Volume 2 - Issue 2, March - April 2026

The present study focuses on the design, analysis, and optimization of a truck chassis to improve its structural efficiency and dynamic performance under realistic operating conditions. A detailed three-dimensional CAD model of the chassis was developed and analyzed using Finite Element Analysis (FEA). Appropriate boundary conditions and loading scenarios were applied to simulate actual service conditions, including uniformly distributed load (UDL), cornering forces, and bump loads.Two critical load cases, namely UDL with cornering and UDL with cornering combined with bump load, were considered to evaluate the structural response of the chassis under normal as well as severe operating conditions. In addition, modal analysis was carried out to study the dynamic behavior and natural frequency characteristics of the chassis.An iterative optimization approach was adopted to reduce the weight of the chassis while ensuring structural safety. The results indicate that the chassis weight was successfully reduced by approximately 10.5%, from 604.14 kg to 541 kg, with only a marginal increase in stress and deformation. Under both load cases, the von Mises stress and deformation remained within acceptable limits, confirming the structural integrity of the optimized design. Modal analysis results showed only slight variations in natural frequencies, indicating that the optimized chassis does not pose any resonance risk.Overall, the study demonstrates that the application of FEA-based optimization techniques can significantly enhance the performance of a truck chassis by achieving weight reduction without compromising strength, stiffness, and dynamic stability. The optimized chassis design is therefore suitable for practical automotive applications, contributing to improved efficiency and performance of heavy vehicles.

Mr.Mandlik Sunil K, Prof.P.S.Ladgaonkar,"Evaluation of Rollover Stability & Dynamic Load Response of Truck Chassis System" International Journal of Advanced Multidisciplinary Research and Educational Development, V2(2): Page(1546-1550) Mar-Apr 2026. ISSN: 3107-6513. www.ijamred.com. Published by Scientific and Academic Research Publishing.