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2 2018

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Weight reduction of motorcycle frame by topology optimization

Bala Manikandan C., Balamurugan S., Balamurugan P., Lionel Beneston S.

Journal of Achievements in Materials and Manufacturing Engineering

2018

Vol. 91, nr 2

67--77

Purpose: of this paper is to improve the fuel efficiency of electrical motorcycle by reducing the weight of its frame without affecting the basic functionalities, dimensions and performance. Design/methodology/approach: Weight reduction of the frame was achieved by topology optimization technique. Initially the load and stresses acting on the frame was studied. Material of the frame was chosen as Aluminium and the frame was geometrically modelled using Autodesk Fusion 360. With the help of ANSYS AIM 18.2, weight of the frame was optimized by the design modifications suggested by the concept of topology optimization, for the corresponding loads and stresses induced on it. It was observed that the stress induced on the modified design was lesser than that of respective permissible yield stress of the frame material. After optimization, the weight of the frame was reduced from 3.0695 kg to 2.215 kg with the weight reduction of 27.84%. The weight reduction shows that the topology optimization is an effective technique, without compensate the performance of the frame. Approach used in the paper for the weight reduction of the frame is the topology optimization. The modelled frame was topology optimized by using ANSYS 18.2. After the topology optimization, the regions where the metal removal is possible, for weight reduction was identified. Findings: In this paper, the motor cycle frame was optimized and weight of the frame was reduced from 3.065 kg to 2.215 kg. Weight reduction of 27.84% was achieved without compensating the performance. Research limitations/implications: All the components of the automobile may be topology optimized for the weight reduction, thereby improving the fuel efficiency. Innovative design/Improvement in design also possible. Practical implications: By reducing the weight of the frame, weight of the automobile also reduces. Reduction in weight of the automobile leads to improved fuel efficiency. Originality/value: Weight of the motorcycle frame reduced by topology optimization. The regions of material removal at the frame, without compensating the performance was identified.

A study on magnetic field assisted laser percussion drilling and its effect on surface integrity

Balamurugan S., Manikandan C. B., Balamurugan P.

Archives of Materials Science and Engineering

2018

Vol. 94, nr 1

35--40

Purpose: of this paper is to reduce the taper angle and surface roughness of the laser drilled hole on Aluminium alloy with the assistance of magnetic field. At lower laser powers, able to achieve higher material removal rate in drilling with reduced taper angle and roughness. Design/methodology/approach: Aluminium alloy is a highly reflective material, while laser drilling it ejects plumes, which makes the drilling unreliable. The plume generated due to this action causes deteriorating effects over the work piece as such affecting surface textures. Removal of plume is the major consideration in laser machining process, especially in laser assisted drilling. The plume is a form of cluster of ions having charges in it. Due to the magnetic field input, the ions line the path along the lines of force of magnets. Thus, the ion cloud can be cleared at the localized plane, where the subsequent laser drilling going to be happens, leads to reduced plume thereby reduces the taper angle and surface roughness. Findings: The defect of percussion laser drilling that is barrelling effect in the drilled hole was reduced with the assistance of magnetic field setup. For the laser energy of 90 mJ, the magnetic assisted laser drilling shows better improvement in the material removal rate of 64.5%, the profile error (spatter height) was reduced to 45% and the taper angle of the drilled hole also reduced by 16.3%. The results confirmed the fact that, the Lorentz force confined the plume particle to be raised upwards and circulated outwards to the sidewall from the centre of the laser beam. This expansion of laser induced plasma plume, improved the material removal rate of the hole. Research limitations/implications: Laser drilling was carried out by a constant magnetic field and the parameters like material removal rate, taper angle, profile error, surface roughness were studied. In the future work, these parameters were studied with the application of varying magnetic field. Practical implications: As a result of the work, laser drilling was carried out on turbine blades or complex shapes for retention properties, with reduced taper hole and surface roughness, thereby improving the efficiency of the systems. Originality/value: The novelty of the work is providing magnetic flux for the laser drilling process, which improves the process parameters. The incorporation of magnetic field to the laser drill needs a cost less setup, which can ensure reliable improvement in the material removal rate, reduction in taper angle and profile error.