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@article{207667,
        author = {BHUSHAN SHANTVEER CHAUDHARI and Dr. Nandkumar .A. RAWABAWALE and Mr. Sachin Shivmurti Walke},
        title = {Under Body Floor Panel Design Optimization and Analysis for Electric Vehicle},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {13},
        number = {3},
        pages = {3492-3511},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=207667},
        abstract = {The rapid growth of electric vehicles (EVs) has created a demand for lightweight and structurally efficient vehicle platforms. The under-body floor panel is one of the most critical structural components in an EV because it supports the battery pack, contributes to vehicle stiffness, and enhances passenger safety. Conventional floor panels designed for internal combustion engine (ICE) vehicles are not suitable for accommodating large battery packs due to packaging limitations and inadequate structural reinforcement. This study focuses on the design optimization and structural analysis of an electric vehicle under-body floor panel. A modified floor-panel architecture was developed by eliminating the conventional transmission tunnel and incorporating battery-supporting reinforcement ribs and cross members, thereby creating a flat-floor layout suited to modern EV battery packaging. Theoretical calculations for load, pressure, bending stress, deflection, strain and factor of safety were carried out for two candidate sheet-steel grades, EDD 513 and HSLA 420, followed by Finite Element Analysis (FEA) in ANSYS Workbench 2024 to evaluate total deformation, equivalent (von Mises) stress, equivalent elastic strain and modal characteristics under a combined battery-and-passenger static load of 5886 N. The optimized design exhibited a maximum deformation of 4.16 mm and a peak von Mises stress of 173.5 MPa, both within acceptable limits, while HSLA 420 Steel delivered a factor of safety of 2.42 against 1.27 for EDD 513 at identical thickness, together with a marginal weight saving. Modal analysis identified the first six natural frequencies (30.56–65.65 Hz) well clear of typical road-excitation bands. The results confirm that the optimized floor panel provides improved stiffness, reduced deformation and enhanced battery protection while maintaining acceptable structural weight, making the proposed configuration a practical and industry-relevant solution for modern electric vehicle platforms.},
        keywords = {Electric Vehicle; Under-Body Floor Panel; Structural Optimization; Finite Element Analysis; ANSYS; Battery Pack Integration; HSLA 420 Steel; Modal Analysis; Body-in-White.},
        month = {August},
        }