Design of a Motorcycle Composite Swing-Arm by Means of Multi-objective Optimisation

A study for the replacement of a metallic swing-arm of a high performance motorcycle with a composite part is presented. Considering the high structural effectiveness of the original metallic component, the case study evaluates the potential of composites in a challenging application. The FE model of the original component is developed to evaluate the structural performance in the most significant load conditions. A manufacturing process, based on a RTM technique, is proposed and analysed in order to develop realistic design hypotheses. The design approach is based on an optimisation process with 60 design variables. A constrained multi-objective genetic algorithm is applied to identify the solutions representing the best trade-off between mass reduction and improvement of torsional stiffness. Results show that composite materials can enhance the structural efficiency of the original metallic part, even considering technological limitations and damage tolerance requirements.