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Lightweight design based on automotive drive axle housing
Yingshuai Liu1, Chenxing Liu2, Jianwei Tan2
1School of Mechanical Engineering, Shandong Huayu University of Technology, Dezhou, China.
Plos One
|September 18, 2025
Summary
This study optimized the integrated electric drive axle housing for pure electric vehicles (PEVs), achieving a 12% weight reduction without compromising strength or stiffness. This enhances PEV efficiency and cruising range.
Area of Science:
- Mechanical Engineering
- Automotive Engineering
- Materials Science
Background:
- Pure Electric Vehicles (PEVs) face limitations in cruising range and efficiency.
- Lightweight design is a key trend in electric vehicle development.
- Integrated electric drive axle housings offer potential for mass reduction.
Purpose of the Study:
- To design and optimize a lightweight integrated electric drive axle housing for PEVs.
- To evaluate the structural performance (stiffness, strength, modal characteristics) of the axle housing.
- To achieve significant weight reduction while maintaining safety and performance.
Main Methods:
- Developed a 3D model of the electric vehicle axle housing.
- Utilized Finite Element Analysis (FEA) to assess stress, deformation, and natural frequencies.
- Optimized the housing structure by adjusting wall thickness and material composition.
Main Results:
- FEA identified areas for mass reduction through targeted structural modifications.
- Optimized housing achieved a more uniform and efficient thickness distribution.
- The optimized axle housing demonstrated a 12% weight reduction.
Conclusions:
- The lightweight optimized axle housing meets strength and stiffness requirements.
- This design provides a feasible solution for improving PEV efficiency and range.
- The study offers a theoretical foundation for further lightweight electric vehicle development.
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