Design and evaluation of hollow frame structures for the development of urban-centric two-passenger electric vehicles

Abstract

This paper focuses on the design and evaluation of hollow frame structures for the development of two-passenger electric vehicles targeted for urban use. The primary problem addressed is the lack of focused research on efficient, lightweight, and safe electric vehicle frame designs, particularly for urban transportation needs. Through 3D simulation and Finite Element Analysis (FEA), this paper successfully develops a hollow frame design with dimensions of 2,148×800×640 mm and a weight of 40.77 kg that meets strength and stiffness criteria. The analysis shows that the design has an adequate safety margin with a safety factor of 2.053e+01. ASTM A36 steel is chosen as the material, balancing strength, stiffness, and cost. The results offer an innovative and practical solution to urban transportation issues, with broad potential applications in the electric vehicle industry. In particular, this study focuses on the specialized needs of urban-centric, two-passenger electric vehicles. The Finite Element Analysis (FEA) used here serves as a robust validation method, effectively reducing the need for extensive physical testing. This accelerates the R&D process and opens possibilities for future studies on alternative materials and dynamic loading conditions. The study's limitations and future research directions are also discussed. Moreover, the study's computational methods offer an eco-friendly alternative to traditional physical prototypes. This aligns with sustainability goals and provides methodologies for future studies. With rising urban populations, the demand for efficient vehicles is increasing. This study paves the way for city-focused, two-passenger electric cars that meet modern urban needs and sustainability goals