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.