Computational Structural Analysis of an Electric Vehicle Frame Using Finite Element Techniques

The structural integrity and safety of electric vehicle (EV) frames are critical factors in ensuring occupant protection, vehicle performance, and longevity. This study presents a computational structural analysis of a two-seater electric vehicle frame using advanced Finite Element Method (FEM) techniques. A detailed CAD model of the EV chassis was developed considering realistic geometrical features and material properties of lightweight automotive-grade steel and aluminum alloys. The model was subjected to a variety of loading conditions, including static, dynamic, and torsional forces, simulating real-world operational scenarios such as cornering, braking, and passenger load distribution. Stress, strain, and deformation distributions were analyzed to identify critical regions susceptible to failure or excessive deformation. The FEM simulations were performed using ANSYS software, incorporating meshing optimization and boundary condition realism to ensure accurate and reliable results. The results indicate that the chassis design can withstand typical operational loads with acceptable safety margins, while highlighting areas where reinforcements or material optimizations could improve performance. Comparisons of different material combinations and cross-sectional designs were also conducted to evaluate the trade-offs between weight reduction and structural rigidity, emphasizing the importance of lightweight design in improving energy efficiency without compromising safety. This study demonstrates the effectiveness of finite element analysis as a predictive tool for EV frame design, enabling engineers to optimize structural performance, enhance safety, and reduce prototyping costs. The insights gained from this work provide a foundation for future improvements in electric vehicle chassis design and contribute to the development of safe, lightweight, and energy-efficient EVs.