Integrated Finite Element and Topology Optimization Approach for NextGeneration Lightweight Automotive Chassis Design

Abstract

The automotive industry is increasingly focused on developing lightweight vehicle structures to enhance fuel efficiency, improve performance, and reduce environmental impact. Among various structural components, the chassis plays a critical role in determining vehicle strength, stability, and overall weight. Conventional chassis designs often employ uniform material distribution, leading to excessive mass and inefficient utilization of resources. This study presents a comprehensive investigation of lightweight automotive chassis design through topology optimization and advanced material removal algorithms. A comparative analysis was conducted on four engineering materials— Structural Steel, Magnesium Alloy, Aluminum Alloy, and Titanium Alloy such as to evaluate their structural behavior under identical loading conditions. The chassis geometry was developed using SolidWorks and subsequently analyzed in ANSYS through Finite Element Analysis (FEA) to assess deformation, equivalent stress, and strain characteristics. The research adopts an optimization-driven approach in which low-stress regions are identified and selectively removed to achieve significant weight reduction while maintaining structural integrity. The primary challenge addressed is the balance between minimizing chassis mass and preserving adequate stiffness and strength. Results indicate that lightweight materials such as magnesium and aluminum offer substantial weight savings, whereas structural steel provides superior strength. Titanium Alloy demonstrated the most favorable performance when subjected to topology optimization, exhibiting considerable potential for material reduction without compromising safety or mechanical reliability. The proposed methodology establishes a validated framework for material selection and structural optimization, contributing to the development of next-generation automotive chassis systems that meet modern sustainability goals while ensuring high levels of structural performance, durability, and efficiency.