Stress and Deformation Analysis of Chassis Frame for Electric Vehicle with Weight Optimization to Improve Overall Vehicle Efficiency

Abstract

This project focuses on the design, modelling, and analysis of an Electric Vehicle (EV) chassis frame to ensure optimal safety and performance under real-world conditions. Recognizing the critical challenge of designing an EV chassis strong enough to support heavy battery packs and powerful motors while maintaining a lightweight structure, the study employs advanced Computer-Aided Design (CAD) and Finite Element Analysis (FEA) methodologies. The methodology involves creating a precise 3D model using industry-standard CAD software (e.g., AutoCAD, CATIA, or SolidWorks), followed by rigorous stress and deformation simulations using the ANSYS FEA tool. The core of the work lies in leveraging these detailed simulations to guide subsequent design optimization for enhanced safety and structural efficiency. Given the global pivot toward EVs as the future of transportation, this project is highly relevant and timely, positioning the work at the forefront of contemporary automotive design challenges. It serves as a practical demonstration of advanced engineering principles and computational tools, offering a focused contribution to the development of safer and more efficient EV structures through rigorous, computer-aided engineering analysis.

Introduction

The project focuses on the design and analysis of an Electric Vehicle (EV) chassis frame, which serves as the primary load-bearing structure and ensures passenger safety. EV chassis design poses unique challenges due to heavy batteries, powerful motors, and specific braking requirements. The project aims to create a lightweight, strong, and crashworthy chassis using optimal materials such as steel and aluminium.

The design process involves 3D modeling in CAD software (AutoCAD, CATIA, or SolidWorks) and structural analysis using Finite Element Analysis (FEA) in ANSYS to evaluate stress, deformation, and safety under static, dynamic, torsional, and lateral loading conditions. Material selection is based on factors such as strength, weight, durability, cost, and corrosion resistance.

Results show that an optimized chassis using topology optimization and selective aluminium substitution reduced mass by 23.3% (from 120 kg to 92 kg) while maintaining safety and performance standards. This demonstrates the potential for improving EV efficiency and structural performance through careful design and analysis.

Conclusion

The project aims to design, model, and analyse an Electric Vehicle (EV) chassis frame using CAD (Computer-Aided Design) and FEA (Finite Element Analysis) tools, specifically ANSYS, to ensure its safety and performance under real-world loading conditions. The project directly addresses the critical challenge of designing an EV chassis that must be strong enough to support heavy battery packs and powerful motors while remaining lightweight and capable of withstanding various operational stresses and potential crashes. The project is highly relevant given the global shift toward Electric Vehicles as the future of transportation, positioning the work at the forefront of automotive design.

References

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Copyright

Copyright © 2025 Rajat Bagade, Vaibhav Bankar. 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.