...

Static structural - These settings (acceleration and fixed support) are the same as in previous files.

Additional Investigation of Stress Results

Originally, a good check to see if the simulation settings were appropriate was to insert the current chassis geometry into a previous simulation file.

This is deemed to take too much time because you would have to re-insert and re-edit a geometry, and re-create the contacts.

Instead, the old project file is used and the bottom panel (BP) is suppressed.
Consequently, this also turns of the Battery Box (100 kg) and 4 passengers (80 kg) mass points each.
So, keep this in mind when you view the results.

Procedures used: Suppress BP → Click Solve. Solutions were checked for reasonable deformation.

Past Simulation Project Used: 2020-03-31.wbpj

Folder Path: D:\Users\Roo\Documents\GrabCAD\MSXIV sims\MS-CHASSIS

Previous to suppressing the BP, this project file had all stresses below 435 MPa. Maximum combined stress was about 280 MPa which suits the criteria of FS of 1.5 from yield strength of 4130 chromoly steel (the chassis tube material).

Latest Simulation Project: August 25_Rev 5.1.wbpj

Folder Path: D:\Users\Roo\Documents\GrabCAD\MSXIV sims\MS-CHASSIS\Spring 2021 Reinforcement Sims

Keep in mind, this latest iteration has the 2 rear passenger masses turned off.
It also has multiple reinforcements.

Iterative Solution Documentation - Mechanical - Confluence (atlassian.net)

Conclusion

Turning off the BP drastically increased stresses in previous simulations.
This means that it can be concluded that the results we see in the newer simulations (where the BP is removed and reinforcements are added) are realistic and are not due to deviation of simulation setup procedures.