Development of High Fidelity Finite Element Model of Motorcycle Telescopic Front Fork

Abstract

This paper describes the development of a fully deformable finite element model of an upright telescopic motorcycle front fork in LS-DYNA environment. The modelling for each of the key components, overall assemblage, and contact interactions involved were presented. Comprehensive validation was performed by comparing the reaction forces in a quasi-static test performed on a universal testing machine with customised fixture, which was specially designed to impose compressive and bending load simultaneously on the fork unit throughout the process. The behaviour of the fork under such loading conditions was studied and explained. Significant localised deformations observed on the components were also identified and compared. The results from the simulations were found to be well agreed to that of the physical testing, with closely matching profile of the reaction forces and a deviation of 1.4 % based on the work done to deform the fork. Major considerations for establishing the full model were concluded and recommendations were suggested for improvement.