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Stream/Area:
-
Subject:
-
Paper ID:
IJSREM64403
Volume:
10 |
5 |
May 2026
Pages:
1-13
Publication Frequency:
Monthly (12 issues per year)
License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.
Mechanical engineering
S. B. Patil College of Engineering Indapur
Mechanical engineering
S. B. Patil College of Engineering Indapur
Mechanical engineering
S. B. Patil College of Engineering Indapur
Mechanical engineering
S. B. Patil College of Engineering Indapur
The chassis is one of the most important structural components of a vehicle because it supports all major systems and withstands different loading conditions during operation. In developing countries, three-wheelers are widely used due to their low cost, compact size, and fuel efficiency. Therefore, the development of a lightweight, safe, and economical chassis is essential for improving vehicle performance and reliability. In this research work, a ladder-type three-wheeler chassis was designed, analysed, and fabricated using AISI 1020 carbon steel. The chassis geometry was developed using PTC Creo software, while structural analysis was performed using ANSYS Workbench 2026 R1. Static structural analysis was carried out by applying driver and passenger loads under practical operating conditions. The Finite Element Analysis (FEA) results showed that the maximum equivalent stress developed in the chassis was 92.392 MPa, which is well below the yield strength of AISI 1020 steel. The maximum total deformation obtained was 1.438 mm, which is within the allowable deformation limit. The factor of safety obtained was 3.18, confirming that the chassis is structurally safe and reliable. The chassis was successfully fabricated using arc welding and CO₂ welding processes. The fabricated model showed good dimensional accuracy, weld quality, and structural rigidity. The total fabrication cost was economical, making the design suitable for practical low-cost vehicle applications.
KEYWORDS
This research successfully achieved the objective of designing, analysing, and fabricating a lightweight and structurally safe three-wheeler chassis using AISI 1020 carbon steel. A ladder-type chassis frame was developed using PTC Creo software and analysed under practical loading conditions using ANSYS Workbench 2026 R1. The Finite Element Analysis results confirmed that the maximum equivalent stress developed in the chassis was 92.392 MPa, which is well below the yield strength of the selected material. The maximum total deformation obtained was 1.438 mm, indicating sufficient stiffness and rigidity of the chassis structure. The factor of safety obtained from the analysis was 3.18, confirming safe and reliable operation under applied loading conditions. The chassis was successfully fabricated using arc welding and CO₂ welding techniques. The fabricated model showed good dimensional accuracy, satisfactory weld quality, and proper structural stability. The overall fabrication cost was also economical, making the design suitable for practical low-cost vehicle applications. Therefore, the developed chassis design was found to be lightweight, cost-effective, structurally reliable, and suitable for real-world three-wheeler applications.
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Publication Date
6/1/2026
Peer Review Type
Double-Blind Peer Review
Review Rounds: 2
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Conflict of Interest
The authors declare no conflict of interest related to this research work.
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