The stacking sequence optimisation of a filament wound composite bicycle frame using the data-driven evolutionary algorithm EvoDN2

This work focusses on identifying the optimal stacking sequence for composite tubes in mountain bike frames using a data-driven model combined with evolutionary algorithms. The objective is to find a frame that is sufficiently stiff while meeting the requirements of weight, strength, and minimum tube wall thickness. The decision variables are the ply winding angles and the ply thicknesses of each tube. The study performs designs for two load cases – Starting and Uphill – and explores two types of winding: the gradual winding of individual layers (1ply) and the winding of layers between predefined inner and outer layers with variable thicknesses (TW). Additionally, the design process is applied to frames made of isotropic materials, such as steel, aluminium, and titanium, using the same methodology to allow for comparison of results. The article demonstrates the successful application of this methodology to common sports equipment, suggesting its potential for beneficial use in other common composite frame structures.