Abstract

The automobile sector has continually evolved in vehicle design, leading to significant advancements that enhance both performance and sustainability. A critical factor influencing these improvements is the vehicle chassis, whose structural integrity under varying loading conditions directly affects overall durability and efficiency. This study presents a detailed numerical analysis of the Eicher Pro 3015 vehicle chassis, examining its structural performance under steady-state loading. The chassis model was developed using American Society for Testing and Materials (ASTM) A148 Gr80-50 steel and P100/6061 aluminum as the primary materials. A comprehensive finite element analysis (FEA) was conducted in Analysis System (ANSYS) Workbench to evaluate stress distribution and deflection across multiple loading scenarios. Mesh refinement and grid independence tests were performed to ensure the accuracy and reliability of the simulations. The results show that ASTM A148 Gr80-50 steel exhibits superior load-bearing capacity and reduced deflection compared to P100/6061 aluminum, making it highly suitable for high-load automotive applications. The FEA outcomes offer valuable insights into chassis behavior, supporting future optimization of material selection to enhance performance and sustainability. Overall, the findings confirm that ASTM A148 Gr80-50 is a more effective material for car chassis construction under heavy loads. Future studies may explore advanced material modifications and lightweighting strategies while preserving structural integrity.

Keywords

Vehicle chassis, Finite element analysis (FEA), ASTM A148 Gr80-50 steel, P100/6061 aluminum, Structural performance, Stress and deflection analysis.

Cite this article

Kulkarni KS, Sawant SH. Structural performance evaluation of an automotive chassis under various load conditions using finite element analysis. International Journal of Advanced Technology and Engineering Exploration. 2025;12(133):1867-1881. DOI : 10.19101/IJATEE.2024.111101710

References

[1] Ashori A. Wood–plastic composites as promising green-composites for automotive industries!. Bioresource Technology. 2008; 99(11):4661-7.

[2] Cheah LW. Cars on a diet: the material and energy impacts of passenger vehicle weight reduction in the US. Doctoral Dissertation, Engineering Systems Division, Massachusetts Institute of Technology. 2010.

[3] Joost WJ. Reducing vehicle weight and improving US energy efficiency using integrated computational materials engineering. JOM. 2012; 64(9):1032-8.

[4] Czerwinski F. Current trends in automotive lightweighting strategies and materials. Materials. 2021; 14(21):1-27.

[5] Zhang W, Xu J. Advanced lightweight materials for automobiles: a review. Materials & Design. 2022; 221:1-20.

[6] Kaseem M, Dikici B. Innovations in lightweight materials for automotive and aerospace applications. Metals. 2024.

[7] Agrawal MS, Razik M. Finite element analysis of truck chassis. International Journal of Engineering Sciences & Research Technology. 2013; 2(12):3432-8.

[8] Naidu RC, Koppula SB, Kuppili HK, Vijay P. Numerical investigation & structural analysis of automotive bus chassis subjected to random vibrations. In international conference on smart materials and structures 2022. AIP Publishing LLC.

[9] Junk S, Rothe N. Lightweight design of automotive components using generative design with fiber-reinforced additive manufacturing. Procedia CIRP. 2022; 109:119-24.

[10] Murali G, Subramanyam B, Naveen D. Design improvement of a truck chassis based on thickness. In Altair Technology Conference 2013 (pp. 1-6).

[11] Ahamed MM, Natrayan L. Dynamic analysis and structural simulation of aluminum composite material based automobile chassis. Materials Today: Proceedings. 2022; 62:2244-9.

[12] Tidke N, Burande DH. Analysis of HCV chassis using FEA. International Journals of Engineering Research. 2017:1-5.

[13] Singh A, Soni V, Singh A. Structural analysis of ladder chassis for higher strength. International Journal of Emerging Technology and Advanced Engineering. 2014; 4(2):253-9.

[14] Chandra MR, Sreenivasulu S, Hussain SA. Modeling and structural analysis of heavy vehicle chassis made of polymeric composite material by three different cross sections. International Journal of Modern Engineering Research. 2012; 2(4):2594-600.

