AUSTRALIAN JOURNAL OF MECHANICAL ENGINEERING, cilt.23, sa.3, ss.1-14, 2025 (ESCI, Scopus)
As the importance of renewable energy sources increases today, particularly in the sphere of transportation, engineering studies on electric vehicles indicate that these vehicles’ energy consumption needs to be optimised. Previous studies in the literature show that the mitigation of the weight of a vehicle decreases energy consumption. One of the parts of a vehicle where weight reduction or optimisation improvements can be realised is the suspension system. Besides that, the suspension system has a vital role in this purpose and is defined as the system is a tire, tire air, spring, shock absorber, and link system that connects a vehicle to its wheels and allows relative movement between the two. In the present study, a swing arm, in a rear suspension system of a solar-powered electric vehicle (EV), has been designed and optimised with respect to mass reduction under a critical driving scenario. After optimisation, the design is 1033 grams lighter, a 45.6% reduction. The finalised design has been produced by the employment of the low pressure die casting (LPDC) method and a validation study has been implemented in comparison between the experimental setup based on stress-strain measurements and the defined finite element analysis (FEA). It revealed that the relative strain errors at three precise points were less than 14%.