Design analysis of electric motorcycle rim using topology optimization

The rim is where the tire is attached and acts as a transmitter of power generated by the engine. The method used in this research consists of two main stages: experiment and simulation. In the experimental stage, tensile test specimens were made and tested to obtain the mechanical properties of aluminum waste materials. The data obtained from the experiment were used as input data properties in the simulation stage. In the simulation stage, the product design model was created using CAD software and optimized using a topology optimization algorithm based on the finite element method (FEM)-ANSYS WB, until the optimal design was obtained. To obtain mass reduction, ANSYS software simulates electric motorcycle rims through the static structure stage using the constituent material from waste brake shoes. Topology optimization will also be carried out with variations in mass reduction. Static pressure and moment load of 0.05 MPa and 4000 N mm, respectively, are provided. Based on the simulations carried out, the initial design of the wheel rim produces Von Mises stress 0.64071 MPa, deformation 0.01941 mm, and safety factor 15. A 10% variation produces Von Mises stress of 0.78895 MPa, deformation 0.02552 mm, safety factor: 15. For variations of 50% Von Mises stress is 1.1969 MPa, deformation 0.08352 mm, safety factor 15. A variation of 80% produces Von Mises stress of 11.323 MPa, deformation of 1.2394 mm, and a safety factor of 2.2771. Topology optimization successfully reduces structural mass by up to 80% from the starting mass. This method is quite effective in creating a lightweight structure that is essential for future design development. The topology optimization approach can also yield several geometrical options for the design of a lightweight scooter rim