proceedings 46(10)2021;4520–4526p. (Conference Proceedings) https://doi.org/10.1016/j.matpr.2020.09.694
  5. Shubham Upreti, Vishal K. Singh, Susheel K. Kamal, Arpit Jain, Anurag Dixit. Modelling and analysis of honeycomb sandwich structure using finite element method Materials Today: Proceedings 25(4)2020;620–625p. (Conference Proceedings) https://doi.org/10.1016/j.matpr.2019.07.377
  6. Hossein Mohammadi, Zaini Ahmad, Michal Petru, et. al. An insight from nature: honeycomb pattern in advanced structural design for impact energy absorption Journal of Materials Research and Technology. 2023; 22: 2862–2887p. https://doi.org/10.1016/j.jmrt.2022.12.063
  7. Utzig, L., Fuchs, A., Weisheit, K., and Marburg, S. Squeak Noise Prediction of a Door Trim Panel Using Harmonic Balance Method. 11th International Styrian Noise, Vibration & Harshness Congress: The European Automotive Noise Conference, Graz, Austria, Nov. 3–5, 2020 – SAE Int. J. Advances & Curr. Prac. in Mobility 3(2) (Conference Proceedings) 2021;1108–1118p. doi:10.4271/2020-01-1577
  8. Woonsang Baek and Duck Young Kim. An in-Process Inspection System to Detect Noise Originating from within the Interior Trim Panels of Car Doors MDPI Sensors 2020; 20(3) 630:1–15p. https://doi.org/10.3390/s20030630
  9. Omkar S Bhosale, Deepak Huajre, Murtaza S Laila. Optimization for squeak and rattle reduction using vibration analysis of passenger car door trim Noise & Vibration Worldwide. 2022;53(9–10):428–432p. doi:10.1177/09574565221128061
  10. S P Zaoutsos. Mechanical behavior of aluminum honeycomb sandwich structures under extreme low temperature conditions IOP Conf. Series: Materials Science and Engineering. IOP Conf. Ser.: Mater. Sci. Eng. 2017; 700. 1–10p. (Conference Proceedings) doi:10.1088/1757-899X/700/1/012017
  11. Mohsin Abdullah AL-Shammari & Muhannad AL-Waily. Analytical Investigation of Buckling Behavior of Honeycombs Sandwich Combined Plate Structure International Journal of Mechanical and Production Engineering Research and Development. 2018; 8 (4): 771–786p. https://www.researchgate.net/publication/326717884
  12. Anil Kumar1, Arindam Kumar Chanda, Surjit Angra. Numerical Modelling of a Composite Sandwich Structure Having Non Metallic Honeycomb Core. EVERGREEN Joint Journal of Novel Carbon Resource Sciences & Green Asia Strategy. 2018; 08 (04): 759–767p, https://doi.org/10.5109/4742119
  13. Jabihulla Shariff, Dr. R. Satya Meher. Design Modulation of Composite Material Sandwich Panels with Different Inner Polyethylene Core Structures International Journal of Engineering Research &Technology. 2014; 3 (11): 404–408p.
  14. Kiran Kumar Reddy, N. Venkatramana Reddy. Design and Analysis of Sandwich Honey Comb Structures. International Journal of Research in Engineering, Science and Management 2019; 2(1).
  15. Saiaf Bin Rayhan, Mahtab Uddin Chowdhury, Xue Pu. Ballistic impact reponse of reinforced honeycomb sandwich panels. IOP Conf. Series: Materials Science and Engineering 2022; 1226- 012079: 1–8p. DOI:1088/1757-899X/1226/1/012079
  16. A Florence, M Arockia Jaswin. Vibration and flexural characterization of hybrid honeycomb core sandwich panels filled with different energy absorbing materials. Materials Research Express “BIOGRAPHIES. Res. Express 2019; 6: 075326 DOI 10.1088/2053-1591/ab1576
  17. ASTM D256 Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics; 2006. ASTM D3039 Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials; 2008.
Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 12/08/2025
Accepted 08/10/2025
Published 09/02/2026
Publication Time 181 Days
85

Login


My IP

PlumX Metrics