Design analysis of AISI 1080 and carbon fibre composite hybrid and conventional chassis

Chassis is a structural backbone of any vehicle, so it should be rigid enough to withstand stresses, shocks and vibrations. Generally, chassis are made from structural steel and have required strength. However gross weight of vehicle increases due to heavy weight of chassis and affects the performance, range and recharge cycle in case of electric vehicles. In present research new material proposed for the chassis is carbon fibreepoxy woven composite (CFEWC).Chassis made from conventional structural steel AISI 1080 and hybrid chassis developed using both AISI 1080 and CFEWC materials are discussed. Smart utility vehicle chassis is considered for case study and analysis. Structural strength, torsional stiffness, and harmonic response analysis are carried in commercial FEA tools. Also, dynamic stability of hybrid chassis is verified under different road roughness, bump profile and vehicle speeds. Chassis performance verified in terms of displacement, acceleration, force and stresses induced. Results shows hybrid chassis is 32% lighter than conventional steel chassis and it has excellent strength in bending-torsion and also in vibrations. Hybrid chassis design approach offers benefit of both materials to improve the performance of electric vehicles by reducing weight of chassis up to 32%.