Design and Failure Analysis of Motorbike Sub-frame Using Finite Element Analysis

All two-wheeler industries validate their product’s fatigue life on proving track before heading for mass production. Proving test tracks are made to simulate the end-user environment in order to find out the possible fatigue failures during each development stage of vehicle design, which in turn helps the CAE analysts to verify the design before it goes to the end-user hands. In this article we present the design and failure analysis of sub-frame assembly of motorbike observed during the accelerated fatigue test on proving track. Sub-frame main rod was found broken exactly between two weld endings during fatigue test before reaching 6% of the target fatigue life. Possible causes of sub-frame failures have been identified/analyzed in detail using fish bone diagram. A finite element analysis (FEA) model of sub-frame assembly was developed and a random response analysis was carried out on initial design. Acceleration input loads measured from test track have been given at the sub-frame mounting points to calculate output responses. Output responses show a high magnitude of amplitude stresses on the sub-frame main rod exactly where track test failure occurred. Fishbone diagram analysis indicates that the improper design of the stay bracket, stress concentrations regions in the design, improper weld/tool fixture, and method of welding could be reasons for failure. FEA on the final design concept shows a reduction of amplitude stress to 49% and an increase of fatigue life to an infinite limit as compared to initial design.