Optimization of Frame Design through Virtual Simulation of Bump Test 2004-32-0021

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. The critical areas identified are validated through experimental strain measurement. The validated model is further used to optimize the design by reducing the stresses at critical areas to below the acceptable limit. The final optimized frame cleared the bump test without any failure. This approach has saved at least 4 weeks of time apart from the need to conduct expensive iterative tests.