Assessment of Braking Systems and Bodywork Innovations for Three-Wheeler Electric Vehicles

Abstract

This paper presents an integrated overview of three essential automotive manufacturing domains braking systems, sheet metal fabrication, and fiber bodywork—along with the design and functionality of a portable pipe cutting machine that supports modern fabrication processes The study emphasizes how these distinct technologies combine to create high-performance, lightweight, and durable vehicle structures. The braking system is a critical safety component designed to convert kinetic energy into heat through friction. To maintain performance and safety, advanced materials with superior thermal conductivity and wear resistance, such as carbon-ceramic or castiron composites, are used. Proper heat dissipation, efficient braking force distribution, and reduced fade are key performance requirements that influence the system’s material selection and design. The sheet metal fabrication process forms the backbone of vehicle structure and design. It involves precise operations such as shearing, bending, rolling, and welding to produce chassis parts, panels, and enclosures. High-strength steels and aluminum alloys are commonly used for their excellent balance between weight and rigidity.Precision forming ensures not only structural integrity but also aesthetic quality in vehicle body panels. The fiber bodywork section focuses on lightweight composite materials such as carbon fiber and glass fiber-reinforced plastics (GFRP). These materials offer superior strength-to-weight ratios, corrosion resistance, and aerodynamic flexibility. Fiber body components significantly reduce vehicle weight, improving fuel efficiency and performance while maintaining safety and visual appeal.