International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
Design and Fabrication of Two Wheeler Frame
Ajith Arul Daniel S1*, Manikandan AR2,Vijay Ananth. S1,Pugazhenthi R1
1
Department of Mechanical Engineering, Vels Institute of Science, Technology & Advanced
Studies – 600117- Chennai, India.
2
Department off Mechanical Engineering, Agni College of Technology, Chennai 603103,
India
*Corresponding Author Mail id:
[email protected] ABSTRACT
The basic aim behind our project is to make a powerful vehicle that can drive comfortably in
the on and off-road with the help of streamline design with high fuel efficiency at affordable
price. We also keeping in mind the parking problems now days, so we decided to make it
compact in structure. The objective of our team is to design a unique, affordable, lightweight,
and modular vehicle which is to be used in on and off-road in order to transport a person
and light cargo. The frame part bear the total load of the vehicle. The modified frame model
was designed and anlyzed in through CATIA Software. The optimized design was fabricated
and tested.
Keywords : Two wheeler Frame, Analysis, Design
1. INTRODUCTION
Scooters are a subclass of motorcycles and are very popular for transportation in urban and rural
areas. A scooter is a type of motorcycle with a step-through frame and a platform for the rider's feet.
This design is possible because most scooter engines and drive systems are attached to the rear axle or
under the seat. Unlike a conventional motorcycle, in which the engine is mounted on the frame, most
modern scooters allow the engine to swing with the rear wheel, while most vintage scooters and some
newer retro models have an axle-mounted engine.
Modern scooters starting from late-1980s generally use a continuously variable transmission
(CVT), while older ones use a manual transmission with the gearshift and clutch control built into the
left handlebar. There is often some integral storage space, either under the seat, built into the front leg
shield, or both. Scooters have varying engine displacements and configurations ranging from 50 cc
single-cylinder to 850 cc twin-cylinder models. Traditionally, scooter wheels are smaller than
conventional motorcycle wheels and are made of pressed steel or cast aluminum alloy, bolt on easily,
and often are interchangeable between front and rear. Some scooters carry a spare wheel. Many recent
scooters use conventional front forks with the front axle fastened at both ends. In the context of
sustainable mobility, the Powered Two Wheel vehicle has been used. The term Powered-Two (or
Three)-Wheel (PTW) vehicle is being used cover a range of two or three wheel vehicles from mopeds
(low power motor cycles typically with engines less than 50cc and usually with a maximum speed of
50 kph) to motor scooters and motorcycles are used to reduce traffic congestion and emissions. In the
last decade, the growth in motorcycling and the associated road trauma has largely been among riders
aged 25 and over who already have car license and are taking up riding for the first time or returning
to riding, mainly for recreation.
2. EXPERIMENTAL DETAILS
The main aim of choosing internal combustion engine is that in mobile equipment, internal
combustion is advantageous since it can provide high power-to-weight ratios together with excellent
fuel energy density. Generally using fossil fuel (mainly petroleum), these engines have appeared in
transport in almost all vehicles. A 125 cc single cylinder petrol engine delivers a maximum output of
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International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
8.58 bhp @ 7000 rpm and torque of maximum 10.2 Nm @ 5000 rpm utilizing CVT (Continuous
Variable Transmission) to transmit power from engine to wheel.
Table 2.1 Engine Specifications
Engine 124.5cc
No Of Cylinder 1
Max Power 8.58 bhp @ 7000 rpm
Max Torque 10.2 Nm @ 5000 rpm
Valves Per Cylinder 2
Fuel Delivery Carburettor
Cooling System Air Cooled
Clutch CVT ( Continuous Variable Transmission )
Front Suspension Telescopic
Rear Suspension Single side Swing Arm Type
The frame is, in an effort to both minimize weight and manufacturing complexity, a step-
through frame. This frame allows for simple load transfer, and the frame is to be made of stream line
design, allowing for minimal manufacturing time, and allowing for the use of automated
manufacturing techniques. This design has been used successfully in commercial vehicles, which is
the strongest configuration between the front wheel assembly and the frame.
Figure 2.1 Frame without engine Figure 2.2 Frame with engine
The frame is fabricated successfully according to the design specifications. Fabrication
techniques included arc welding, bending, cutting, grinding and assembly of various parts required.
Fabrication was carried out in two phases, namely phase-I which included initial spot welding of all
the joints for assuring proper shape of the frame and phase-II included complete welding of all the
joints in the frame.
