Design and Analysis of a Biocomposite Monocoque Frame for an Electric Moped
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Ongoing climate changes have increased concerns that impact the mobility industry. Several initiatives have been implemented to encourage more environmentally friendly modes of mobility, especially inside metropolitan areas. The two-wheel sector stands out as an alternative to intraurban mobility since these vehicles provide a more cost-effective and sustainable solution (Will et al, 2021). The introduction of electrification has emerged in this sector, particularly in low-powered two-wheeled vehicles called mopeds, which are motor vehicles with a maximum design speed of not more than 45 km/h, limited to a maximum power of 4 kW for electric models (European Parliament, 2013). One of the main challenges is the moped’s autonomy which can be improved by making the frame lighter. Composite materials can be incorporated to reduce the frame weight. They are naturally corrosion-resistant and allow design optimisation for improved performance and functionality, making them an ideal alternative to manufacturing the frame. Additionally, biocomposites are known for their lightness and strength, further improving both performance and sustainability (Rogacki et al, 2019). There is a lack of information regarding biocomposite properties, due to the large variety of their constituents, which compromises its use in structural applications (Al-Oqla et al, 2017). However, with proper characterisation, these materials can be optimised to guarantee structural integrity. This work presents the development of a biocomposite frame, manufactured by vacuum resin infusion, using a bio-based epoxy resin (with 38 % carbon derived from plant sources) reinforced with flax fibres. The material characterisation, structural analysis, and design considerations were studied to improve the vehicle's overall performance while creating a more sustainable solution with a lower environmental impact. A monocoque design was proposed to reduce the frame's weight, minimising internal components. The results demonstrate that biocomposite materials can be used in this application, offering a promising solution for sustainable electric two-wheelers.