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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 Simulayt’s 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

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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 Simulayt’s 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 Simulayt’s 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 Simulayt’s 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. Simulayt’s 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 Simulayt’s 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

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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

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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 Simulayt’s Composites Modeler and Fiber

Modeler software packages can found online at www.simulayt.com.

End [Word Count: 1871]

Release date: 5th

July 2011

Photos of following 6 pages

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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.

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Photo 3: Fiber Simulation on the 3D CAD Model

Caption: SMU used Simulayt’s 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 Simulayt’s 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.

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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.

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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.

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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 3M’s 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 60°C.

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.

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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 Group’s activities and the academic course available log onto to:

http://www.motoeng.com/

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