Lightweighting of Two-Wheeler Frame with CAE - Multi Domain Optimization (MDO)

Lightweighting in the automotive industry without the use of finite element methodologies is now inconceivable. With the development and enhancement of various CAE tools available in the market, CAE-driven optimization has become part of the product development cycle. Using a variety of CAE techniques in a lightweight optimization process can significantly reduce product development lead time with good results. Traditional light weighting can be done through different iterative approaches with different manual inputs from cross-domain teams, which is usually time consuming and leads to repeated analyses, etc. The current method describes the case of a multi-domain optimization (MDO) approach involving E-Motorcycle frame weight reduction while taking into account various important cross-domain load cases using CAE methodologies. For frame optimization, the most important loads - stiffness, durability/strength (Normal & Abusive), and NVH (Modes & Vibration) - were taken into account, as well as design variables such as thickness and material. This Multi Domain Optimization (MDO) approach has resulted in significant weight savings in the final product and in reducing the product lead time.