Finite Element Analysis of the Subframe in a Hydrogen Fuel Vehicle

This study investigates the structural integrity and fatigue performance of subframes in hydrogen fuel cell vehicles under complex operating conditions. A systematic approach based on finite element analysis (FEA) is proposed to evaluate subframe performance across various conditions, including vertical impact, cornering, braking (front and rear), cornering braking, and front-wheel obstacle crossing. A 3D model of the subframe is first created using CATIA, followed by high-quality meshing in HyperMesh, which incorporates detailed geometric features, material properties, and connection characteristics. Multi-body dynamics simulations are conducted using Adams to extract data for typical operating conditions. Static and modal analyses are performed with Optistruct and Nastran to assess stress distribution, deformation behavior, and variations in natural frequency. Additionally, fatigue analysis is conducted using HyperLife to evaluate the subframe’s durability under these conditions. The results show that the subframe design exhibits excellent structural safety and fatigue resistance, meeting all design specifications. This research provides valuable theoretical and practical insights for optimizing subframe design in hydrogen fuel cell vehicles. Future work may integrate topology optimization and lightweight design strategies to further enhance subframe performance and cost-effectiveness.