Structural and Performance Optimization of Universal Brackets for Electric Vehicle Using FEA

Electric vehicles (EVs) are subjected to high torque and rapidly changing load conditions, which place significant demands on drivetrain components. Conventional universal brackets made from structural steel increase overall vehicle weight and tend to develop high stress concentrations near geometric discontinuities such as slots and holes. Since reducing weight directly improves vehicle efficiency and driving range, there is a need for lightweight materials and optimized designs. This study evaluates the replacement of steel brackets with a Titanium alloy reinforced with silicon carbide (SiC) metal matrix composite. Finite Element Analysis (FEA) is used to analyze stress distribution and deformation behavior, followed by experimental validation through tensile testing. The findings show improved strength-to-weight ratio, enhanced fatigue life, and superior corrosion resistance. The proposed composite bracket demonstrates better structural performance and durability, making it suitable for advanced EV applications.