Investigations on the Mechanical and Vibrational Characteristics of an Electric Vehicle Chassis using Finite Element Analysis (FEA)

The chassis of an electric vehicle represents a critical nexus between safety, efficiency, and performance. Its role extends beyond conventional vehicular frameworks, assuming responsibility for housing and protecting vital components, managing thermal dynamics, and providing a robust safety envelope. With the rapid evolution of EV technology, continued advancements in chassis design and engineering will undoubtedly play a pivotal role in shaping the future of sustainable mobility. Structural analysis of the Chassis yields deformation, stress and strain. Similarly, vibration analysis provides the natural frequencies of vibration. Under dynamic conditions, the investigations of these characteristics are done in the present work. Further, failure modes of vibrations are also found using Finite Element Analysis. 

From the present study, it is concluded that, with an increase of pressure by 19%, the average percentage increase in the stress, strain and total deformation is observed to lie in the range of 18 to 20%. Further, it is observed that, the amplitude in the Grey Cast Iron is higher as compared to the other materials considered in the present investigation while the amplitude in the Titanium Alloy is lowest. Additionally, vibration frequency in the Structural Steel is higher as compared to the other materials considered in the present investigation while vibration frequency in the Grey Cast Iron is lowest.  

FEA, Structural and Vibrational Analysis, Phase Response, Harmonic Analysis, Frequency, Deformation, Electric vehicle analysis

1. D. Sammangi, L. Kayathi, J. Kanaparthi, R. Kutcherlapati, and R. Sarimalla, “A study on structural behaviour and vibrational characteristics of a go-kart chassis,” E3S Web Conf., vol. 391, 2023. [Google Scholar] [Crossref]

2. D. Karale, S. Thakare, V. Khambalkar, M. Desmukh, and R. Walke, “Design and Analysis of Battery Electric Vehicle Sprayer Chassis by Using Finite Element Method,” International Journal of Innovations in Engineering and Science, vol. 5. 2020. [Google Scholar] [Crossref]

3. N. Saini, M. Panwar, A. Maurya, and P. A. Singh, “Design and Vibration Analysis of Go-kart Chassis,” Int. J. Appl. Eng. Res., vol. 14, pp. 53–57, 2019. [Google Scholar] [Crossref]

4. C. Bulgu, “Design a Space Frame Chassis for Light Weight Automobiles for Improved Safety and Reliability,” Mech. Eng. Res., vol. 9, p. 36, 2020. [Google Scholar] [Crossref]

5. H. H. Rathod, S. Kumar, and V. Goel, “A Review on Analysis and Design of Vehicle Chassis and its Materials,” 2018. [Google Scholar] [Crossref]

6. D. Sharma and Y. D. Vora, “Design and Analysis of Heavy Duty Vehicle (Trailer) Chassis through FEM Software,” 2017. [Google Scholar] [Crossref]

7. K. Subburathinam and V. S N, “Finite Element Analysis of Automotive Chassis with Various Cross-Section,” 2016. [Google Scholar] [Crossref]

8. H. Jaiswal, A. Kumar, A. Anand, and P. P. Patil, “Free Vibration Mode Shape Analysis of Space Frame Chassis of a Sports Car based on FEA,” 2014. [Google Scholar] [Crossref]

9. B. E. Gajbhiye, S. V Bhalerao, and K. B. Salve, “Study of Vibrational Effects on Heavy Duty Truck Chassis with the Help of Model Analysis Using Fem Technique,” Int. J. Eng. Res. Technol., vol. 2, 2013. [Google Scholar] [Crossref]

10. S. Rosbi, H. Desa, K. Saifullah, M. Abdul Rahman, K. Salleh, and I. Ibrahim, A study of Vibration Analysis for Gearbox Casing Using Finite Element Analysis. 2009. [Google Scholar] [Crossref]

11. R. Rahman and H. Teo, “Statics and dynamics structural analysis of a 4.5 ton truck chassis,” Jan. 2007. [Google Scholar] [Crossref]

12. Ansys Inc, Academic Research, Release 16. 2014. [Google Scholar] [Crossref]

13. Zhang, L., et al. (2023). Experimental Modal Analysis of EV Chassis Structures, Journal of Automotive Engineering. [Google Scholar] [Crossref]

14. Lee, S., & Kumar, P. (2022). Dynamic Stress Evaluation of Lightweight Automotive Frames, International Journal of Vehicle Design. [Google Scholar] [Crossref]

15. L. Scurtu and D. Moldovanu, “Conceptual design of an electric vehicle chassis using topology optimization method,” IOP Conf. Ser.: Mater. Sci. Eng., vol. 1311, 012022, 2024. [Google Scholar] [Crossref]

16. O. Zamzam, A. A. Abdelaziz, T. Elnady, and A. Ayman, “Structural analysis of an electric vehicle chassis using finite element analysis,” J. Eng. Adv. Technol. Sustain. Appl., vol. 1, pp. 48–54, 2025. [Google Scholar] [Crossref]

17. K. Wang, P. Wang, Y. Lin, and X. Wang, “Modal analysis and optimization of electric vehicle chassis structure,” World Scientific Research J., vol. 11, no. 9, pp. 11–19, 2025. [Google Scholar] [Crossref]

• Students' Perception Towards Artificial Intelligence in Higher Education in India
• Strategic Leadership and Cybersecurity Readiness in Digitally Transforming Organisations
• Spatial Distribution of Tourism Infrastructure in Awka, Onitsha and Nnewi Urban Areas of Anambra State.
• Emerging Technologies, Education and Skill Development for A Sustainable Blue Economy in Nigeria.
• Quantum Dot–Based Solar Cells: Advancements, Challenges, and Future Prospects