Design and optimization of lightweight car chassis for improved fuel efficiency

Abstract

This thesis focuses on the design and optimization of a lightweight car chassis to enhance fuel efficiency. The chassis, as the structural backbone of a vehicle, significantly impacts fuel consumption due to its weight. In this study it was aimed to reduce the weight of the chassis while ensuring it retained the required strength, safety, and durability. In this study SolidWorks for design and Finite Element Analysis (FEA) for evaluation were used, material selection, structural improvements, and manufacturing processes were explored to achieve these goals. This thesis was conducted by Agbii Emmanuel Ugha and Richard Okorocha as part of our Bachelor’s degree research project at Savonia University of Applied Sciences.

The results of the study revealed that through careful optimization, including adjustments to the chassis geometry and the use of materials like AISI 4340 steel and 6061-T4 aluminum, a weight reduction of over 10% was achieved. Comprehensive stress, fatigue, and torsional analyses confirmed the structural integrity and reliability of the new design. The lighter chassis improves fuel efficiency by reducing energy demands, contributing to lower carbon emissions and cost savings for users. These results are applicable not only to combustion-engine vehicles but also to electric vehicles, where weight reduction enhances battery efficiency and range. This research serves as a foundation for further advancements in sustainable automotive design, emphasizing cost-effective material innovation and energy efficiency for future generations.