[15] Bhandarkar D. Analysis of vehicle chassis frame made of different composite materials. International Journal of Creative Research Thoughts. 2021; 9(4):4450-5.

[16] Asker HK, Dawood TS, Said AF. Stress analysis of standard truck chassis during ramping on block using finite element method. ARPN Journal of Engineering and Applied Sciences. 2012; 7(6):641-8.

[17] Prasad TR, Solasa G, Satyadeep NS, Babu GS. Static analysis and optimisation of chassis and suspension of an all-terrain vehicle. International Journal of Engineering and Advanced Technology. 2013; 2(5):1-6.

[18] Murali G, Subramanyam B, Naveen D. Design improvement of a truck chassis based on thickness. In Altair technology conference 2013 (pp. 1-6).

[19] Xue W, Wang T, Wei M, Wu J, Zhang L, Luo Z. Analysis and optimization of the front subframe of vehicle. Advances in Mechanical Engineering. 2024; 16(11):1-12.

[20] Singh A, Soni V, Singh A. Structural analysis of ladder chassis for higher strength. International Journal of Emerging Technology and Advanced Engineering. 2014; 4(2):253-9.

[21] Zheng B. Analysis of static and dynamic characteristics and lightweight design of titanium alloy frame. Manuf. Technol. 2024; 24:507-19.

[22] Arun GV, Kumar KK, Velmurugan S. Structural analysis of chassis using AISI 4130 and AA 7068. In IOP conference series: materials science and engineering 2021 (pp. 1-12). IOP Publishing.

[23] Li Z, Dai W, Yue H, Guo C, Ji Z, Li Q, et al. Fatigue life prediction of 2024-T3 clad Al alloy based on an improved SWT equation and machine learning. Materials. 2025; 18(2):1-24.

[24] Prabakaran S, Gunasekar K. Structural analysis of chassis frame and modification for weight reduction. International Journal of Engineering Sciences & Research Technology (IJESRT). 2014; 3(5):595-600.

[25] Zamzam O, Ramzy AA, Abdelaziz M, Elnady T, El-wahab AA. Structural performance evaluation of electric vehicle chassis under static and dynamic loads. Scientific Reports. 2025; 15(1):1-20.

[26] Agarwal A, Mthembu L. Structural analysis and optimization of heavy vehicle chassis using aluminium P100/6061 Al and Al ga 7-230 mmc. Processes. 2022; 10(2):1-14.

[27] Harikrishnan KC, Jose J, Joseph JC, Chacko C, Mangalathu GS, Abraham BC. Design optimization of electric all-terrain vehicle chassis. In AIP conference proceedings 2024. AIP Publishing LLC.

[28] Jiang W, Zhang Y, Liu J, Zhang D, Yan Y, Song C. Multi-objective optimization design for steel-aluminum lightweight body of pure electric bus based on RBF model and genetic algorithm. Electronic Research Archive. 2023; 31(4):1-16.

[29] Sowmith L, Varma VM, Shinde HK, Karthikeyan R, Goud RR. Static and dynamic analysis of heavy vehicle chassis with different cross sections and materials. In AIP conference proceedings 2023. AIP Publishing LLC.

[30] Czerwinski F. Current trends in automotive lightweighting strategies and materials. Materials. 2021; 14(21):1-27.

[31] https://www.energy.gov/eere/vehicles/lightweight-materials-cars-and-trucks. Accessed 20 October 2025.

[32] Mundt B, Schröder LC. Innovative and sustainable lightweight solutions while staying cost-competitive. In international munich chassis symposium 2022 (pp. 122-9). Berlin, Heidelberg: Springer Berlin Heidelberg.

[33] Yan L, Xu H. Lightweight composite materials in automotive engineering: state-of-the-art and future trends. Alexandria Engineering Journal. 2025; 118:1-10.

[34] Skosana SJ, Khoathane C, Malwela T. Driving towards sustainability: a review of natural fiber reinforced polymer composites for eco-friendly automotive light-weighting. Journal of Thermoplastic Composite Materials. 2025; 38(2):754-80.

[35] https://www.energy.gov/eere/vehicles/fuel-efficiency. Accessed 20 October 2025.