For Immediate Release

July 2011

FEATURE ARTICLE PRESS RELEASE

Honda CRF450 Racing Motorcycle Swingarm Redesigned 31% Lighter In Carbon Fibre Composite and Manufactured Faster Using Simulayts Composites Modeler Fiber Simulation Software

An engineering student at Swansea Metropolitan University (SMU) has redesigned and manufactured the swingarm from a Honda CRF450 motor-cross bike and made it 31% lighter The swingarm currently on the bike is made from aluminium and weighs 3.9kg including bearings. The redesigned carbon fibre epoxy prepreg composite part with moulded in metal inserts weighs just 2.7kg, with the performance capabilities of the original Honda part. To minimise stress concentration areas and overcome various manufacturing issues, the final composite swingarm design was vacuum moulded in two separate sections. These were then bonded together using the same 3M adhesive system that has been used successfully in Formula 1 cars. This swingarm composite redesign was the final year dissertation project of B.Eng. undergraduate Sven Lemmerling, supervised by Dr Owen Williams, the SMU Motorcycle Engineering Group course director. The redesign of this complex shaped motorcycle rolling chassis section in a carbon fibre epoxy prepreg was made possible by using the Composites Modeler ply modelling and fibre simulation software, developed by Simulayt Ltd. The software provided a combination of design benefits and significant production cost savings by highlighting potential production problems during the design phase and generating accurate flat patterns for faster production, lower scrap and increased productivity. Enhanced Virtual Product Development It is well established that composite materials offer significant weight reduction opportunities. However, research carried out for this SMU project found little evidence of the widespread use of structural composites in racing motorbikes, with prior work being confined to a couple of specialist

manufacturers. This has been attributed to the complex shapes in a motorcycle chassis and the major design and production challenges faced as a consequence. By using a specialist composites software package like Simulayts Composites Modeler, which is fully integrated within established 3D Computer Aided Design (CAD) packages such as SolidWorks or Computer Aided Engineering (CAE) tools like Abaqus/CAE, it becomes viable for motorbike and other engineers to consider advanced composite materials for complex structural parts. Composites Modeler enables virtual product development for composites by allowing the user to define the model in terms of plies in the same way that it is later manufactured, then simulating the manufacturing process to identify and correct design flaws and manufacturing problems. Doing this at the virtual design stage allows the design to be improved before money is spent on tooling, and can avoid the need to create costly prototypes or even throw away impractical designs. For the SMU project, SolidWorks was used to define the initial 3D CAD model of the mould, as well as the positioning of the various metal inserts. Having accurately modelled the mould and part geometry in SolidWorks, Lemmerling then went on to use Simulayts Composites Modeler for SolidWorks software to model the composites layup and generate manufacturing information. The functionality in Composites Modeler allowed him to define feasible ply layups rapidly while working in the familiar SolidWorks environment. Ply Layup Made Easy Composites Modeler allowed Lemmerling to define the composite layup in the same way as it would later be manufactured, on the basis of individual plies. For each ply, faces on the 3D solid model to be covered by the ply were selected. Next, a coordinate system defining the basic orientation of the ply was identified, followed by specifying a nominal rotation angle. Finally, a start point for the draping process (i.e. where the material is first applied to the mould) was defined. With these key inputs set, fibre simulations could be run to identify the fibre orientations and highlight potential problems. The effects of changes were immediately apparent, so the design could be improved within the CAD model. Finally, the stacking sequence of the individual plies was defined to complete the virtual model of the composite layup. According to Lemmerling, a key advantage of Simulayts Composites Modeler software for a design engineer is that it can create accurate net shape flat patterns for Gaussian surfaces, which are undevelopable surfaces with double curvature and non-zero Gaussian curvature. For these types of surfaces, the material has to shear to conform to the surface, affecting the fiber orientations and deformation of the material. Simulayts fiber simulation allows instant prediction of these phenomena, allowing the designer to improve the design before it is too late. An important benefit of the fibre simulation at this pre production stage in a project is that it ensures unmanufacturable plies cannot be specified. A further complication of doubly-curved surfaces is that there are infinite ways of covering the surface with fabric, so specifying the best starting point of the draping process is vitally important. Because of the speed of Simulayts fiber simulation, Lemmerling was able to define the most suitable starting points rigorously at the design stage so these could be used during manufacture so that the manufactured part reflected the design model. For the properties needed for this part, MULTIPREG E722 epoxy resin with 2x2 twill 650gsm carbon fibre prepreg from Amber Composites Ltd. was selected after extensive lab tensile testing. Depending on the specific area of the part, combinations of 0/90 and -45/45 plies were specified to provide the mechanical performance needed. Lemmerling explained how vital the Composite Modeler software had been to the success of his design project: It would simply not have been possible for me to succeed with this project without this

