The minimization of the mass is a key factor in the design of motorcycle wheels for using in the competitions. At the same time constraints of the project relative to the stiffness and structural integrity of the component must be respected. In this thesis, the numerical models of finite element for the preliminary design of a new front wheel for a racing motorcycle were developed. The topological optimization of the component was performed in order to identify the optimal structural layout to minimize the mass within the constraints of stiffness and structural integrity. The optimization was performed by the use of commercial software Altair OptiStruct. The software uses a method known as SIMP. It was initially developed a finite element model of an existing wheel. This model was used to calculate the radial, lateral and longitudinal stiffness of the component. The stiffness values calculated were used as reference for the topological optimization of the new wheel. The FEM model was developed for the topology optimization is made of a region called "design" and a "non-design". The region of "design" is the area in which, the distribution of the material is modified in order to obtain the most efficient structural layout. The region of "non-design" instead is fixed and does not change during the optimization process. The total strain energy of the component subjected to the constraints on the final mass and values of stiffness has been minimized in the optimization process. The load conditions related to the straights line braking and through the corners were considered. They were analyzed and compared structural layout with different number of spokes in terms of mass, stiffness and stress state. Finally, further analyzes were performed and the manufacturability constraints of the component were introduced during the optimization process. The results obtained are an excellent starting point for the development and the realization of a new component for participating in the competitions.
La minimizzazione della massa è un fattore chiave nella progettazione di ruote motociclistiche per l’impiego nelle competizioni. Al tempo stesso vincoli di progetto relativi alla rigidezza ed integrità strutturale del componente devono essere rispettati.In questo lavoro di tesi sono stati sviluppati modelli numerici ad elementi finiti per la progettazione preliminare di una nuova ruota anteriore per una motocicletta da competizione. È stata effettuata un’ottimizzazione topologica del componente volta ad individuare il layout strutturale ottimale per minimizzarne la massa nel rispetto dei vincoli di rigidezza ed integrità strutturale.L’ottimizzazione è stata eseguita con l’ausilio del software commerciale Altair Optistruct. Il software utilizza il cosiddetto metodo SIMP. Inizialmente è stato sviluppato un modello ad elementi finiti di una ruota esistente. Tale modello è stato utilizzato per il calcolo della rigidezza radiale, laterale e longitudinale del componente. I valori di rigidezza calcolati sono stati utilizzati come riferimento per l’ottimizzazione topologica della nuova ruota. Il modello FEM sviluppato per l’ottimizzazione topologica è costituito da una regione di “design” ed una di “non-design”. La regione di “design” costituisce la zona all’interno della quale viene modificata la distribuzione di materiale per cercare il layout strutturale più efficiente. La regione di “non-design” invece è fissata e non viene modificata durante il processo di ottimizzazione. Nel processo di ottimizzazione è stata minimizzata l’energia di deformazione totale del componente soggetto a vincoli sulla massa finale e sui valori delle rigidezze. Sono state considerate condizioni di carico relative a frenata in rettilineo e percorrenza di curva. Sono stati analizzati e confrontati layout strutturali con differente numero di razze in termini di massa, rigidezza e stato di sforzo. Infine sono state eseguite ulteriori analisi introducendo anche dei vincoli di manufatturabilità del componente nel processo di ottimizzazione. I risultati ottenuti rappresentano un ottimo punto di partenza per lo sviluppo e la realizzazione di un nuovo componente per l’impiego nelle competizioni.
Development of a wheel rim for high performances motorcycle
VATANKHAH CHOKAMI, BEHNAM
2013/2014
Abstract
The minimization of the mass is a key factor in the design of motorcycle wheels for using in the competitions. At the same time constraints of the project relative to the stiffness and structural integrity of the component must be respected. In this thesis, the numerical models of finite element for the preliminary design of a new front wheel for a racing motorcycle were developed. The topological optimization of the component was performed in order to identify the optimal structural layout to minimize the mass within the constraints of stiffness and structural integrity. The optimization was performed by the use of commercial software Altair OptiStruct. The software uses a method known as SIMP. It was initially developed a finite element model of an existing wheel. This model was used to calculate the radial, lateral and longitudinal stiffness of the component. The stiffness values calculated were used as reference for the topological optimization of the new wheel. The FEM model was developed for the topology optimization is made of a region called "design" and a "non-design". The region of "design" is the area in which, the distribution of the material is modified in order to obtain the most efficient structural layout. The region of "non-design" instead is fixed and does not change during the optimization process. The total strain energy of the component subjected to the constraints on the final mass and values of stiffness has been minimized in the optimization process. The load conditions related to the straights line braking and through the corners were considered. They were analyzed and compared structural layout with different number of spokes in terms of mass, stiffness and stress state. Finally, further analyzes were performed and the manufacturability constraints of the component were introduced during the optimization process. The results obtained are an excellent starting point for the development and the realization of a new component for participating in the competitions.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/101810