Evaluation of Heavy Vehicle Chassis Using E-Glass Epoxy and S-2 Glass Epoxy Materials Through CAD-FEA Simulation

Abstract

The chassis is one of the most critical structural components of a heavy vehicle, responsible for supporting loads, maintaining structural integrity, and ensuring overall vehicle stability and safety. Traditionally, chassis structures are manufactured using steel due to its high strength and durability. However, the increasing demand for lightweight vehicles and improved fuel efficiency has led to the exploration of advanced composite materials such as E-Glass Epoxy and S-2 Glass Epoxy. This study focuses on the design and evaluation of a heavy vehicle chassis using these composite materials. A 3D model of the chassis is developed and analyzed using Finite Element Analysis (FEA) to assess parameters such as stress distribution, deformation, and factor of safety under various loading conditions. E-Glass Epoxy is known for its cost-effectiveness and good mechanical properties, while S-2 Glass Epoxy offers higher strength, stiffness, and improved fatigue resistance. The performance of both materials is compared to determine their suitability for heavy vehicle chassis applications. The results aim to highlight the advantages of composite materials in reducing weight while maintaining structural performance. This study provides valuable insights into material selection for modern automotive chassis design, contributing to enhanced efficiency, durability, and sustainability.

Introduction

The chassis is the primary structural framework of a heavy vehicle, supporting key components such as the engine, transmission, suspension system, and payload. Traditionally, chassis structures are made from steel because of its high strength and durability. However, steel significantly increases vehicle weight, resulting in higher fuel consumption and lower efficiency.

To address this issue, the automotive industry is increasingly adopting composite materials such as E-Glass Epoxy and S-2 Glass Epoxy, which offer high strength-to-weight ratios, corrosion resistance, and improved fatigue performance. E-Glass Epoxy is cost-effective and provides adequate mechanical properties, while S-2 Glass Epoxy offers superior strength, stiffness, and durability, making it more suitable for heavy-duty applications.

Literature Review

Previous studies have shown that:

• Composite materials can significantly reduce chassis weight while maintaining structural strength and stiffness.
• S-2 Glass Epoxy generally performs better than E-Glass Epoxy in terms of load-carrying capacity, deformation resistance, fatigue life, and durability.
• E-Glass Epoxy remains a practical and economical option for moderate-load applications.
• Finite Element Analysis (FEA) is an effective tool for predicting stress distribution, deformation, and structural performance of chassis designs.
• Proper fiber orientation and layering can further improve the mechanical properties of composite structures.
• Composite chassis improve fuel efficiency and vehicle performance compared to conventional steel chassis.

Objectives

The study aims to:

1. Design a heavy vehicle chassis using CAD software.
2. Perform structural analysis using Finite Element Analysis (FEA).
3. Compare the performance of E-Glass Epoxy and S-2 Glass Epoxy under identical loading conditions.
4. Evaluate the effects of material properties on weight reduction, strength, and stiffness.

Methodology

A heavy vehicle chassis model is designed using standard dimensions and analyzed through FEA. The structural behavior of the chassis is assessed by examining:

• Stress distribution
• Deformation
• Factor of Safety

The performance of E-Glass Epoxy and S-2 Glass Epoxy is compared to identify the most suitable material for a lightweight, strong, and efficient chassis design.

Conclusion

The study concludes that composite materials are effective alternatives to conventional steel for heavy vehicle chassis design. Both E-Glass Epoxy and S-2 Glass Epoxy offer significant weight reduction, which improves fuel efficiency and vehicle performance. However, S-2 Glass Epoxy demonstrates superior strength, stiffness, and fatigue resistance compared to E-Glass Epoxy, making it more suitable for high-load applications. On the other hand, E-Glass Epoxy is more cost-effective and can be used where moderate strength is sufficient. The use of Finite Element Analysis (FEA) helps in accurately predicting structural behavior and optimizing the design. Overall, the selection of material depends on the balance between performance requirements and cost considerations, with S-2 Glass Epoxy being the better choice for high-performance chassis applications.

References

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Copyright

Copyright © 2026 Mr. Pavan Gajanan Gurav, Dr. Pankaj P. Awate, Mrs. Swati P. Shinde. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.