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Light weighting in the automotive industry without the use of finite element methodologies is now inconceivable. With the development and enhancement of various CAE tools available, CAE-driven optimization has become part of the product development cycle. Using a variety of CAE techniques in a lightweight optimization process can significantly reduce product development lead time with good results. Traditional light weighting can be done through different iterative approaches with different manual inputs from cross-domain teams, which is usually time consuming and leads to repeated analysis. This method describes the case of a multi-domain optimization approach with the reduction of the frame weight of an e-scooter while considering important cross-domain load cases using CAE. For frame optimization, the important load cases such as Durability/Strength (Normal and Abusive), and NVH (Stiffness, Modes and Vibration) - were taken into account.

A typical motorcyclist experiences different vibration transfer functions at the point of body-vehicle interaction while riding. The main sources of vibration are engine-induced vibrations (for internal combustion engines), motor-induced vibrations (for electric vehicles), and road-induced vibrations. These vibrations can be perceived as criteria for driving comfort or as that is undesirably irritating and physically affecting the human body in various ride scenarios. Vibration Dose Value (VDV), Exposure Action Value (EAV), Exposure Limit Value (ELV) and RMS acceleration-A (8) Values are key metrics for accessing a perception of overall level of vibration transfer to the human body during various vibration exposures. The purpose of this study is to develop and propose a simulation method to calculate the VDV and A (8) values using a full vehicle CAE/FE simulation-based approach.

Virtual Product Development (VPD) with a vision to eliminate prototype testing is the recent trend in the automotive industry. Reducing the total vehicle development period with optimized output has been the major advantage of this new trend, fueled by increasing competition and shorter product life cycle. In this regard, Computer Aided Engineering (CAE) has taken a more significant role than ever in the vehicle development programs. Prediction of road noise in passenger cars is one of the important attributes to NVH (Noise Vibration Harness) Simulations. In the present work, CAE - NVH simulation of road noise is carried out on the finite element model of the vehicle, eliminating the costly and laborious test procedures & the process of awaiting information from various departments. One of the major challenges in these simulations are generating the load inputs for the structure-borne road noise in a cost and time saving method with accuracy.

Structural optimization has evolved vastly based on the development of computational based analysis – CAE. Structural optimization is usually a linear static response optimization because nonlinear response structural optimization is very expensive to perform. But in the real world, most of the automobile load cases are non-linear in nature. Equivalent static load structural optimization is a structural optimization method where Equivalent Static Loads (ESLs) are utilized as external loads for linear static response optimization. ESL is defined as the static load that generates the similar displacement by an analysis which is not linear static. This paper explains the development of a weight optimized BIW structure from an already existing model satisfying the NVH and Crash requirements. Basic structural crash loads are converted into ESLs with appropriate constraints.