Motorcycle frame design and optimization

Abstract

The objective of this project is to develop the chassis of an electric motorcycle that takes part in the international competition Smart Moto Challenge 2016, showing the work that has been done inside the e-Ride ETSEIB team. It focuses on the design of the frame and the swing arm, their FEM simulation and the manufacturing process to obtain them. Design is done taking in account the different requirements that must accomplish the motorcycle, such as the components that must hold the structure or the desired geometry of the chassis. Final design not only includes the frame and the swing arm, but also all the commercial parts that form the chassis assembly: wheels, fork, suspension, brakes, bearings, handlebar, footrests... The FEM study includes stiffness simulations of the frame and the swing arm in order to prove the dynamic properties of the motorcycle. It also has been considered several resistance simulations of the parts of the chassis that receive the higher loads to guarantee that they will resist any unforeseen critical stresses during the life of the motorcycle. All the simulations and the consequent optimization process have been done with the aim of keeping the weight of the tested parts as low as possible. The manufacturing process of both frame and swing arm is explained with detail and has been proved by the manufacturing sponsor that is going to build these parts.