International Journal of Science, Engineering and TechnologyAuthors: Priyanka Ekanath Patil, Prof. Dr. Tushar Badgujar
Abstract: The chassis frame is the primary structural member of an electric bike (e-bike); it carries the battery, motor, suspension and rider and must remain safe under static and dynamic loads. This paper presents a comparative finite element analysis (FEA) of an e-bike chassis made of aluminum alloy, stainless steel and mild steel, with the aim of identifying a lightweight yet durable design. The chassis was modeled in CATIA and analyzed in Fusion 360 and ANSYS for loads of 1667.7 N, 2354.4 N and 3041.1 N, corresponding to one, two and three riders. Von Mises stress, total displacement, equivalent strain and factor of safety (FoS) were compared. All three materials remain safe at the heaviest load (FoS ≥ 1.6); stainless steel gives marginally lower stress and higher FoS, whereas aluminum alloy has by far the highest strength-to-weight ratio. A swing arm study of hollow and rhombus sections in structural steel and carbon fibre shows that the rhombus design deforms least. The findings support the development of lightweight, cost-effective e-bike chassis.
DOI: https://doi.org/10.5281/zenodo.24154014
