Structural analysis of an electric car chassis by numerical and experimental methods

An important issue in efficiency maximization of an electric car is the successful achievement of a lightweight design while keeping static stiffness and safety of the mechanical structure. The paper presents the structural integrity analysis of a metallic frame chassis designed for a lightweight electric car manufactured by composite materials. The existing frame was analyzed for static loadings by numerical and experimental methods. Experimental tests for static loading conditions were performed using strain gauges placed in different points of the chassis. Finite element simulations allowed evaluation of safety and structural integrity of the chassis under static and impact loads. The results showed that chassis was able to withstand the required loads with minimal deflections and stresses.