Design of a Motorcycle Frame at an Automotive Company in Indonesia

摘要

Experimental tests used in the automotive industry in Indonesia to evaluate the effectiveness of a new motorcycle frame design are costly and time-consuming. A valid Finite-Element (FE) model can be employed to replace the experimental testing. This paper describes how to create a FE model of a new design of a motorcycle frame at an automotive company in Indonesia. The first step is to develop a 3D solid model of the frame by using Catia V5R25 software. Based on this model, the actual frame prototype was built from STAM 390 pipe material and welded together by DR4000 welding robot using MIG welding process. The next step is to revise the 3D solid model based on the geometries of the actual prototype obtained from the 3D Scan GOM Atos Triple Scan II. In addition, the 3D model of the frame is assumed to have bead welding on all welded joints. Meshing of the FE model is generated using Sim-Designer 2017 software. Finite element analysis (FEA) is done using Nastran 2014 SOL 103 in order to obtain the dynamic characteristic of the FE model. To validate the FE model, the experimental modal analysis (EMA) of the actual frame prototype is performed. The frame prototype is hanged under free-free condition on a fixed jig and subjected to the impact hammer test. Frequency response function (FRF) was then obtained from the ratio of a response and a force that is acquisition in a dynamic signal analyser. The eigenvalue from the EMA is used to validate the eigenvalue of the FEA. The frame model is then subjected to corresponding constraints to simulate the actual driving condition of the motorcycle. The frequency response from the simulation shows that the dominant response occurs at the first natural frequency of 3 Hz. Safety analysis of the frame structure can be carried out based on these resonance conditions. The proposed method provides a useful tool for the analysis and design of a new motorcycle framework.