Design and Simulation of Mechanical Components in EV Using CATIA

Abstract

The transition toward electric vehicles (EVs) has created a need for efficient, lightweight, and structurally robust mechanical components tailored to the unique demands of electric propulsion. This paper presents a comprehensive study on the design and simulation of the principal mechanical components of a two-wheeler EV - the chassis and the handlebar using CATIA V5, a computer-aided design (CAD) and computer-aided engineering (CAE) software suite. The work begins with a review of two-wheeler EV architecture, chassis types, and suspension systems, followed by a systematic CATIA-based design methodology covering sketching, part modelling, assembly, and simulation. A scooter chassis was modelled in AISI 1018 mild steel and a handlebar in aluminium alloy, with wheelbase, ground clearance, and geometric specifications derived from SAE-style frame guidelines. Finite Element Analysis (FEA) was carried out on the handlebar using the Generative Structural Analysis workbench in CATIA, with restraints and loads applied to obtain the Von-Mises stress distribution. The resulting peak stress of 135.93 N/mm² was found to lie safely below the 90–140 MPa allowable stress range for aluminium, confirming that the design meets structural safety requirements. The study demonstrates that CATIA-based virtual prototyping allows engineers to validate the strength, stiffness, and durability of EV mechanical components prior to physical fabrication, reducing development cost and time while improving design reliability.