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All Journal Mechanical Engineering for Society and Industry Automotive Experiences
Stevanus Brian Kristianto
University of Indonesia, Indonesia
Aerospace Engineering Automotive Engineering Chemical Engineering, Chemistry & Bioengineering Control & Systems Engineering Electrical & Electronics Engineering Energy Engineering Industrial & Manufacturing Engineering Materials Science & Nanotechnology Mechanical Engineering Transportation

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Experimental study on a new prototype design of electric bus vehicle structure under torsion loading conditions Budi Haryanto; Danardono Agus Sumarsono; Djoko Wahyu Karmiadji; Mohammad Adhitya; Stevanus Brian Kristianto; Lukyawan Pama Deprian
Mechanical Engineering for Society and Industry Vol 5 No 2 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/mesi.13559

Abstract

Vehicles commonly encounter uneven road conditions, which can lead to torsional deformation of the frame structure. The results of finite element analysis (FEA) indicate that the highest stress occurs under torsion loading conditions. To validate these simulation results, an experimental study was conducted involving static load testing under torsional loading conditions on a hybrid frame structure, composed of SS 400 carbon steel and 6061 aluminum alloy, designed for a 70-passenger electric bus. The test was performed by applying a static load of 6,825 kg as sandbags on the seating area and aisle, and supporting the frame on three wheels only. Strain measurements were recorded using 28 strain gauges: 20 on the SS 400 carbon steel underframe and 8 on the 6061 aluminum alloy structure of the side and roof frames. The total load was the weight of 70 passengers plus a 30% dynamic load factor. Experimental analysis revealed a maximum stress value of 76.42 MPa in the SS 400 carbon steel of the underframe at location 9 in the central section of the underframe. In the 6061 aluminum alloy structure, the maximum stress value of 15.56 MPa was obtained in the roof frame directly below the air conditioner unit. Overall, the measured stress values were within the elastic ranges of the materials used, demonstrating structural integrity under load. The average difference between the experimental results for stress and the finite element analysis (FEA) simulation was approximately 11.21%.
Experimental Stress Analysis on Frame Structure of A 70-Passengers Electric Bus Stevanus Brian Kristianto; Mohammad Adhitya; Budi Haryanto; Lukyawan Pama Deprian; Umar Abdul Aziz; Ridho Dwimansyah; Danardono Agus Sumarsono
Automotive Experiences Vol. 8 No. 2 (2025)
Publisher : Universitas Muhammadiyah Magelang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.13757

Abstract

Structural strength testing of buses using static vertical load has not previously been explored to validate the structural integrity of bus frames. In this study, the static vertical load method was employed to validate the structural strength of the Universitas of Indonesia electric bus, which utilizes two different materials SS400 for the lower frame and Aluminum Alloy 6061 for the upper frame. Finite Element Analysis (FEA) was conducted to identify critical areas on both the lower and upper frames. The stress values in the simulation were also obtained at the same location as the strain gauge placements in the experiment. Experimental vertical load testing was carried out by incrementally applying a load of 1000 kg up to the equivalent of 70 passengers, with an additional dynamic coefficient of 30% resulting in a maximum load of 6850 kg. Strain measurements were taken using 20 strain gauges on the lower frame and 8 on the upper frame. The experimental result showed the highest stress occurred at strain gauge no. 9 on the lower frame, measuring 78.10 MPa, and 15.32 MPa on the upper frame under 6850 kg load. The comparison between the simulation and experimental results reveals an 18% deviation. Nevertheless, both methods indicate the same critical area of the structure. The stress distribution indicated that the central deck area of the lower frame, where passengers sit and stand, experienced the highest loads. On the upper frame, significant stress was observed in the area where the air conditioning system is mounted. These findings demonstrate that static vertical load testing can be effectively used to validate the structural strength and stress distribution of electric buses, particularly in areas subject to concentrated loading.
Co-Authors Budi Haryanto Budi Haryanto Danardono Agus Sumarsono Djoko Wahyu Karmiadji Lukyawan Pama Deprian Mohammad Adhitya Ridho Dwimansyah Umar Abdul Aziz