Light frame design for quad bike using topology optimization

Abstract

The paper describes a quad bike frame design procedure with the use of topology optimization technique. The design space specific properties, quad bike specific load cases and problem formulation for topology optimization are presented. Topology optimization results – beneficial load paths of the frame structure – have been interpreted into a new frame design providing sufficient space for placement of all systems of the vehicle. The new frame strength has been proved using finite element method. Comparing with the previous steel frame design, the new frame of the quad bike has become 2 times as stiff and 17% lighter while having low stress levels due to the substitution of aluminum material for steel and a new optimized topology of the frame load-bearing structure.