What tests should I do for lightening an ev chassis

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Discussion Overview

The discussion revolves around the testing and evaluation of using carbon fiber to lighten the chassis of an electric vehicle (EV) to improve its range. Participants explore the types of analyses that can be conducted using software like Ansys or Matlab to assess the safety and structural integrity of the proposed material and design changes.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant seeks advice on the specific tests needed in Ansys or other software to verify the safety of using carbon fiber for chassis lightening and to determine the necessary thickness of the material.
  • Another participant inquires about the specifications of the EV, including weight, wheelbase, payload, and maximum speed, to better understand the context of the project.
  • A participant suggests conducting a static structural analysis to evaluate how reducing the thickness of the chassis affects stresses and deformation.
  • There is a discussion about the differences in physical properties between steel, aluminum, and carbon fiber chassis, with one participant noting that carbon fiber may allow for a thinner chassis while maintaining strength.

Areas of Agreement / Disagreement

Participants express various viewpoints on the testing methods and material properties, but no consensus is reached on the specific tests or the implications of using carbon fiber versus aluminum or steel. The discussion remains open with multiple competing ideas.

Contextual Notes

Participants have not provided detailed assumptions or specifications regarding the testing parameters or the exact nature of the analyses to be performed. The discussion is limited by the lack of specific data on the EV's design and performance metrics.

engineer123
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TL;DR
Wondering if anyone could help me with what kind of tests I should conduct on Ansys or Matlab to for lightening the weight of the chassis
Hi, I am an engineering student and for my project I have decided to try and improve the range of ev through chassis lightening, the main point I'm focusing on is using a carbon fibre material, so I was just wondering if anyone could tell me what kind of tests I would need to do on Ansys or other softwares to verify if the material was safe to use and how thick the chassis would need to be?
Also, if anyone has any ideas I could incorporate to help improve the range in any other aspects of the cars that would be really helpful!

Thank You!
 
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engineer123 said:
Summary:: Wondering if anyone could help me with what kind of tests I should conduct on Ansys or Matlab to for lightning the weight of the chassis

Hi, I am an engineering student and for my project I have decided to try and improve the range of ev through chassis lightening, the main point I'm focusing on is using a carbon fibre material, so I was just wondering if anyone could tell me what kind of tests I would need to do on Ansys or other softwares to verify if the material was safe to use and how thick the chassis would need to be?
Also, if anyone has any ideas I could incorporate to help improve the range in any other aspects of the cars that would be really helpful!

Thank You!
Welcome to PhysicsForums. :smile:

What size EV? Weight, wheelbase, payload, max speed, etc.? What other carbon fiber chassis designs have you studied?
 
Hi thank you for welcoming me!
In terms of the ev details, its a uni team vehicle that I was going to focus my study on, so I could ask them and get back to you on that information.
The payload is roughly 50 kg driver plus 1.8kg battery section.
Its chassis is made of aluminium, so I was pitching to improve its range through using a carbon fibre material. I am just not sure what kind of tests I should be running on Ansys to comprehensively determine if the how much weight reduction can be achieved.
Only thing I've got right now is maybe do a static structural analysis in which the thickness of the chassis is decreased and see how the stresses and deformation hold up.
 
engineer123 said:
The payload is roughly 50 kg driver plus 1.8kg battery section
Wow, that's a tiny battery! Is there solar cell input power too, or just that small battery?

Can you say what the physical differences are between steel, aluminum and carbon fiber structures like chassis?
 
As far as I am aware I think its only powered by that battery.

I think the real physical difference between the chassis would be that with the stronger material like carbon fibre maybe a thinner chassis could be used to provide the same strength that a steel chassis could, with lower weight.
 

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