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Two wheelers are very popular as means of transportation in ASIA. It is also used as load carrier in some places. Chassis frame is a very critical part of a two wheeler taking most of the loads coming from the roads. During the design and development stage, structural integrity of the frame needs to be established. Bump test is one of the critical life tests performed on the vehicle for evaluating the fatigue life of the frame. Normally, three to four iterations take place before frame passes this bump test. This is a time taking test process (1week per iteration) and does not guarantee the end result. In the new approach, the bump test simulation is made using ADAMS software. The ADAMS model is validated by using the axle accelerations measured in the physical bump test. Subsequently, the loads obtained from ADAMS model are used in FEM software and the stresses are predicted. The stress pattern helped in identifying the critical areas.

Safety aspect has been a key requirement in designing braking system. However, non-safety aspect like NVH and thermal performance are gaining equal importance. High engine capacity (cc) motorcycles are prone to thermal and NVH issues as braking energies are more. Therefore, virtual validation of brake disc system by considering both dynamic and thermal load with predefined assumptions is a toughest challenge when confronted with reality boundary conditions. Thus, the paper comes in a unique way of coupling dynamic and thermal load executed between multi body dynamics (MBD) and heat transfer equation which will convey results closer to real time scenario. MBD solves motion and the dynamic influence on heat transfer is calculated using “sliding boundary condition”. A series of repeated braking condition are performed on front brake disc of motorcycle. The results obtained from the analysis shows critical temperature rise.