Finite Element Analysis and Structural Optimization of Electric Vehicle Chassis Design

Abstract

In 2018, the design of electric vehicle (EV) chassis leveraged Finite Element Analysis (FEA) and structural optimization to meet competing demands of lightweight construction, safety, and dynamic performance. This study surveys two representative FEA applications from that year: one involving a lightweight electric bus frame and another analyzing an electric car chassis. Yang et al. performed FEA under full-load bending, torsion, emergency braking, and steering conditions to optimize an electric bus frame using structural steel and aluminum alloy combinations, ultimately reducing weight without sacrificing structural integrity Matec ConferencesResearchGate. Meanwhile, Mardji & Prasetiyo used ANSYS 18.1 along with Autodesk Inventor 2018 to model an electric car chassis, revealing key metrics: equivalent stress of ~59.98 MPa, equivalent elastic strain ~3.325×10⁻⁴ mm/mm, total deformation ~2.43 mm, and a safety factor of ~3.55 Matec ConferencesMendeley. These works demonstrate that FEA was being systematically applied for both lightweight and structural reliability goals in EV chassis design. This paper builds on those 2018 studies: it examines methodologies for lightweight optimization and strength validation, compares results and approaches, and discusses their implications for EV chassis engineering. The findings highlight the viability of FEA-driven design adjustments in achieving weight savings, ensuring safety margins, and addressing diverse load scenarios. Structural optimization via material substitution and geometry adjustments emerges as a powerful strategy. This study concludes with insights on how 2018-era techniques laid the groundwork for further advancements in operational efficiency, design methods, and integrated optimization workflows in EV chassis development