Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

Design and Analysis of Automobile Chassis by

using Alternative Materials
S.NAVEEN KUMAR1 ,R.KARTHIK2 ,S.KANISHKAR3 ,M.VIGNESWARAN4 ,
S.SYEDFAKHRUDDEEN5
(1)
Asst.professor, Department Of Mechanical Engineering, Knowledge Institute Of Technology, Salem, Tamilnadu
(2,3,4,5)
Student, Department Of Mechanical Engineering, Knowledge Institute Of Technology, Salem, Tamilnadu
(snmech@kiot.ac.in1, 2k17me083@kiot.ac.in2, 2k17me079@kiot.ac.in3, 2k17me207@kiot.ac.in4,
2k17me228@kiot.ac.in5)

ABSTRACT: The Chassis is the most integral part of the conditions. The frame should be able to flex under different

vehicle. It is the frame of the chassis on which the entire situations, while being able to return to its

body of the vehicle is built. The entire external load of the original shape when loads or forces are removed. From the
comparison it has been found that Eicher has lowest height of
vehicle including its self-weight is on the chassis. Thus, frame section and Eicher 11.10 has maximum load body
this chassis design and its analysis forms the most length (length of Frame). So this frame is having greatest
possibility of bending among all, thus this frame has been
important part of the vehicle manufacturing. This paper considered for the case study. The chassis frame is made of
deals with the structural analysis of a light duty automobile two side members joined with a series of cross members.
These cross members provide better handling of the vehicle,
chassis which is replaced an existing material (Grey Cast prevents deflection and gives torsional strength to resist
Iron) by ASTM A710, AISI 4130 steel and Al6063. twisting of the chassis. For the analysis of the chassis frame
appropriate model of the chassis is developed and analysed
Material properties are applied on an automobile chassis by the Finite Element Method (FEM).
and analysed under maximum load conditions. An
automobile chassis is modelled in Solid Works with the Chassis frame and body

appropriate dimensions. Analysis for the different Introduction of Chassis Frame: Chassis is a

materials is done in ANSYS based on the model. French term and was initially used to denote the frame
parts or Basic Structure of the vehicle. It is the back bone

I.INTRODUCTION of the vehicle. A vehicle without body is called Chassis.

The components of the vehicle like Power plant,
The chassis of an automobile provide mounting
Transmission System, Axles, Wheels and Tires,
points for the components like engine, driveline,
Suspension, Controlling Systems like Braking, Steering
suspension system and wheels. The main functions of the
etc., and also electrical system parts are mounted on the
chassis are to support the chassis components and the body
Chassis frame. It is the main mounting for all the
to withstand static and dynamic loads without excessive
components including the body. So it is also called as
deflection or distortion. The frame must be rigid enough to
Carrying Unit.
support or carry all the loads and forces that the vehicle is
subjected to in operation. A frame must also be flexible
enough to handle shock loads and the twists, bends, sway
and sag that it encounters under different road or load

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

bear up forces and make a fast drive. The added engine to

Chassis body

In most passenger cars through the middle of the 20th

century, a pressed-steel frame the vehicle’s chassis formed
a skeleton on which the engine, wheels, axle assemblies,
transmission, steering mechanism, brakes, and suspension
members were mounted. The body was flexibly bolted to
the chassis during a manufacturing process typically
referred to as body-on-frame construction. This process is
used today for heavy-duty vehicles, such as trucks, which
benefit from having a strong central frame, subjected to the
forces involved in such activities as carrying freight,
including the absorption of the movements of the engine
and axle that is allowed by the combination of body and
frame.
In modern passenger-car designs, the chassis
frame and the body are combined into a single structural
element. In this arrangement, called unit-body

construction, the steel body shell is reinforced with braces

that make it rigid enough to resist the forces that are
applied to it. Separate frames or partial “stub” frames have
been used for some cars to achieve better noise-isolation
characteristics. The heavier-gauge steel present in modern
component designs also tends to absorb energy during
impacts and limit intrusion in accidents.
An automotive Chassis plays important role in the
suspension system as handling becomes much easier when
one drive quality one. Suspension system take charge
when driving on bad road, causing the stress on the entire
chassis of a vehicle and causes same stress on the
suspension system when accelerated. This is to say, chassis

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

the chassis also add serious weight to a vehicle

chassis butthe good news is there is enough strength
to carry it.
Breaking system as one of the essential part
in an automobile. It is also mounted to the chassis
frame, the chassis have the ability of resist the
sudden braking of the vehicles. On a heavy load
vehicle, great force is also needed to immediately Conventional Chassis
stop the vehicle. This is why an automobile chassis
are design according to the force bearing capacity.
Functions of the Chassis Frame
• To carry load of the passengers or goods carried in
the body.
• To support the load of the body, engine, gear box etc.
• To withstand the forces caused due to the sudden
brakingor acceleration
• To withstand the stresses caused due to the bad road
condition.
• To withstand centrifugal force while cornering
TYPES OF FRAME
• Conventional frame
• Semi integral frame
• Integral frame

Conventional frame
It is non load carrying frame. The loads of
the vehicle are transferred to the suspensions by the
frame. This suspension in the main skeleton of the
vehicle which is supported on the axles through
springs. The body is made of flexible material like
wood and isolated frame by inserting rubber
mountings in between. The frame is made of channel
section or tubular section of box section. Example:
This type of frame is used for trucks.