3. RESULT AND DISCUSSION
3.1 MATERIAL PROPERTIES
The material used in this scooter is 1.25inch stainless steel pipe with overall length of 83
inches. It has given a clearance of 200mm. Initially we bought all the materials such as stainless steel
pipe, square rod, cone set other connecting pipes from shop and then we bended all those pipes and
rods as per the design in the private shop. After that, all the pipes, rods, cone set and connecting rods
are welded together in welding shop. In the first stage, the disc braking system was selected. But it’s
is quite costly and not easily available in the market, so we think about its alternative and used drum
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International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
brake system. Due to the compact structure and engine mounting problems, we are not able to provide
double side swing arm suspension. So, single side swing arm suspension is used.
Table 3.1Modified Model of the Frame
3.2 LOADS AND FIXTURES
In scooter design, there are key dimensions in sizing which determine handling, steering, and
controllability. These, in part, are wheelbase, steering angle, fork offset and wheel radius. In addition
to these, ground clearance and stand-over height are important constraints for realistic usability,
determining where the vehicle may operate and rider size. Modelling, Meshing and Analysis were
given below.
Table 3.2 Design of the Parts
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Table 3.3 Meshing Details
Mesh type Mixed Mesh
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Jacobian check for shell Off
Element Size 13.0356 mm
Tolerance 0.651782 mm
Mesh Quality Plot High
Fig 3.1 Meshed Model
Fig 3.2 Analysis Results
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Fig 3.3 Analysis Results
3.3 TESTING OF THE MODEL
Followed by the fabrication of the actual model, the model has been tested for different road,
different load and various environmental conditions to identify any defects or flaws in the design or
fabrication processes, and eventually no defects or flaws where noticed or observed.
Fig.3.1 Fabricated Two Wheeler
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4. CONCLUSION
Due to the many problems of congestion, pollution, high fuel cost and urban mobility, increasingly
seem to be a vehicle that can able to run in all condition of roads to widespread automobile use. The
Ergonomic evaluation also demonstrated that this scooter is easy to use in normal use situations,
including situations involving obstacles, for a broad cross section of users. This scooter would also
use to transfer moderate loads and use for long distances. The reliability and safety of this scooter
helps to reduce traffic problem.
5. REFERENCES
[1] DOT Regulation Part 571.123: Standard No. 123; Motorcycle controls and displays. Federal
Motor Carrier Safety Administration. Retrieved 2010-06-03.
[2] Traffic safety facts, 2008. Report no. DOT HS-811-159 (PDF). NHTSA's National Center for
Statistics and Analysis. 2008. Retrieved 15 September 2010.
[3] Motorcycle Sales Down 40.8% Says MIC". Motorcycle USA. Retrieved 2011-01-01.
Scooters sales, which boomed in 2008 during all-time highs for gas prices, fell 59% from
2008 – the most precipitous segment drop.
[4] Motorcycles and emissions: The surprising facts. LA Times. Retrieved 8 August 2008.
[5] Derek Covilla*, Steven Begga, Eddy Eltona, Mark Milnea, Richard Morrisa, Tim Katza
“Parametric finite element analysis of bicycle frame geometries” The 2014 conference of the
International Sports Engineering Association.
[6] Jorge E. Rodrigueztx,And& L. Medaglia' ,Juan P. Casas', “Approximation to the optimum
design of a motorcycle frame using finite element analysis and evolutionary algorithm”. [3]
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FXR 150cc Motorcycle chassis”.
[7] Dario Croccolo* ‒ Massimiliano De Agostinis ‒ NicolòVincenzi “Structural Analysis of an
Articulated Urban Bus Chassis via FEM: a Methodology Applied to a Case Study”
Strojniškivestnik - Journal of Mechanical Engineering 57(2011)11, 799-809
[8] Prof. M.Sc. Božič S.1, Prof.Gombač E.2, Prof.Harmel A.3 “Redesign of motorcycle rear
suspension with CAD technology” [6] Maulik Lohia, Prof. Mohsin Bukhari, Prof. Mit Patel
“Review Paper on Bike Chassis for Stability of Rider by Ergonomic”Research article IJESC
(Volume 6 Issue No. 12)
[9] D.Kondayya, “3-Dimensional FE Analysis and Optimization of Bike Structure’’,
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[10] Aparna Deshpande, Amol B. Gaikwad, “Design and Optimization of Bicycle Frame
for the Cyclist's Comfort’’, International Journal on Recent and Innovation Trends in
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[11] Gaurav Vasantrao Bhunte and Dr. Tushar R. Deshmukh, “A Review on Design and
Analysis of Two Wheeler Chassis’’, International Journal For Research In Emerging Science
And Technology, Volume-2, Issue-1, January-2015.
[12]Bhagyashri Adake, Dr. A. D. Desai, H. S. Bawiskar, “Cost and Structural Optimisation of
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