Failure Analysis of Main Beam of Three-Wheeler Chassis Frame – A Comprehensive Review

Three-wheeler vehicles constitute an essential mode of transportation in developing economies due to their low cost, compact size, and adaptability for passengers and goods transport. The chassis frame forms the primary load-bearing structure of the vehicle, and the main beam is the most critical component responsible for maintaining structural integrity under static, dynamic, and fatigue loading conditions. Premature failure of the main beam can lead to unsafe operating conditions, reduced service life, and economic losses. This review paper presents a detailed analysis of failure mechanisms of the main beam in three-wheeler chassis frames, covering material selection, design configurations, loading conditions, fatigue behavior, manufacturing defects, and environmental effects. Analytical, numerical, and experimental approaches reported in literature are critically reviewed, including Finite Element Analysis (FEA), fracture mechanics, and metallurgical investigations. Mitigation strategies and future research directions are also discussed.