Testing Oscillation and Optimization of the Motorcycle Frame Body Using Co-Simulation Method

The article is devoted to researching the durability of motorcycle frames with calculated loads in some cases of actual vehicle operation based on Vietnamese standards. The paper uses the multi-body system method to build a dynamic model suitable for the actual test problem according to the standard and optimize the mass of the motorcycle frame by the finite element analysis. The study includes an overview and analysis when choosing a motorcycle frame commonly used in Vietnam. A motorcycle frame of Wave brand is used to calculate and test the chassis durability with different parameters. Various internal loading modes are applied to the multi-body system model to help optimize the vehicle chassis mass by using specialized software. The authors calculated the load, built a durability model with static loads in practical working situations, built a multi-object system model to investigate the vehicle dynamics problem with the standards. This paper leads to the problem of optimizing the chassis thickness to reduce the weight of the chassis. Computers and optimization tools help engineers to save much time in the product design process. Investigating product optimization helps solve problems quickly, finding the best design, assisting engineers in developing the best strategies, and reducing time and costs during prototyping and testing.

Design and Manufacture of a Frame for a Small Electric Motorcycle

This article deals with the theoretical basis for the design of a motorcycle frame such as the geometry of the motorcycle, the choice of the shape of the frame and the choice of material for the manufacture of the frame. The article is devoted to the use of simulation tools to detect critical points in the design using Autodesk Inventor 2020 software. The results of the simulations were used in the production of a real frame for an electric motorcycle.

Weight reduction of motorcycle frame by topology optimization

Purpose: of this paper is to improve the fuel efficiency of electrical motorcycle by reducing the weight of its frame without affecting the basic functionalities, dimensions and performance. Design/methodology/approach: Weight reduction of the frame was achieved by topology optimization technique. Initially the load and stresses acting on the frame was studied. Material of the frame was chosen as Aluminium and the frame was geometrically modelled using Autodesk Fusion 360. With the help of ANSYS AIM 18.2, weight of the frame was optimized by the design modifications suggested by the concept of topology optimization, for the corresponding loads and stresses induced on it. It was observed that the stress induced on the modified design was lesser than that of respective permissible yield stress of the frame material. After optimization, the weight of the frame was reduced from 3.0695 kg to 2.215 kg with the weight reduction of 27.84%. The weight reduction shows that the topology optimization is an effective technique, without compensate the performance of the frame. Approach used in the paper for the weight reduction of the frame is the topology optimization. The modelled frame was topology optimized by using ANSYS 18.2. After the topology optimization, the regions where the metal removal is possible, for weight reduction was identified. Findings: In this paper, the motor cycle frame was optimized and weight of the frame was reduced from 3.065 kg to 2.215 kg. Weight reduction of 27.84% was achieved without compensating the performance. Research limitations/implications: All the components of the automobile may be topology optimized for the weight reduction, thereby improving the fuel efficiency. Innovative design/Improvement in design also possible. Practical implications: By reducing the weight of the frame, weight of the automobile also reduces. Reduction in weight of the automobile leads to improved fuel efficiency. Originality/value: Weight of the motorcycle frame reduced by topology optimization. The regions of material removal at the frame, without compensating the performance was identified.

Development of a motorcycle frame as a problem-based learning experience in design courses for Mechanical Engineering students

The paradox that exists between the necessity of testing physical prototypes to achieve as much design criteria as possible and the desire to minimize the number of iterations at the experimental validation stage to manage development time and cost, has led the authors to develop a detailed design methodology that guides the engineers and designers through the main activities of the product development process (PDP).The numerical validation activities and the iterations performed at the detailed design phase of the PDP have become key in achieving a product that meets the client needs from a price/performance/reliability perspective. However, before starting the fabrication of a physical prototype, the multidisciplinary team must understand the issues linked to the material behavior under critical conditions of use and in relation with the range of selected processes.In previous papers, a generic methodology that takes into account several design criteria was presented. This methodology was applied to the recreational product industry with the aim of reducing the weight of a roadster frame while controlling its production cost. Specific to vehicle, fatigue and rigidity are amongst the structural criteria that are central to the safety of the user and the handling of the vehicle.The objectives of this paper are thus to outline the advantages of this methodology, show how it could be applied to the structural sub-systems and components of a vehicle, and how it could be integrated in an undergraduate project, taking into account all the design criteria established up-stream in the PDP.As this approach has already been validated in the recreational product industry, it will allow students to converge toward creative, effective but realistic solutions while providing a comprehensive feedback on the client needs.

Design and Fatigue Life Analysis of a Motorcycle Frame

An off-road motorcycle frame has been analyzed and modified to optimize its fatigue life. The fatigue life of the frame is very important to define the service life of the motorcycle. The strain levels on key parts of the frame were collected during experimental tests. It has been possible to locate the areas where the maximum stress level is reached. A finite element (FE) model of the frame has been developed and used for estimating its fatigue life. Static test bench results have been used to validate the FE model. The accuracy of the finite element model is good, the errors are always below 5% with respect to measured data. The mission profile of the motorcycle is dominated by off-road use, with stress levels close to yield point, so a strain-life approach has been applied for estimating the fatigue life of the frame. Particular attention has been paid to the analysis of the welded connections. A shell and a 3D FE model have been combined to simulate the stress histories at the welds. Two reference maneuvers have been considered as loading conditions. The computed stresses have been used to assess the life of the frame according to the notch stress approach (Radaj & Seeger). The method correlates the stress range in a idealized notch, characterized by a fictitious radius in the weld toe or root, to the fatigue life by using a single S-N curve. New technical frame layouts have been proposed and verified by means of the developed finite element model. The considered approach allows to speed up the design process and to reduce the testing phase.

A Race Motorcycle Frame: Advanced Design

The concept and the embodiment design of a frame for a race motorcycle is addressed. The motorcycle is designed for the Moto3 World Championship. The aim is to develop a frame that could be eventually produced by die casting. Given the basic geometry of the motorcycle and the engine dimensions, a multi-body model is derived by Modelica. The model is able to simulate the dynamic behaviour of the motorcycle in the two most critical conditions of use, namely braking and passing over a cleat. A comparison with experimental data has allowed the validation of the model. By means of Optistruct, an optimized structure for the frame is proposed and compared to the one derived by an experienced designer. A technique is proposed for the computation of stresses in the frame that exploits, in an integrated manner, FEM and multi-body modeling. A fatigue analysis aimed at assessing the life of the frame is performed. The combination of the most advanced modeling tools has enabled the design of a very light and stiff frame, additionally a process has been derived for future development of optimised motorcycle frames.