Structural Analysis and Weight Optimization of a Four-Wheeler Automotive Chassis Using Composite Materials and Finite Element Approach

Abstract

Nowadays, the transport industry plays a significant role in the economies of both industrialized and developed nations. Weight reductions is currently the primary concern in the vehicle industry. The bottom body of a car, containing the tires, motor, outline, driveline, and suspension, is referred to as the chassis. The frame is the most important of them, as it supports the vehicle's components. The chassis frame is an essential component in cars. The primary functions of an automotive chassis are to transport the products and goods that are placed on it. As a result, it must be strong enough to withstand twists, shocks, stresses and vibration. In this work, data from a current light vehicle chassis of a TOYOTA vehicle are utilised for modelling and analysis of a vehicle chassis employing composite materials, namely HSLA Steel and S-GLASS epoxy, exposed to the same load as a steel chassis. Weight reductions in numerous parts of a vehicle may increase performance and efficiency. Composites material has a high strength-to-weight ratio and might be used in place of traditional materials. This article investigates the structural analysis of a fronted cross bar that has been replaced with s-glass Fibre Reinforced Polymer composite material. The maximum deflection and the maximum stress are critical parameters for chassis designs. The objective of the current research is to identify the maximum deflection and maximum stress. Vertical loads working horizontally in existing cross sections are used to test the design. Using commercial finite element analysis software packages like ANSYS and CATIA, I use finite element analysis for light modeling in this work. Next, I present a lightweight and robust chassis for an eco-friendly car.

Cite as:

Naveen Singh, & Adarsh Kumar. (2025). Structural Analysis and Weight Optimization of a Four-Wheeler Automotive Chassis Using Composite Materials and Finite Element Approach. Research and Reviews: Journal of Mechanical Engineering, 1(2), 14–27. 

https://doi.org/10.5281/zenodo.16265043