Design Optimization of Two Wheeler (Bike) Chassis

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1 ISSN Design Optimiztion of Two Wheeler (Bike) Chssis #1 Prksh Ktdre, #2 S.C.Shilwnt 1 ktdrep21@gmil.com 2 scshilwnt.se@sinhgd.edu #1 PG Student, Mechnicl Engg. Dept., SAOE Kondhw, Pune #2 HOD, Mechnicl Engg. Dept., SAOE Kondhw, Pune ABSTRACT The chssis frme forms the bckbone of vehicle; its principle function is to sfely crry the mximum lod for ll designed operting conditions. Automotive chssis is the min crrige system of vehicle. The chssis serves s skeleton upon which prts like gerbox nd engine re mounted.the two-wheeler chssis consists of frme, suspension, wheels nd brkes.the chssis is wht truly sets the overll style of the twowheeler. Commonly used mteril for two-wheeler chssis is steel which is hevy in weight or more ccurtely in density. There re vrious lternte mterils like luminium lloys, titnium, crbon fiber, mgnesium, etc. which re lesser in weight nd provide high strength nd thus cn be used for chssis. This pper dels with design of two wheeler chssis frme nd its weight optimiztion. Vrious loding conditions like sttic nd dynmic lodings were crried out on the chssis nd the design is optimized by reducing the weight of the chssis by using lternte mteril while mintining the strength. ARTICLE INFO Article History Received :18 th November 2015 Received in revised form : 19 th November 2015 Accepted : 21 st November, 2015 Published online : 22 nd November 2015 Keywords - Bike Chssis, FEA, Weight Optimiztion I. INTRODUCTION A chssis consists of n internl frmework tht supports mn-mde object. It is nlogous to n niml's skeleton. An exmple of chssis is the under prt of motor vehicle, consisting of the frme (on which the body is mounted) with the wheels nd mchinery.in the cse of vehicles, the term chssis mens the frme plus the running ger like engine, trnsmission, driveshft, differentil, nd suspension. A body, which is usully not necessry for integrity of the structure, is built on the chssis to complete the vehicle. The utomotive chssis is tsked with holding ll the components together while driving nd trnsferring verticl nd lterl lods, cused by ccelertions, on the chssis through the suspension nd the wheels. Therefore the chssis is considered s the most importnt element of the vehicle s it holds ll the prts nd components together. It is usully mde of steel frme, which holds the body nd motor of n utomotive vehicle. Chssis frme forms the bckbone of hevy vehicle, its principle function is to sfely crry the mximum lod for ll designed operting conditions. It is essentil tht the frme should not buckle on uneven rod surfces nd tht ny distortions which my occur should not be trnsmitted to the body. The frme must therefore be torsion resistnt [2]. Weight optimiztion is now the min issue in utomobile industries. Weight optimiztion will give substntil impct to fuel economy, efforts to reduce emissions nd therefore, sve environment [3].Steel is commonly used chssis mteril t present. Optimiztion process involves preprtion of CAD model of existing component with help of 3D modelling softwre like CATIA V5, Pro-E. Anlysis is done on this model with the help of nlysis softwre like ANSYS which helps in determining the mximum stress, nd displcement vlues of existing model. Further the nlysis is done with lternte mterils to verify the best mteril. Simultion using softwres like ANSYS nd Hyperworks cn successfully vlidte the model in sttic conditions nd dynmic conditions with the sfety index ginst previous results. Vlidtion cn lso be done with the help of experimenttion, prototype of proposed mteril cn be produced nd mximum stress nd displcement vlues cn be found out through UTM testing. Utiliztion of new mterils, e.g. luminium lloy or vrious composite, cn bring bout n unprecedented strength while sustining or even decresing weight of prts. There re vrious lternte mterils like composites, luminium lloys, titnium, crbon fibre, mgnesium, etc. which re lesser in weight nd provide high strength nd thus cn be used for chssis. Vrious 2015, IERJ All Rights Reserved Pge 1

2 compositions cn be tested nd experimented so tht the overll weight of the vehicle cn be reduced for better fuel efficiency [6], [7], [8]. II. MODEL OF FRAME Fig. 2 CAD model of chssis in CATIA V5 Fig. 1 Bjj Pulsr Chssis With the use of strong design nd simultion tools like CATIA, Hyper-Mesh nd ANSYS optimiztion of existing Bjj Pulsr 180 DTS-i chssis is done. The optimiztion process consists of CAD model genertion of existing chssis in CATIA, its nlysis using Hyper-Mesh nd ANSYS. An lternte mteril is used for the redesign nd nlysis of model. Experimenttion is lso done for vlidtion of proposed model. III. STRUCTURAL ANALYSIS OF BIKE CHASSIS A generl-purpose commercil finite element code, Hyper- Mesh nd ANSYS is pplied to conduct the sttic simultions. A full 3-D solid model is constructed for the sttic test simultion. The schemtic of proposed FEA model used in sttic test simultions is shown in figure 3. Mixed type of elements which contin qudrilterl s well s tringulr elements, hve been used in nlysis. These 2D elements re converted into 3D tetr elements. The sensitive regions hve been re-meshed mnully considering the shpe nd size of the prts. A. Specifictions of Bjj Pulsr 180 DTS-i TABLE I DIMENSIONS AND WEIGHT OF BAJAJ PULSAR Kerb Weight (Kg) 147 Overll Length (mm) 2035 Overll Width (mm) 765 Overll Height (mm) 1165 Wheelbse (mm) 1350 Ground Clernce (mm) 150 Set Height (mm) 790 TABLE II CHASSIS AND SUSPENSION OF BAJAJ PULSAR Chssis Type Double Crdle Front Suspension Rer Suspension Telescopic, Anti-friction bush 5 wy djustble, Nitrox shock bsorber B. CAD Model CAD model of existing chssis hs been prepred in CATIA V5 s shown in figure 2. The dimensions were mesured from existing chssis by reverse engineering. Fig. 3 Meshed model with rigids The finite element nlysis is crried out on steel chssis s well s on three other lternte mterils viz. luminium lloy 6063, crbon fibre nd titnium. From the nlysis the equivlent stress (Von-mises stress) nd displcements were determined nd re shown in figure Tble III shows the comprtive nlysis of propertiesof steel nd other three mterils while Tble V shows comprison of result of ll the chssis mterils TABLE III MATERIAL PROPETIES S.N o. Mteril Young s Modul us E 1. Steel Alumini um Alloy Crbon Fibre Titnium 119 Poisso n s Rtio υ Densi ty ρ Yiel d Stre ss Ulti mte Tens ile Stres s , IERJ All Rights Reserved Pge 2

