ABSTRACT

This paper presents a comprehensive Computer-Aided Engineering (CAE) analysis and material selection study for the chassis of a four-wheel Efficycle — a hybrid human-electric powered vehicle designed for student competitions and sustainable mobility applications. The objective of the study is to evaluate the structural integrity, stiffness, and crashworthiness of the chassis under various loading scenarios including front impact, side impact, rollover, and torsional loads. Using CAD models developed in SolidWorks and structural simulations performed in ANSYS Workbench, different design configurations were virtually tested to assess stress distribution, deformation patterns, and safety margins.

Three candidate materials — AISI 1018, AISI 1020, and AISI 4130 — were compared based on mechanical properties, manufacturability, cost, and availability. The analysis revealed that AISI 1018 provides the most balanced solution, offering adequate strength, good ductility, weldability, and affordability. The CAE results confirmed that under defined loading conditions, the AISI 1018 chassis design performs within permissible deformation limits while ensuring driver safety and regulatory compliance.

The study builds upon existing research on CAD/CAE integration and validates the effectiveness of simulation-based design in reducing prototyping costs, improving reliability, and accelerating the development cycle of student-level vehicles such as SAE Efficycle and BAJA SAE. In addition, the research highlights key design considerations for lightweight hybrid chassis structures, including reinforcement strategies in high-stress regions and stiffness optimization for rollover resistance.

The findings provide a robust framework for future design optimization and material selection in academic vehicle engineering projects. Further extensions of this work could involve fatigue testing, dynamic load simulations, and topology optimization to improve durability and weight efficiency. Overall, the research demonstrates how simulation-driven design and careful material selection contribute to safer, lighter, and more cost-effective vehicles.

Keywords CAE Analysis, Chassis Design, AISI 1018, Structural Simulation, Efficycle, Impact Testing.

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ABSTRACT

This paper presents a comprehensive Computer-Aided Engineering (CAE) analysis and material selection study for the chassis of a four-wheel Efficycle — a hybrid human-electric powered vehicle designed for student competitions and sustainable mobility applications. The objective of the study is to evaluate the structural integrity, stiffness, and crashworthiness of the chassis under various loading scenarios including front impact, side impact, rollover, and torsional loads. Using CAD models developed in SolidWorks and structural simulations performed in ANSYS Workbench, different design configurations were virtually tested to assess stress distribution, deformation patterns, and safety margins.

Three candidate materials — AISI 1018, AISI 1020, and AISI 4130 — were compared based on mechanical properties, manufacturability, cost, and availability. The analysis revealed that AISI 1018 provides the most balanced solution, offering adequate strength, good ductility, weldability, and affordability. The CAE results confirmed that under defined loading conditions, the AISI 1018 chassis design performs within permissible deformation limits while ensuring driver safety and regulatory compliance.

The study builds upon existing research on CAD/CAE integration and validates the effectiveness of simulation-based design in reducing prototyping costs, improving reliability, and accelerating the development cycle of student-level vehicles such as SAE Efficycle and BAJA SAE. In addition, the research highlights key design considerations for lightweight hybrid chassis structures, including reinforcement strategies in high-stress regions and stiffness optimization for rollover resistance.

The findings provide a robust framework for future design optimization and material selection in academic vehicle engineering projects. Further extensions of this work could involve fatigue testing, dynamic load simulations, and topology optimization to improve durability and weight efficiency. Overall, the research demonstrates how simulation-driven design and careful material selection contribute to safer, lighter, and more cost-effective vehicles.

Keywords CAE Analysis, Chassis Design, AISI 1018, Structural Simulation, Efficycle, Impact Testing.

🔒 This is a subscription article

Full text is available to subscribers and institutional members. Please choose an option below to access it.