Failure Analysis of Main Beam in Three-Wheeler Chassis for Improved Structural Reliability

Abstract

Scooters India Limited (SIL), a well-established automobile manufacturer based in Lucknow, produces three-wheeler chassis frames under the Vikram brand for both passenger and goods carrier vehicles. The main beam is a vital structural component of the chassis frame and, together with the fork, forms the primary load-bearing framework of the vehicle. This tubular main beam runs longitudinally from the front to the rear and is subjected to significant loads and shocks, particularly near the front wheel where it is welded to the fork support plate. During service, this region has exhibited a high tendency for crack initiation, posing serious safety concerns and leading to costly replacements. Production data from 2012–13 revealed that 160 out of 2,855 manufactured frames were defective, resulting in notable financial losses and damage to the company’s reputation. Since chassis replacement costs around ₹2,00,000 and typically falls under warranty, the issue places a substantial burden on SIL. Additionally, the complex replacement process negatively affects customer satisfaction and brand image. Owing to the recurring nature of this problem, the present study aims to investigate the causes of crack formation in the main beam to reduce failures, improve structural reliability, lower costs, and enhance vehicle safety and customer confidence.

Cite as:

Pawan Kumar, & Ajay Kumar Singh. (2026). Failure Analysis of Main Beam in Three-Wheeler Chassis for Improved Structural Reliability. Recent Trends in Automation and Automobile Engineering, 9(1), 1–14. https://doi.org/10.5281/zenodo.18359015