Bike Frame FEA Analysis







Design optimization of new bike structural frame for mechanical strength and weight through a detailed bike frame FEA analysis (Finite element analysis).



This case study highlights the Engineering Simulation and Design Optimization work that was done to optimize a titanium bike frame to meet our client design criteria and performance requirements in terms of Strength, Durability, and Stiffness.
Such Engineering Analysis and design optimisation approach are generally applicable to the Validation and Test verification of most frame design.

Load Cases Simulated & Tested

Bike Frame FEA Analysis

Key FEA Analysis Workflow


● ‘Shell element’ FEA modeling with detailed features developed for bike frame and fork assembly
● Wall thicknesses and internal structure geometry of frame parameterized to function as design variables within optimization
● Individual cases for Fatigue, Impact (implicit transient), and Stiffness loading analysis is defined
● Automated optimization of gradient sizing performed for each Fatigue, Impact, & Stiffness case scenario
● Design validation of FEA solid models with ‘Converged stress’ developed for final FEA verification of stress-critical features
● The FEA analysis work was validated against the existing physical prototypes and shown to accurately predict deflection displacement when subjected to load.

Base on the test loading cases as defined by the ISO4210:6 (Impact Strength and Fatigue Durability) regulatory requirements, the following virtual loading scenario are simulated

1. Impact Test Simulation (Falling Frame)
2. Impact Test Simulation (Falling Mass)
3. Fatigue Test Simulation (Horizontal Forces)
4. Fatigue Test Simulation (Vertical Forces)
5. Fatigue Test Simulation (Pedalling Force)

* Discrete Load Vectors, Masses, Initial Velocities, and Constraints are not shown in the diagram

Optimized Structure Design Achieved


BroadTech Engineering is a Leading Engineering Simulation & Numerical Modelling Consultancy based in Singapore.
We Provide a Simulation-Driven Engineering Product Development & Design Validation Solutions that is Cost Effective & Carried Out to the Highest Standard.
Our Strength is in FEA, CFD, SPDM and CAD/CAE to Help Our Clients Gain Valuable Insights to Optimize and Improve Product Performance, Reliability, and Efficiency.


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