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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.

This paper aims at the estimation of dynamic wheel loads of a two-wheeler through mathematical modeling that will aid during the initial stages of product development. A half car model that represents a two-wheeler was used for this purpose. Road displacements were given as input to the model and the wheel loads estimated. Actual road data obtained from two-poster rig was used as input to the model thereby making it possible to calculate the wheel loads for different customer usage conditions on different roads. In this paper, a severe rough road was chosen for verification of the model with that of the rig as the rider dynamics on such roads are the most difficult to simulate even on the rigs. The estimated values from model were verified with those measured using a two-poster rig for the same road displacement. Attempt has been further made to establish a correlation between the ride comfort predictions from the model and the two-poster rig.