Electric Racing Motorcycle Frame
Design of an aluminum racing frame for an electric moto gp bike to improve upon the club's existing steel frame for international competition.
Overview
The Problem
The first-generation electric motorcycle had an overbuilt frame that added unnecessary weight, limiting performance and increasing costs. A carbon swingarm and other components were also being redesigned and needed to be integrated into a new frame.
The Solution
Developed an optimized frame design with improved geometry, weight reduction, and enhanced component compatibility while balancing structural requirements and cost & manufacturing capabilities.
Key Outcomes
- •Created a comprehensive frame design with optimized geometry & compatibility
- •Performed extensive FEA simulations for multiple load cases
- •Projected approximately 25% weight reduction from V1 frame
My Role
Frame Design Engineer
(2-person team)
Project Gallery
Rendered final design of the V2 motorcycle frame
V1 Superbike with original steel frame
Bike load case model equipped with strain gauges
Design Challenges & Solutions
Proprietary Industry Information
With most motorcycle manufacturers treating frame geometry as proprietary information, we faced a significant challenge in determining optimal parameters like rake angle, wheelbase, and load distribution.
Reverse Engineering Approach
To overcome the lack of industry data, we methodically analyzed existing motorcycles from Honda, Ducati, and Zero, then worked backward using physical principles to understand their design choices. This allowed us to develop evidence-based specifications for critical parameters like the 23.5° rake angle we ultimately selected, based primarily on the Honda NSF250R.
Material Selection Constraints
While our initial calculations showed aluminum would provide optimal weight reduction, we faced practical limitations in budget, material donations, and welding expertise within our student team. This created a challenge in achieving our weight reduction goals while working within our manufacturing capabilities.
Strategic Material Compromise
Instead of switching to aluminum, we optimized the steel frame design through targeted geometry improvements, focusing on removing unnecessary material while maintaining structural integrity. This pragmatic approach allowed us to achieve significant weight reduction while working within our manufacturing capabilities.
Analysis Complexity
As undergraduate engineers with limited FEA experience, properly modeling and analyzing extreme load cases (maximum acceleration, braking, cornering) presented significant technical hurdles. We needed to ensure our design would withstand racing conditions while identifying areas for material reduction.
Collaborative Analysis Method
We developed a systematic approach to FEA by consulting with engineering professors, dividing the frame into manageable sections, and creating a standardized testing protocol for different load cases. This methodical approach allowed us to identify critical stress points and optimize the frame design despite our limited experience.
Impact & Results
Impact
Although changes in club management priorities prevented the design from moving to the manufacturing phase, the project provided valuable engineering experience and established a foundation for future frame designs within the team.
Weight Reduction
Achieved a 25% theoretical reduction in frame weight compared to V1 design
Documentation
Created comprehensive engineering documentation for knowledge transfer
Analysis Innovation
Developed novel approach to frame analysis within student team context
Key Takeaways
- Effective communication and collaboration techniques for engineering teams
- Methodologies for approaching large-scale engineering problems
- Advanced skills in CAD modeling and finite element analysis
- Designing for extreme load cases and safety factors
Skills Developed
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