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Structural performance evaluation of electric vehicle chassis under static and dynamic loads
Omar Zamzam1, Aly A Ramzy2, Mohamed Abdelaziz3
1Design and Production Engineering, Faculty of Engineering, Ain Shams University, Cairo, Egypt. omar.zamzam@eng.asu.edu.eg.
Scientific Reports
|February 12, 2025
Summary
This study analyzes electric vehicle (EV) chassis dynamics when hitting speed bumps. The EV chassis is safe, experiencing only elastic deformation under transient loads.
Area of Science:
- Automotive Engineering
- Mechanical Engineering
- Sustainable Transportation
Background:
- Electric vehicle (EV) chassis design is critical for energy efficiency and range.
- Optimizing chassis weight while maintaining robustness under dynamic loads is a key engineering challenge.
- Understanding transient forces from road irregularities like speed bumps is essential for EV chassis integrity.
Purpose of the Study:
- To perform a dynamic analysis of an electric vehicle chassis subjected to transient suspension forces from speed bumps.
- To propose a load factor that relates static and dynamic loads experienced by the chassis.
- To evaluate the safety and structural integrity of the EV chassis under simulated dynamic loading conditions.
Main Methods:
- A quarter vehicle model was simulated using MATLAB Simulink to determine transient forces.
- Finite Element Analysis (FEA) was conducted using SimSolid software for static and dynamic load cases.
- Three dynamic analysis scenarios were simulated: Front Loading, Rear Loading, and Torsional Loading.
Main Results:
- Dynamic analysis revealed a maximum stress of 288 MPa with a safety factor of 1.12.
- Static analysis showed a maximum stress of 64 MPa with a safety factor of 5.69.
- A load factor of 4.44 was determined between static and dynamic loads, indicating significant dynamic amplification.
Conclusions:
- The electric vehicle chassis exhibits only elastic deformation under the analyzed dynamic loading conditions.
- The calculated safety factors confirm the structural integrity of the chassis for practical use.
- The proposed load factor provides valuable insight for designing robust EV chassis capable of withstanding dynamic road impacts.
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