Reducing the weight of truck frames using advanced materials and innovative designs is a critical pathway for improving energy efficiency. However, weight reduction must not adversely affect the frame rigidity to prevent excessive deflections and distortions. Integrating finite element analysis (FEA) into the development of truck frames allows designers to quantify the potential weight savings through alternative material substitutions without compromising the frame rigidity. This study has developed beam element-based FEA models for a baseline truck frame to evaluate the potential weight reduction through replacing mild steel with aluminum alloy. The torsional and bending stiffness of the frame has been maintained by appropriately modifying the thickness of the frame members. It is concluded that the aluminum alloy frame achieves a 17.45% weight reduction compared to the baseline steel design. The influence of lightweighting on the frame’s natural frequencies and internal stress distributions is also evaluated.
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