Optimizing enhanced smart architecture frame (eSAF) topology: A computational approach to weight and strength trade-offs

• Topology optimization was applied to the eSAF frame to achieve significant weight reduction while maintaining structural integrity. • Finite Element Analysis (FEA) under flexural and torsional loads confirmed that both original and optimized frames remained below the yield stress of 680 MPa, indicating fully elastic behavior. • Stress concentration at critical cracking zones was reduced from 171.67 MPa to 151.09 MPa, and overall frame stress dropped from 284.69 MPa to 134.98 MPa after optimization. • Despite a 29% increase in torsional stress post-optimization, the frame preserved its functionality with a safety factor above 1.5. • Three topology algorithms (SCIPIP, MFD, and C-MFD) were compared, with MFD providing the best trade-off between mass reduction and structural robustness. • The optimized geometry introduced smoother transitions and eliminated redundant ribs, enhancing manufacturability and stiffness distribution. Engineers developed the Enhanced Smart Architecture Frame (eSAF) to create a lighter motorcycle frame through advanced engineering efforts. Despite its advantages, the eSAF frame came under scrutiny after reports of structural failures. To prevent structural failures due to frame stresses, this study was conducted by identifying frame parts that need to be removed to achieve lower structural stresses after the topology optimization process. Furthermore, an evaluation of the optimization impact of such mass reduction on the overall mechanical performance of the truss is examined. This research works under a method known as topology optimization. By specifying three static load scenarios, topology optimization removes material in some parts. It reduces the bending stress to 164.52 MPa in the total area and the stress in the crack region to 154.13 MPa, as well as the torsional stress at 132.26 MPa. Both designs remained below the yield strength of 680 MPa, indicating a fully recoverable frame and confirming that no permanent melting occurred and that the structure maintained exclusively elastic behavior throughout the test under regular use. Although the present research model employs High-Strength Steel as the reference material, the incorporation of lightweight composites, such as carbon fiber reinforced polymer (CFRP), can markedly alter the optimal design envelope. This shift facilitates an improved balance between deformation control and the preservation of high-frequency response, thereby rendering CFRP a highly suitable candidate for mitigating vibration-induced crack propagation.