3 A. Applied Boundry Conditions The rer end portion nd portion of hndle in front is mde fixed (s shown in figure 4 by whitish portion) nd then vrious lods re pplied nd the nlysis ws done. TABLE IV LOAD CONDITIONS APPLIED Rider Weight Pillion Weight Fuel Tnk Weight Engine Weight 70 kg 70 kg 20 kg 40 kg Fig. 6 Displcement pttern for steel chssis Aluminium Alloy 6063 Fig.4 Boundry conditions pplied on model Fig. 7 Stress distribution of luminium chssis B. Meshing Detils No. of element = No. of nodes = C. Anlysis Results Steel Fig. 8 Displcement pttern for luminium chssis Crbon Fibre Fig. 5 Stress distribution for steel chssis Fig. 9 Stress distribution for crbon fibre chssis 2015, IERJ All Rights Reserved Pge 3

4 IV. PROPOSED EXPERIMENTATION AND VALIDATION A prototype for experimenttion is produced by using luminium lloy 6063 for testing s shown in figure 13. The input conditions will be recreted in the lb while the component testing. The loding nd the boundry conditions will be mtching the prcticl working conditions in which the chssis is expected to perform. For simplicity, Universl Testing Mchine long with suitble fixture for the component shll be engged for testing purpose.the mesured vlues will be compred with the results from softwre nd will be vlidted ccordingly. Titnium Fig. 10 Displcement pttern for crbon fibre chssis Fig. 11 Stress distribution for titnium chssis Fig. 12 Displcement pttern for titnium chssis TABLE V COMPARATIVE ANALYSIS OF STEEL CHASSIS WITH OTHER TYPES S.No. Mteril Mx. Stress Mx. Displcement 1. Steel mm 2. Aluminium Alloy mm 3. Crbon Fibre mm 4. Titnium mm From results of finite element nlysis of chssis it is observed tht stresses re mximum t joint loctions. It is lso observed tht ll the mterils hve stress vlues less thn their respective permissible yield stress vlues. So the design is sfe. Fig. 13 Prototype model produced The proposed setup is expected to be performing better with stisfying mount of weight reduction. The weight reduction will hence led to better fuel efficiency of the vehicle. V. CONCLUSION Structurl nlysis hs been done on chssis by using four mterils viz. steel, luminium lloy 6063, crbon fibre nd titnium. The mximum stress vlues re coming out to be 43.44, 43.70, 43.59, respectively. From the results it is observed tht the stresses re mximum t joint loctions nd lso for ll the mterils the stress vlues re less thn their permissible yield stress vlues. So the design is sfe. By using luminium lloy 6063, prototype is prepred for experimenttion.as the mteril hs less density compred to other mterils used nd is lso chep in cost, this isthe best suited lternte mteril for the chssis nd is expected to perform better with stisfying mount of weight reduction. REFERENCES 1. Tony Fole, Motorcycle Hndling nd Chssis Design the rt nd science, I edition, Cycle World Mgzine, Spin, CH.Neerj, C.R.Sireesh, D.Jwhrll, Structurl Anlysis of Two Wheeler Suspension Frme, Interntionl Journl of Engineering Reserch nd Technology, August M.RviChndr, S.Sreenivsulu, Syed Altf Hussin, Modeling nd Structurl nlysis of hevy vehicle chssis mde of polymeric composite mteril by three different cross sections, Interntionl Journl of Modern Engineering Reserch, August pp D.Ngrjun, Junid Mohmmed Frooq, A.S.N.Sitej, P.Siddhrth Sri Tej, Optimiztion of Chssis of n All-Terrin Vehicle, Interntionl 2015, IERJ All Rights Reserved Pge 4

5 Journl of Innovtive Technology nd Exploring Engineering, Jnury pp K.S.Sunil, Jy Christiyn, Integrtion of Reverse Engineering nd 3D Printing for Development of Bike Chssis, Journl of Mechnicl Engineering Reserch nd Technology, pp Wng Li-rui, Yng Xio-long, Simultion nd Improvement of Vehicle Frme Using FEM, Interntionl Conference on Mechnicl Engineering nd Mteril Science, pp Dr.R.Rjppn, M.Viveknndhn, Sttic nd Modl Anlysis of Chssis by using FEA, Interntionl Journl of Engineering nd Science, pp Jkub Smirus, Michl Richtr, Design of Motorcycle Active Chssis Geometry Chnge System, Technicl University of Ostrv, Number 5, Volume VI, December pp Chien-Ping Chung, Ching-Fng Lee, Prmeter Decision on the Product Chrcteristics of Bike Frme, Asi Pcific Business Innovtion nd Technology Mngement Society, pp , IERJ All Rights Reserved Pge 5