2-D bicycle frame design

Problem description
The schematic dimensions of a bicycle frame made of aluminium tubes are shown in Fig. 1.
Approximate the frame as a plane frame by giving the same coordinates to Locations 5 and
6. The minimum outside tube diameter is 12 mm and the tube wall thickness is 2 mm.
For aluminium, take Youngs modulus E 70 GPa, Poissons ratio 0. 33, density
2, 580 kg/m 3 , yield strength Y 210 MPa.
When a dynamic environment is simulated using static analysis, the static nominal loads
may be mutiplied by a dynamic load factor G. In this design project, use G 2 to represent
suddenly applied loads. Consider the following two independent loading scenarios:

1) Dynamic vertical loads

When an adult rides the bike, the static loads are estimated as a downward load of 900 N at
the seat position and a load of 300 N at the pedal crank location. Use ball-joint boundary
conditions for the front dropout (Location 1) and sliding conditions for the rear dropouts
(Locations 5 and 6).

2) Horizontal impact
The frame should be able to withstand a static horizontal load of 1,000 N applied at the front
dropout with rear dropouts constrained from any translational motion. For this load case,
assume the front dropout can only move in the horizontal direction.

Figure 1

Project deliverables

1) MatLab program
A commented MatLab program is to be obtained by modifying the Lab4.m file in any way
needed to determine the displacements at Locations 1 to 6. Use only one element for each
straight member of the 2-D frame, and consider both loading cases independently. In this
part, the outside tube diameter is set at 12 mm for all tubes. The displacement values
obtained in this part will provide a reference against which you will check the initial results of
the FE analysis to follow.

2) ANSYS script and analyses

One commented programmed input deck is to be created that allows you to do all the
following steps except for detailed postprocessing (which is usually best done using the
GUI).
2.1) Initial check
Using the exact same conditions as in Part 1), check your displacements against those
obtained from MatLab.
2.2) Mesh sensitivity analysis
After passing the initial check, run a mesh sensitivity analysis to decide what element size is
needed for the rest of the analyses.
2.3) Manual design optimization
By trial-and-error, choose aluminium tubes of various outside diameters for the various
members of the frame such that the bicycle is as light as possible. Use a safety factor of 2.5
for yielding (von Mises failure criterion). For compression members, include buckling as an
additional criterion, also with a safety factor of 2.5. For convenience, calculations such as
frame weight and buckling loads may be done using MatLab rather than ANSYS.

3) A report
Hand out a printed version of your report. The report should be easily readable and
complete by itself, e.g. include introduction, approach, assumptions, results, discussion,
conclusion, references and appendices (program scripts). Note that ANSYS-generated
figures used in the report should have white backgrounds.