Numerical Investigation of Low Velocity Impact Perforation in Natural–Synthetic Hybrid Composites for Automotive Applications

The increasing demand for sustainable and lightweight materials in the automotive industry has accelerated interest in natural fiber reinforced polymer composites. However, their limited impact resistance restricts application in structural and crash-relevant components. This work presents a numerical investigation of the low velocity impact (LVI) and perforation behavior of jute (J) and flax natural fiber reinforced epoxy composites (N) and their glass fiber (G) hybrid forms with synthetic fiber reinforced epoxy laminates (S), using LS-DYNA. A finite element model, developed with a discounted ply approach and MAT54 damage model, was first validated against published experimental data for glass/epoxy laminates, showing strong correlation in peak load and energy absorption. The validated model was then extended to simulate bidirectional natural fiber and hybrid laminates under 2–10 J impacts, replicating typical energy levels relevant to low-speed collisions and road debris impacts in vehicles. Key performance indices such as absorbed energy, peak load, damage initiation, and progression were predicted using Chang–Chang failure criteria. Results demonstrate that interlaminar glass hybridization significantly enhances impact resistance and energy dissipation while mitigating catastrophic failure, with [S/N/N/S] and GJJG configurations performing most effectively. The findings establish finite element modeling as a reliable tool for designing sustainable hybrid composites with improved crashworthiness, supporting their adoption in next-generation automotive body and interior applications.