Entwicklung eines struktur- und gewichtsoptimierten Basaltfaser-Heckrahmens für ein Rennmotorrad

In the context of motorsports, the practice of lightweight construction is of central importance, as any reduction in weight that contributes to enhanced acceleration is a significant advantage. As part of the "MotoStudent" competition, a structurally and weight-optimised basalt fibre subframe for a racing motorcycle is being developed. The utilisation of basalt fibre is increasing in the field of lightweight construction, representing an environmentally sustainable alternative. In compliance with the regulations, the subframe, which also serves as the rider's seat, must be conceptualised from scratch to be topology-optimised and suitable for production. The maximum dimensions and the minimum required test force are specified by a static test. The evaluation of various manufacturing options and the production of concept components form the basis for a targeted manufacturing process. The material utilised is epoxy resin-coated basalt fibre, which, when combined with aluminium components, results in a weight-optimised subframe. The iterative development process was characterised by the repeated progression through a series of distinct stages including design, topology optimisation, redesign, static simulation and the creation of a manufacturing sequence. A start-up company specialised in the manufacturing of reinforcement elements made of basalt fibres supports the production process with the necessary equipment and expertise. In the course of this process, a number of prototypes were being manufactured, with a variety of epoxy resins also being used during the developmental phase. In the area of robot-controlled filament winding with basalt fibres, the use of temperature-curing epoxy resin has been shown to be highly beneficial. This manufacturing process enables the creation of load-bearing structural elements, which are becoming increasingly important in the automotive sector. The reliability of the subframe was confirmed through static and cyclic material tests, in accordance with regulatory guidelines. This ensured that driving under racing conditions was done safely. It has been demonstrated that the utilisation of basalt fibres facilitates the production of fibre-reinforced components that generate reduced carbon dioxide emissions in comparison to components manufactured from carbon fibres.