Application of finite element method in industrial design, example of an electric motorcycle design project

Abstract

This study presents the use of finite element method (FEM) in solving the real engineering problems, e.g., an electric motorcycle design project. A simplified scheme of industrial design is presented, followed by an indication of how to use the capabilities of the selected CAD/CAM/ CAE software in the industrial design of industrial form. Using concurrent design based on the CAD system with the simultaneous use of CAE modules, the interdisciplinary of industrial design engineering was shown, which cannot exist without access to numerical methods. In the electric motorcycle project discussed in this article, the close relation between CAD and CAE modules was used, looking for the best solution in the construction of the motorcycle frame. By conducting a series of numerical simulations based on the FEM and topological optimization, the final shape of the frame and the rear control arm mounting was presented. The designed structure was optimized in terms of mass and effective stress distributions determined from the Huber-Mises-Hencky hypothesis. The resulting model of the frame was adapted to the design project, briefly discussed in the summary of the article. This study indicates the need to use the FEM and CAD/CAM/CAE applications at almost every stage of engineering design.