Simulayt software, which was easy to use and is clearly specifically designed for fibre reinforced composite modelling. We did look at various other textile based software packages, but none of them were able to calculate the optimised fibre orientation and ply lay-up to obtain the required mechanical performance in the final moulded carbon fibre epoxy component. Overcoming Design and Production Problems The fibre simulations highlighted areas of excessive shear resulting from the draping process, allowing the designer to optimise the ply shapes and fibre orientation. The key benefits in being able to highlight problem areas at the virtual CAD stage are firstly, a significant reduction in the overall project design time and secondly, the avoidance of costly design errors. Without Composites Modeler, these design errors would not have been detected until after mould tooling and parts had been produced. For the SMU project, this proved invaluable in identifying very early on the need to redesign a critical part of the initial swingarm design around the suspension mounting lugs. In order to lay up sufficient plies at the base of the lugs, the entire design approach was modified to reflect the opportunities and restrictions of advanced composites. This change resulted in a different split line being incorporated in the mould to enable a sufficient number of plies to be laid down in this highly stressed area. As Composites Modeler is fully integrated within the SolidWorks CAD programme, the late stage design modifications were automatically recalculated throughout the whole design tree. By identifying the problem at the design stage, considerable effort and cost were saved. Dr. Williams, who approved the software for this project commented: Using the Simulayt software, Sven was able to proceed to the manufacturing stage of this swingarm project with a high degree of confidence that the final moulded composite part would have the mechanical performance required for the application. Net Shape Flat Patterns Traditionally, rough oversized flat patterns were created manually by a moulder using paper. The paper patterns were then digitised and exported to a cutter. When the plies were laid up in the mould, any excess material was trimmed and usually scrapped. The more complex the shape the greater the inefficiencies and scrap wastage, which was prohibitive for intricate parts. Now, a key benefit of the Composites Modeler software for manufacturers is that it now removes the restrictions of traditional methods by taking 3D CAD data and immediately calculating accurate two dimensional (2D) net shape flat patterns for dry reinforcing fabrics and resin-impregnated prepregs. This 2D data can be exported from Composites Modeler in a standard DXF file format into a 2D drawing package to make very precise templates. Using the templates, accurate net shaped flat patterns for the plies can be cut manually, minimising trim wastage. Alternatively, for larger manufacturers, production efficiencies can be fully exploited as the 2D flat pattern data can also be used to programme automated cutting machines to mass-produce kits of plies. These flat pattern shapes can be nested manually or automatically before cutting to optimise usage of expensive raw materials. Cost Saving Benefits While not so critical for a university research project with low production volumes, by using the Composites Modeler software, many OEMs and independent composite convertors have seen significant overall cost savings. A large number of design projects have become commercially viable due to the faster flat pattern production, lower trim scrap and overall increased productivity. Based on comparisons between using the traditional manual flat pattern paper method versus using the Composites Modeler software, ply production times can be reduced by over 75% with 15% less trim scrap. This means that a composite part fabrication which needed 50hrs labour time for flat pattern

making and laying up and using 20,000 worth of prepreg material, could be done using Composites Modeler in under 12 man hours and save around 3,000 in ply trimming scrap. With such significant time and material cost savings, payback on the initial investment in the Simulayt software is easily achieved within a single production project. Finished Swingarm The final stage of the SMU project was to mould the two separate swingarm sections. The cut flat patterns for the plies were laid up on the epoxy moulds in the sequence specified by a ply book generated by Composites Modeler, after which the metal inserts were positioned accurately in the preform. The parts were vacuum bagged and cured under vacuum in an autoclave to minimize voids. The vacuum bagging system needed extensive development work, due to the complexity of the component geometry. Once the two sections were fully cured, they were demoulded, cleaned and then bonded together using the 3M 9323 adhesive system. The finished, fully assembled composite swingarm was given a show room finish by first using fine waterproof sandpaper, then lacquering and polishing it to bring out the carbon fiber architecture. Engineering students in the SMU Motorcycle Engineering Group have now fitted the redesigned swingarm onto the Honda motocross bike, which is currently undergoing on and off road trials to fully test the design. Continuing SMU Research By proving the suitability of this composite design approach in one of the most demanding areas of a motorcycle chassis, further composite design projects are now ongoing in the Motorcycle Engineering Group at SMU; their aim is to develop a complete advanced composite racing motorcycle chassis. Dr Williams stated: Sven's work has provided us with the knowledge and confidence to proceed with similar projects. We now have a number of different studies underway at both undergraduate and PhD level where we are developing and characterising the modern competition motorcycle. Our ultimate aim is to produce a complete composite motorcycle chassis, with the dynamics and handling characteristics of current state of the art machines. Further information about these SMU projects is available online at www.motoeng.com Datasheets and further information about the full range of Simulayts Composites Modeler and Fiber Modeler software packages can found online at www.simulayt.com.

End Release date: 5 July 2011

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Photos of following 6 pages

Accompanying Photos & Diagrams with Captions

Photo 1: Original Aluminium Swingarm from Honda

Caption: Dimensional copy of the original Honda swingarm design produced in alumimum.

