Finite Element Method Based Technical Investigation of ICEV Chassis with EV Conversion Module

Abstract

Nepal is shifting towards cleaner and sustainable means of transportation through import of electric
vehicles and conversion of conventional vehicles into electric. The conversion process requires
static and dynamic analysis of vehicle chassis to ensure structural integrity. This study aims to assess
static structural performance of a conventional car model that is the brink of 20-year age limit. CAD
modelling is done using SolidWorks and Finite Element Analysis is done in ANSYS on the chassis
of a Maruti 800 model with electric retrofitting components. The study carries out on-field
measurements and literature review to gather vehicle specifications, and defines simulation variants
related to chassis material and configuration of battery and motor. The materials considered are
carbon fiber, high-strength steel, low alloy normalized steel 4140, and aluminum alloy wrought
6061. A total load of 5,405.36 N was applied on different placement configurations of motor and
battery: front, trunk, motor in front, battery in front, motor in trunk, battery in trunk, motor in front
with battery at the bottom, and motor in trunk with battery in front. The ultimate stresses for the
varied materials employed in this study for the chassis falls within the range of 3-12 MPa, all well
below the allowable stress range of 104-1470 MPa. It can be inferred that the selected materials
exhibit a high degree of safety for the structural integrity of the vehicle's chassis. Based on the
simulation results, the optimal placement for the motor and battery is found to be at the front of the
chassis. Additionally, low alloy steel stands out as the safest material choice for the chassis. The
results stand out by addressing Nepal specific transportation needs and offering a comparative
material performance analysis tailored for EV retrofitting in low-to-mid-income economies. The
study underscores the need for identifying minimal stress conditions for maximum load capacity,
and can be used as an important component to form guidelines for vehicle conversion in Nepal.