DESIGN AND ANALYSIS OF LEG GUARD OF TWO-WHEELER FOR OPTIMIZATION OF WEIGHT AND STRENGTH

Abstract

This study presents the design, explicit dynamic analysis, and material optimization of a diamond-shaped two-wheeler leg guard. A three-dimensional leg guard model was developed in CATIA V5 and analyzed in ANSYS 19.0 Explicit Dynamics under an impact condition against a fixed concrete block. Four materials—SS202, SS440C, Mild Steel, and Titanium Alloy—were evaluated under identical geometry, meshing, and loading conditions. A 10 mm tetrahedral mesh was used, with an initial velocity of 8560 mm/s and an analysis end time of 0.005841 s. The numerical response was assessed using maximum equivalent (von Mises) stress and total deformation, while theoretical load-carrying capacity and component weight were calculated from material yield strength, tube cross-sectional area, and density. The calculated load-carrying capacities were 32.39, 53.01, 53.01, and 97.53 kN for SS202, SS440C, Mild Steel, and Titanium Alloy, respectively. The corresponding weights were 1.56, 1.54, 1.62, and 0.89 kg. A Weighted Sum Method, with priorities of 0.8 for strength and 0.2 for weight, identified Titanium Alloy as the optimum material with a score of 1. The study demonstrates a numerical material-selection approach for achieving a lightweight leg guard with improved theoretical strength performance.