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

the air pollution. Reducing the weight of the vehicle

Semi integral frame
In this case the rubber mountings used in
conventional frame between frame and suspension are
replaced by more stiff mountings. Because of this some of
the vehicle load is shared by the frame also. This type of
frame is heavier in construction. Example Popular in
European and American car.

Semi-integral chassis

Integral Frame
In this type of construction, there is no frame. It
is also called unitized frame body construction. In this
case, the body shell and underbody are welded into
single unit. The underbody is made of floor plates and
channel and box sections welded into single unit. This
assembly replaces the frame. This decreases the overall
weight compared to conventional separate frame and
body construction.

II. PROBLEM IDENTIFICATION

Automobiles that use gasoline or diesel fuels
affect the environment and the country economy
specially the developing country like Ethiopia. So, it is
necessary to build green and light vehicle. We can solve
this problem by reducing the size and the weight of
automobile by using light weight material such as
aluminium, composite like metal metrics composite and
polymer composites. When the vehicle number
increases, the usage of petrol (fuel) also increases. At
the same time, the emission from the vehicles increases

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

which can reduce the usage of petrol. If the chassis RESULT &
is designed in an optimal material usage then it will
CONCLUSION
save the amount of material consumed for single
time also the reduction in fuel cost will also be
economical for customer.
III. DESIGN
Design is the plan or specification of the object
which also shows the model in three-dimensional
view. Solid works is used to design the product
model. Some of the major tools used for designing
the project are extrude, sketch, mirror, bend, boss,
swept boss

Chassis model

IV.RESULT AND

ANALYSIS

EXISTING

PROPOSED

MATERIAL SELECTION

DESIGN

ANALYSIS

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

GREY CAST IRON MATERIAL AISI 4130 STEEL MATERIAL

Total Deformation of Grey Cast Iron Total Deformation of AISI 4130 Steel

Total Deformation of Grey Cast Iron Total Deformation of AISI 4130 Steel

Stress of Grey Cast Iron Stress of AISI 4130 Steel

Stress of Grey Cast Iron Stress of AISI 4130 Steel

Strain of Grey Cast Iron Strain of AISI 4130 Steel

Strain of Grey Cast Iron Strain of AISI 4130 Steel

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

AL 6063 ALLOY MATERIAL ASTM A710 STEEL

Total Deformation of Al 6063 Total Deformation of ASTM A710 Steel

Total Deformation of Al 6063 Total Deformation of ASTM A710 Steel

Stress of Al 6063 Stress of ASTM A710 Steel

Stress of Al 6063 Stress of ASTM A710 Steel

Strain of Al 6063 Strain of ASTM A710 Steel

Strain of Al 6063 Strain of ASTM A710 Steel

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

V. GRAPH Strain for various materials

Total Deformation
5
4.5
Deformation in mm

4
3.5
3
2.5
2
1.5
1
0.5
0
GREY AISI 4130 Al 6063 ASTM A710
CAST IRON STEEL Steel
Materials

Total deformation for various materials

Von misses Stress

355
350
Stress in MPa

345
340
335
330
325
320
GREY AISI 4130 Al 6063 ASTM A710
CAST IRON STEEL Steel
Various materials

Von misses Stress for various materials

Strain
0.007
0.006
0.005
0.004
Strain

0.003
0.002
0.001
0
GREY AISI 4130 Al 6063 ASTM
CAST STEEL A710 Steel
IRON
Various materials

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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

VI. CONCLUSION Vol.05, Issue.51,pp.10437-10444, 2016.

The static structural analysis of 3. Hari Kumar and V. Deepanjali, “Design & Analysis of
chassis was carried out. In the present Automobile Chassis”, International Journal of
work, chassis frame was analysed using Engineering Science and Innovative Technology,
ANSYS software. From the results, it is Volume 5, Issue 1, ISSN: 2319-5967, pp. 187-196, 2016.
observed that AISI 4130 STEEL and 4. Jagilam Kumar Chandra, Krishna Toli and Telkar
ASTM A710 Steel materials are having Mahesh, “Design and Analysis of Chassis by Using
more strength than grey cast iron and Al FEA”, International Journal of Research in Advent
6063 material Chassis. The AISI 4130 Technology, Special Issue, E-ISSN: 2321-9637, pp.
STEEL and ASTM A710 Steel materials 288-305, 2019.

are having least deformation i.e., 1.49

mm and least strain value i.e., 0.0021
respectively. Based on the analysis
results of the present work, the following
conclusions can be drawn. Part is safe
under the given loading condition. To
improve performance, chassis material
has been changed. From the result, AISI
4130 Steel and ASTM A710 Steel are
having less deformation and strain when
compared with grey cast iron and Al
6063. These materials are highly suitable
for automobile chassis manufacturing.

VII. REFERENCES
1. Abhishek Sharma, Mr. Pramod Kumar,
Abdul Jabbar and Mohammad Mamoon
Khan, “Structural Analysis of a Heavy
Vehicle Chassis Made of Different
Alloys by Different Cross Sections”,
International Journal of Engineering
Research & Technology, ISSN: 2278-
0181, Vol. 3 Issue 6, pp. 1778-1785,
2014.
2. Dandu Prasad Babu and V. Narasimha
Reddy, “Design and Analysis of
Automobile Frame”, International
Journal of Scientific Engineering and
Technology Research, ISSN 2319-8885,
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 Journal of Xi’an Shiyou University, Natural Science Edition ISSN : 1673-064X

5. MD Azhar Kazmi, Mr. V. Sunil and Mr. S. Udaya behaviour of Al/SiC/Al2O3 hybrid metal matrix
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