Topology Optimization Helps Reduce a Sports Bike Design to 187 Pounds
Sports bikes need to be fast and lightweight to race past the competition.
So, when Asotech and Vins teamed up to design the Duecinquanta, they used simulation to iterate the motorcycle’s design.
Traditionally, the team would iterate the motorcycle’s design manually. However, this strategy would delay the Duecinquanta’s release.
So, Asotech and Vins used ANSYS Mechanical’s topology optimization and fatigue analysis tools.
Topology optimization automated much of the iterative process, while the fatigue analysis tool acted as a yardstick to ensure the longevity of the product.
How to use Topology Optimization to Lightweight a Sports Bike
Asotech and Vins started with the Duecinquanta’s frontal node.
They loaded the geometry of the part into Mechanical and assigned it a series of loads. The team then defined areas of the part that needed to remain constant — like connections to other parts.
The team also input an optimization goal — to reduce the weight while limiting the maximum stress.
Based on these inputs, the software showed the team where material could be removed and how much needed to be kept.
The team investigated if they could cut more weight by tweaking the inputs and using the new part as the next starting point for the topology optimization.
When Asotech and Vins were satisfied with the topology optimization, they moved on to fatigue analysis.
Fatigue Analysis is an Important Tool to Lightweight Motorcycle Designs
When Asotech and Vins saw the results from the fatigue analysis they were happy to see that the frontal node’s service life was well within the safety limit.
As a result, the team started another round of topology optimization to further reduce the weight of the frontal node.
The fatigue analysis was a good measuring stick.
It showed Asotech and Vins that they could safely cut more material from the frontal node than they originally thought possible.
After a few more topology optimization iterations, the motorcycle’s frontal node dropped from an initial 40 lbs. (18 kg) to 18 lbs. (8 kg).
In fact, topology optimization helped get the Duecinquanta’s roadway weight to 209 lbs. (95 kg). Since some of the Duecinquanta’s parts are only needed for city driving, the raceway model is even lighter — a mere 187 lbs. (85 kg).
To see in detail how Asotech and Vins optimized the Duecinquanta sports bike, read Speedy, Lightweight Motorcycle Design. Or watch the video below.
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