COMPARATIVE STATIC STRUCTURAL PERFORMANCE OF ALUMINUM 6061 PROTOTYPE ELECTRIC VEHICLE CHASSIS WITH H, X, AND Y REINFORCEMENT CONFIGURATIONS USING FINITE ELEMENT ANALYSIS

Riyan Ariyansah; Nicky Yongkimandalan; Agus Fikri; M. Mujirudin; Arry Avorizano; Sunaryo Sunaryo; Rini Widaswari Purba

doi:10.32500/jebe.v8i1.11900

Authors

Riyan Ariyansah Universitas Muhammadiyah Prof. Dr. HAMKA
Nicky Yongkimandalan Universitas Pembangunan Nasional Veteran
Agus Fikri Universitas Muhammadiyah Prof. Dr. HAMKA
M. Mujirudin Universitas Muhammadiyah Prof. Dr. HAMKA
Arry Avorizano Universitas Muhammadiyah Prof. Dr. HAMKA
Sunaryo Sunaryo Universitas Sains Al-Qur'an
Rini Widaswari Purba Universitas Muhammadiyah Bekasi Karawang

DOI:

https://doi.org/10.32500/jebe.v8i1.11900

Keywords:

6061 Aluminum, Autodesk Inventor, Chassis, Finite Element Analysis, Electric Car, von Mises Stress

Abstract

This study aims to analyze the effect of variations in the chassis configuration of an electric vehicle prototype on structural performance using the Finite Element Analysis (FEA) method. The chassis was designed using 6061 aluminum with a C-channel profile in three configuration variations: H, X, and Y. Three-dimensional modeling and simulation were performed using Autodesk Inventor 2025 software based on a total static load of approximately 1,668 N, derived from an assumed mass budget of 170 kg for a single-seat prototype, was applied at the driver's feet, seat, and backrest, and at the motor and battery mounts, representing the weight of the driver and vehicle components. The analyzed parameters included the distribution of von Mises stress, displacement, and the safety factor to determine the most optimal chassis configuration. The simulation results showed that all variations met the safety criteria, as they had a safety factor of 15. The H-pattern configuration produced a maximum von Mises stress of 18.13 MPa with a displacement of 0.70 mm; the X-pattern produced a stress of 17.17 MPa with a displacement of 0.57 mm; while the Y-pattern produced the lowest stress of 16.48 MPa with a displacement of 0.59 mm. Based on a comparison of these three parameters, the Y-pattern configuration provides a more even load distribution, resulting in the best structural performance compared to the H and X patterns. The research findings indicate that variations in chassis geometry affect stress and strain characteristics, and can therefore serve as a reference in the development of prototype electric vehicle chassis designs that are lightweight, safe, and have good structural strength.

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