Business Challenges
KTM Technologies used carbon-fibre materials for the frame and rear swingarm of the bicycle. The light material and a bionics design concept reduced the weight of the e-bike’s frame to 1.6kg. With a challenging timeframe of 16 weeks — which included concept, design, manufacturing and marketing — KTM Technologies used a truly simulation-driven design process. To simulate the frame, rear swingarm and handlebars — all made from carbon-fibre materials — engineers used ANSYS Composite PrepPost.
Engineering Solution
- Use ANSYS Composite PrepPost to model and analyse e-bike’s composites frame, rear swingarm and handlebars.
- Analyse different possible layups, fibre orientations and composites materials.
- Analyse failure behaviour of the composites design for given standard loads as well as loads expected from sport and trick cycling.
- Perform parametric design studies to achieve an efficient development process.
Benefits
- The intuitive approach of ANSYS Composite PrepPost enabled simulation to drive development of the bike’s composites parts.
- Using simulation, engineers reduced the weight of the bicycle frame to 1.6kg.
- By employing ANSYS simulation during concept and final design phases, prototype development and production was completed in 16 weeks.
“While developing the super-light electric bicycle Wörthersee for Audi, it was very important to use composite materials to reduce weight while maintaining durability,” said Martin Perterer, head of research and simulation, KTM Technologies GmbH. “Our experts in composites technology turned to ANSYS Composite PrepPost to model and analyse the e-bike’s frame, rear swingarm, and handlebars. By employing the ANSYS composites simulation tool and robust design practices, we were able to reduce the frame weight by 1.6kg within the challenging 16-week timeframe.”
