In this research, stress measurement tests and advanced application algorithms based on computer-aided design and engineering (CAD and CAE) were developed and tested. The algorithm was put implemented through a case study on the strength-based structural design and fatigue analysis of a chassis. This algorithm consists of numerical and experimental methods and additionally includes material tests, three-dimensional CAD, a finite element method (FEM)-based analysis procedures, a structural optimization strategy, prototype production, stress tests, a fatigue analysis, and design verification procedures. In the optimization study targeting the optimum chassis weight/strength ratio, two chassis prototypes, with 8 mm and a 5 mm wall thicknesses, were manufactured to verify the structural analysis and experimental tests. As a result of the FEA analyses, for 20 kN, which is the target load value of the chassis, for chassis thicknesses t = 5 mm and t = 8 mm, the maximum tensile strength was obtained as 93 MPa and 83 MPa, respectively. Thus, the material gain of 35.85 kg mass was achieved, and chassis utilization efficiency was increased. This research provides a useful methodology for experimental and advanced CAE techniques, especially for further research on complex stress and deformation analysis of chassis that are desired to be of optimum weight/strength ratio.
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