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Structural performance evaluation of an automotive chassis under various load conditions using finite element analysis

Kalyani S. Kulkarni¹ and Sanjay H. Sawant²

PhD Scholar, Department of Technology,Shivaji University, Vidyanagar, Kolhapur,Maharashtra, 416004,India¹
Professor, Sant Gajanan Maharaj College of Engineering,Mahagaon, Kolhapur,Maharashtra, 416503,India²

Corresponding Author : Kalyani S. Kulkarni

Recieved : 19-September-2024; Revised : 23-November-2025; Accepted : 06-December-2025

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

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