Design and Fabrication with Validation of a Smart Adaptive Anti-Roll Bar System for Enhanced Stability in Electric Vehicles

This project presents the design and characterisation of high-performance automobile anti-roll bars from the metal matrix composite of AA6082 aluminium alloy reinforced by 5 wt% Boron carbide (B4C), 10 wt% Fly ash, and 10 wt% Silicon carbide (SiC), prepared by stir casting for optimum particle dispersion. Mechanical characterisation revealed 22% greater ultimate tensile strength to 415 MPa, 31% greater hardness to 132 HB, and 27% greater fatigue life than the unreinforced AA6082, with only moderate lower density from fly ash addition. Finite Element Analysis in SolidWorks also confirmed the reinforced anti-roll bar to demonstrate 11% lower maximum Von Mises stress and 14% lower equivalent strain in simulated cornering loads, indicating greater durability and deformation resistance. Optical microscopy also confirmed homogeneous reinforcement particle dispersion and optimum grain refinement for greater grain refinement and wear resistance. These results demonstrate the technical promise of hybrid ceramic reinforced AA6082-based MMCs for high-performance lightweight anti-roll bars for extensive vehicle stability, handling, and safety advantages by body roll suppression and optimum weight transfer in high-speed manoeuvres.