Photo 2: 3D CAD Modelling

Caption: SMU used SolidWorks 3D CAD software to model the solid geomerty accurately and then build a virtual 3D model of the mould tool and the required metal inserts.

Photo 3: Fiber Simulation on the 3D CAD Model

Caption: SMU used Simulayts Composites Modeler to simulate the draping of woven fabric reinforcement over the mould surface. Blue or yellow indicates that the material has to shear to an acceptable extent to conform to the curved surface. The flat pattern is shown alongside the draped fiber orientations as a further check of the manufacturability of a ply.

Photo 4: Correcting Mould Design Problems

Caption Simulayts Composites Modeler fibre simulation identified a problem in the initial swingarm design. Insufficient carbon fibre prepreg plies could be laid down around the originally specified suspension mounting metal inserts, so a new geometry and mould construction had to be defined with different split lines to overcome this production problem. Identifying the problem early saved significant downstream costs.

Photo 5: Finalised 3D Modelled Composite Design

Caption: After completing fibre orientation and drape simulations using Composites Modeler, the finalised composite part design with metal insets was created, with a mould design, a full description of the ply layup, and manufacturing information including the net shape flat pattern ply data.

Photo 6: Complete 3D Model of Motorbike Rear Chassis Suspension Section, Chain and Wheel.

Caption: Using the finalised composite design, a complete 3D model of the assembly was created to validate the design and to make sure the swingarm would not interfere with the rear suspension, chain or wheel.

Photo 7: Net Shape Flat Patterns for Plies

Caption: Composites Modeler software takes the 3D CAD data and accurately calculates two dimensional (2D) net shape flat patterns. This 2D data can be exported from Composites Modeler in a standard DXF file format into a 2D drawing package or nesting system to make very precise templates that optimise material usage.

Photo 8: Ply Layup and Metal Inserts on Mould

Caption: The moulding process was significant faster overall, using the accurate net shape templates to cut out the flat ply sections. Composites Modeler produces a ply book of the composite layup to ensure that each ply is laid down in the correct sequence and fibre orientation.

Photo 9: Vacuum Bagged Moulding Cured in an Autoclave

Caption: The composite structure was cured under vacuum in an autoclave to minimise voids. The bagging system needed considerable development to accommodate the complex geometry of the component.

Photo 10: Two Composite Parts Prior to Bonding

Caption: The two halves of the swingarm were bonded with 3Ms adhesive were now ready to be glued. Having mixed the 2 parts of the adhesive with a mix ratio of 1:0.27, the parts where clamped together and left to set overnight. This was followed by a cure cycle of 60 min at 60C. Photo 11: Finished Composite Swingarm

Caption: The final bonded carbon fiber swingarm was aesthetically finished off with fine waterproof sandpaper, lacquered and polished to bring out the fiber architecture.

Notes to the Editor: About Simulayt

Simulayt Ltd. develops and licenses the Layup Technology, which incorporates advanced fiber simulation and ply modeling capabilities. This technology allows the efficient and integrated design, analysis and manufacture of fiber reinforced products. By simulating manufacturing processes and linking this data to analysis and design models, the engineer can develop better products with greater robustness at lower cost. The Layup Technology was first developed by Dr. J. W. Klintworth in 1991, initially driven by the aerospace composites industry. The technology was soon adopted by advanced motorsport engineers, and now, for example, the majority of successful Formula 1 cars are developed using Simulayt technology. With the continuous expansion of composite materials, the Layup Technology is now used extensively in the automotive, marine, energy, leisure and other industries utilising fiber reinforcement. The initial use of the Layup Technology was focused within Computer Aided Engineering (CAE) and Virtual Product Development (VPD) tools utilising the finite element analysis method. More recently, the technology has been embedded within Computer Aided Design (CAD) and Product Lifecycle Management (PLM) tools used by design engineers. Simulayt can therefore uniquely offer solutions which bridge all engineering disciplines to offer a composites engineering solution of proven capability and broad application. For more information visit www.simulayt.com

About the Motorcycle Engineering Group at Swansea Metropolitan University

The BEng Motorcycle Engineering Degree programme at Swansea Metropolitan University started in October 2003. It has been developed to support the growing interest in the motorcycle racing sector. It enables its students to develop the specific expertise required in the design, development and sophistication of the modern motorcycle. The course has a good mix of theoretical and practical taught elements as well as individual and group projects, subject specific assignment work and module options that enable the student to tailor the programme to their own needs and career aspirations. The Motorcycle degree scheme gives students the opportunity to experience the world of motorcycle racing first hand. Links with Tech3 Yamaha, at MotoGP and Peter Clifford of the former MotoGP team WCM, provide data and potential projects, where they can compare data and data acquisition results with real race setups and race performance on a very high spec race bike with a highly competent and fast rider. For further information about the Motorcycle Engineering Groups activities and the academic course available log onto to: http://www.motoeng.com/

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