Optimisation of Scooter Frame for Target Life on 2-Poster Rig with Virtual Simulation

Vehicle frame evaluation at early stages of product development cycle is essential to reduce product turnaround time to market. In conventional approach of virtual validation it is required to evaluate the strength of the vehicle structure to account for the standard Service Load Analysis (SLA) loading conditions. But this paper describes on the strength analysis of scooter frame with derivation of critical static load cases. The critical load cases are extracted from the load-time history while the vehicle was simulated on durability virtual test rigs which is equivalent to proving ground tests. This methodology gives the better accuracy in prediction of stress levels and avoids the overdesign of components based on traditional validation technique. There is significant drop in stress levels using the critical load case approach as compared to conventional load case method.

The identified critical load cases were validated using the measured strain data and it shows good agreement of correlation with physical testing. Using this approach frame optimization is also achieved and with further validation no structural failures were seen. Hence, this approach can be very useful and effective for future design of frames not only for two wheeled vehicle but also can be extended to other automobiles.