DESIGN AND OPTIMIZATION

OF
E-BAJA CHASSIS
Ananthu Krishna G. V. – 20BME012, Kalaiselvan P. – 20BME053, Kiruthivasan M. – 20BME226
Dr. M. Thirumalaimuthu Kumaran
Department of Mechanical Engineering,
Kumaraguru College of Technology, Coimbatore - 641049.

ABSTRACT BACKGROUND OF THE STUDY RESULTS DISCUSSIONS

This project focuses on enhancing The evolution of electric off-road vehicles, The results highlights the design Based on the study Frame design proposed on the
exemplified by E-Baja competition, poses application of an equal amount of force on the
the chassis design for E-Baja vehicles implementation process, structural analysis
challenges in optimizing chassis design for designs for various impact tests, results are drawn,
by favoring the use of AISI 4130 results, manufacturing phases, and quality and the following judgments are contemplated.
performance, safety, and sustainability. The
(Chromoly) over AISI 1018 due to its assurance measures. Considering chromoly as the material and the
superior mechanical properties. chassis, a critical structural component, must
chosen geometry
Through the application of finite support the powertrain, suspension, and body
In front-impact test, design performs significantly
element analysis (FEA) and under rigorous off-road conditions. AISI 4130 well with a max deformation by 0.3208 mm and max
Table 1. Material and Geometry Specification
comprehensive simulations, we (Chromoly) emerges as a promising material combined stress by 46.833 MPa.
meticulously evaluate the structural choice, offering high strength, fatigue During the rear impact test, design performed
performance of AISI 4130 under resistance, and weldability. This project negligibly well in case of max deformation by 0.024
focuses on optimizing E-Baja chassis design, mm
diverse loading conditions, ensuring
emphasizing AISI 4130's advantages. The performs better in max combined stress by 6.941
optimal robustness and safety
process integrates FEA, simulation, and MPa during the side impact test.
standards. Employing geometric
engineering principles to refine chassis Considering front bump analysis, design performs
refinement techniques, our objective well in case of max deformation by 3.391 mm
is to maximize the chassis's strength geometry, aiming to maximize strength-to-
weight ratio and ensure compliance with During rear bump analysis, design performs quite
while simultaneously minimizing its well in the case of max deformation by 0.814 mm,
safety standards. This research contributes to
weight, potentially resulting in and max combined stress by 1.775 MPa during
sustainable mobility by exploring weight rollover analysis.
significant weight reduction
reduction and energy efficiency. By optimizing During the torsional test, design performs well in
compared to alternative materials.
chassis design, we enhance competitiveness, both max deformation by 9.626 mm and max
The insights gained from this analysis
safety, and environmental sustainability in E- combined stress by 49.86 mm.
offer valuable perspectives into the
Baja vehicles, advancing electric vehicle
structural integrity and cost-
OUTCOMES
Table 2. Overall Dimension of Frame.
technology. In summary, this paper
effectiveness of the frame, promising
investigates chassis design optimization for E-
heightened performance and In this project, a single design for the All-terrain
Baja vehicles, leveraging AISI 4130's
durability for sustainable electric off- vehicle chassis, using Chromoly steel as the
properties, to push innovation and material had been meticulously developed and
road vehicles. This research
sustainable mobility solutions. tested. Through rigorous testing, including
represents a significant stride
frontal, rear, bump, rollover impacts, and
towards advancing the engineering
torsional tests, we evaluated its structural
principles underlying E-Baja vehicle
design, with a focus on achieving
METHODS AND MATERIALS/ PROCESS performance. Analysis of static structural data
provided crucial insights into the design's
superior functionality, safety, and Initially, AISI 4130 was chosen as the
Figure 1. CAD MODEL OF CHASSIS
strengths and weaknesses. Notably, this design
efficiency in off-road environments. exhibited commendable performance across
Frame material. Next, the outer diameter
various impact scenarios, demonstrating
of primary member was chosen as 1.25
robustness in torsional, side, and rollover tests,
inch and thickness being 1.65 mm. ensuring high occupant safety. Chromoly steel
Following that a hollow circular tube of emerged as the preferred choice over Carbon
outer diameter 1 inch and 1 mm thickness steel due to its superior performance in key
Graphical And Process Flowchart was selected as secondary member. impact tests. The structural integrity and
Bending stiffness and Bending strength for performance of this design, particularly with
both selected dimensions are calculated Chromoly steel, highlight its suitability for All-
and compared with the recommended terrain vehicle applications. Overall, our
dimensions specified in the rulebook. project's single design, combined with Chromoly
Figure 2. CAD Model of Chassis with Figure 3. FEA Analysis. steel, represents a significant advancement in
Based on Driver’s measurements, CAD Fixture All-terrain vehicle chassis engineering,
model of the frame was made in emphasizing commitment to engineering
Solidworks Software. excellence in off-road vehicle development.

Finite Element Analysis (FEA) is carried out

for different real-time conditions including ACKNOWLEDGEMENT
front impact, side impact, rear impact, We extend our heartfelt gratitude to Dr. B. K. Krishnaraj
front roll-over, side roll-over, front bump, Vanavarayar, Thiru. M. Balasubramaniam, and Thiru.
side bump, and torsional analysis. The Shankar Vanavarayar for providing the necessary
analysis demonstrates the structural facilities at Kumaraguru College of Technology. Special
Figure 4. RULA Analysis Figure 5. Welding of Frame
robustness and performance of the thanks to Dr. M. Ezhilarasi for her unwavering support
optimized Roll Cage design under diverse and guidance throughout the project. We also express
loading scenarios, ensuring enhanced our appreciation to Dr. C. Velmurugan for his constant
safety and reliability. motivation and cooperation. Our sincere thanks to Dr.
Thirumalaimuthu Kumaran M for his guidance as the
The Rapid Upper Limb Assessment (RULA) Project Supervisor. We acknowledge the contributions
Analysis, conducted in Catia V5, evaluates of the review committee members and the faculty of
the ergonomic aspects of the E-Baja the Mechanical Engineering Department. Lastly, we are
vehicle design. It assesses the interior grateful to our families, relatives, and friends for their
layout, control accessibility, and driver support and encouragement.
Figure 6. T-Joint Figure 7. Material Test Figure 8. Y-Joint
posture to enhance comfort and minimize
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