Assessfy Pvt. Ltd Moderate 5 milestones 100 marks

CAD Design and FEA Analysis of a Lightweight Electric Bike Frame

Target year: TE Sem 5-6 (Mini-Project-IIA/IIB) AICTE: 3 credits · ~75 hrs Bloom: Analyze MU CBCS: MEC601/MEC701 Mini-Project 2A/2B

Real-world project · AICTE-aligned · AI-graded · Audit-ready certificate

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Milestones

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Core skills

About this project

Design a lightweight e-bike frame in SolidWorks (or Fusion 360), then run Finite Element Analysis to predict stress + deformation under realistic load cases (rider + battery + bumps). Optimize wall thickness / material choice to reduce weight by at least 15% vs a baseline steel frame while meeting safety factor of 2.

Course Learning Outcomes (CLOs):
CLO1: Apply CAD modeling principles to a real engineering artifact.
CLO2: Conduct linear-static FEA and interpret stress + deformation results.
CLO3: Justify material + geometry tradeoffs using engineering reasoning.
CLO4: Document a design-iteration loop with quantitative improvement.
CLO5: Communicate engineering findings in a professional report.

Industry/societal relevance: Indian EV sector (Ola Electric, Ather, Bajaj Chetak) hires hundreds of mechanical design + CAE engineers; this is an interview-ready portfolio project.

Milestones

1. Requirements + Reference Survey

15 marks 7d

Spec: rider weight 75kg + battery 12kg + max speed 45kmph. Benchmark 3 existing e-bike frames online. Submit requirements doc + reference photos.

2. Baseline CAD Model + Drawings

20 marks 12d

Model the baseline steel frame in SolidWorks. Generate engineering drawings with dimensions, weight calculation.

3. FEA on Baseline

25 marks 14d

Apply load cases: vertical static, bumpy-road dynamic factor 2x, hard-braking torque. Report max von Mises stress + safety factor.

4. Optimization Iteration

20 marks 14d

Switch to aluminum 6061, reduce wall thickness in low-stress zones. Re-run FEA. Confirm SF >= 2 + weight reduction >= 15%.

5. Final Report + Comparison Table

20 marks 11d

Side-by-side: baseline vs optimized — weight, max stress, SF, material cost. 8-page IEEE-format report + isometric renders.

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Skills you'll learn

SolidWorks (or Fusion 360) modelingFinite Element Analysis (ANSYS Workbench / SimScale)Material selection (Al alloys vs steel)Design optimizationEngineering report writing

Tools used

SolidWorks 2025 (student edition)ANSYS Workbench / SimScale (free tier)MATLAB (for optimization)Inkscape (for technical drawings)

Prerequisites

Strength of Materials; Machine Design-I; CAD basics (drafted in earlier sem); comfort with units + free-body diagrams

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