Optimization in Product Design with CAE

Abstract

Before a design or structure is manufactured in real life, the virtual model needs to undergo a series of tests and analyses. One of these tests and analyses is to predict if the design or structure’s mass can be optimized without compromising the safety and structural requirements that are to be met by the design. This thesis explores the design and optimization of a bicycle frame in the SolidWorks environment. The appropriate material for the bike frame is selected by using the Ashby plots. The stresses on all truss members of the bike frame were also calculated manually by using the method of sections and the method of joints. During the simulation process, five different load cases were studied. These five load cases included static startup, steady-state pedalling, vertical loading, horizontal loading, and rear-wheel braking. The Von Mises stress, displacements and strains that resulted from all five load cases were compared and the case that had the highest equivalent Von Mises stress was used to carry out the design study. This optimization was done by using the Design study tool in the SolidWorks simulation environment. The optimization was done by defining variables, constraints, and goals. While running the study, a total of 222 scenarios were generated of which out of all 222 scenarios, 137 of them were successful. At the end of the optimization of the design, there was a significant decrease in mass of the design from 3.880 kg to 2.273 kg. This optimization does not only lead to the decrease in mass of material needed to manufacture the product but also reduces the manufacturing time, manufacturing cost and also makes the manufacturing process more sustainable. Conclusively, this optimized design had a factor of safety of 1.83 and a maximum stress 252 MPa which is both acceptable and reliable so far as safety is concerned.