Mechanical analysis of an ultra-light chassis model for a single-seat vehicle

The article presents a mechanical analysis of an ultra-light chassis designed for a single-seat vehicle, focusing on weight optimization and energy efficiency. The methodology includes material selection using constraint graphs and mechanical testing, with aluminum 6060 chosen for its favorable strength-to-weight ratio. Tensile and flexural tests were conducted to evaluate the material’s strength, followed by static, dynamic load, and wind tunnel simulations in SOLIDWORKS, validating the aerodynamic and structural design The results show good safety factor distribution throughout the chassis, although a critical component, Element 58 (rear suspension support), has a low safety factor and exceeds the yield limit under maximum load conditions, indicating a need for redesign or reinforcement. Recommendations include increasing the cross-sectional area of the critical element or using a higher-strength material to ensure structural integrity and enhance the vehicle’s overall performance.