Bike Project Complete

product dissection 03.12.
17
The Bicycle
SADDLE GRIPS
GEAR LEVER
HANDLEBAR
SEAT POST STEM BOLT
BRAKE LEVER
SEAT BOLT STEM
BRAKE CABLE
HEAD TUBE
CABLE CABLE YOKE
TOP TUBE
TIRE STOP
SEAT TUBE
TREAD DOWN TUBE
BRAKE
SIDEWALL FRONT
DERAILLEUR
FORK
TOE HUB FLANGE
TUBE
CLIP
FORK
HUB SPINDLE DROPOUTS
PEDAL
RIM
SPIDER
REAR SPOKE
DERAILLEUR CHAIN
CHAINRINGS
Used by permission, Cannondale Corp, ©1996

TENSION PULLEY
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product dissection 03.12.17
Bicycle Module Contents
1.  Introduction, History and Development of

Bicycles
2.  Biomechanics of Cycling
3.  Basic Construction and Design
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Bicycle History
1815 Hobbyhorse by Karl von Drais,
Germany
1490 DaVinci drawing
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1839 Treadle cycle by Kirkpatrick

Macmillan, Scotland
1861 Velocipede by Pierre

Michaux, France
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In the quest for more speed, the velocipede

evolved into the “ordinary”
1.5 m
The “ordinary”
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Bicycle Evolution - continued
1885 Rover “Diamond Frame”

Safety by John Starley, England
1888 Pneumatic tire by John Boyd Rover Safety Bicycle
Dunlop, Scotland
1895 Derailleur gears
1895 - 1970 Nothing significant

happened in the development of
the bicycle
Modern Rear Derailleur
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The Revolution since 1970

§  New materials (composites, titanium, aluminum)
§  Cross-over technologies (aircraft, skiing)
§  Mass production
§  Increased environmental consciousness
§  Bikes are “cool” again,
§  Mountain bikes
§  Human powered vehicles
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The Bicycle Today
§  The world’s 1 Billion bikes outnumber cars by

two to one
§  Bike production outnumbers car manufacture by
3 to 1
§  In Asia alone, bicycles transport more people
than do all the cars worldwide
§  The bike is the most energy-efficient mode of
transport: one US study found that to cycle one
mile burns 35 calories, to walk uses 100 calories,
while a car’s engine burns 1,860 calories
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Bicycle Facts - continued
§  Each mile of highway consumes about 25 acres

of land
§  The average motorist spends four hours a day
either driving, maintaining, or earning the money
for a car
§  Americans spend a billion hours a year stuck in
traffic, wasting two billion gallons of gas at a cost
of $10-30 billion
§  In one hour, a lane of highway can carry twice as
many people riding bikes as those traveling by
car (reference 2, pp 10-11)
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Cycling Bio-Mechanics
§  Basic Terminology (fill in the details as a class)

§  Work
§  Energy
§  Power
§  Force
§  Torque
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Things I’ve always

wondered about
1. Why do we shift gears on a bicycle?
2. What determines how fast our bike goes for a
given power input?
3. Are toeclips worth the trouble?
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Newton’s Second Law

F = ma = m dv/dt
F4
F1
a
C.G. A Rigid Body
F2
F3
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External Forces acting on Bike

RIDER WEIGHT
WIND RESISTANCE
HANDLEBAR FORCE
BIKE WEIGHT
PEDAL
FORCE
GROUND REACTION FORCES
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Force Transmission
L3 F1 Purpose of bike transmission

F3=F2 F2 is to convert the high force, low
L2 velocity at the pedal to a
higher velocity (and necessarily
L4
lower force) at the wheel. The
power at pedal (F1 x V1) equals
L1
the power at the wheel (F4 x V4)
(assuming no friction losses)
F4
F4 = F1 x ?
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Pedal Forces
A clock diagram showing the

total foot force for a group of
elite pursuit riders using toe
clips, at 100 rpm and 400 W.
Note the orientation of the force
vector during the first half of the
revolution and the absence of
pull-up forces in the second
half. (ref 3, pg 105)
used by permission of Human Kinetics Books,

©1986, all rights reserved
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Pedal Force Components
Fr = Total Foot Force
Fe=Effective Force
(causes useful Torque)
CRANK
PEDAL
The total foot force can be resolved

into vector components
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Effective Pedal Force
EFFECTIVE FORCE
RESULTANT FORCE
UNUSED FORCE
FORCE NEGATIVE EFFECTIVE FORCE
(N)
0 180
360
CRANK ANGLE (Degrees)

(ref 3, pg 106)
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Horizontal
Force between
Rear Wheel and
Road
A plot of the horizontal force between the rear wheel and the road,
due to each leg. The total force is shown as the bold solid line.
Note that this force is not constant, due to the fact that the force
applied at the pedal is only partly effective. (ref 3, pg 107)
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MOST EFFICIENT
Pedal Speed
PEDALLING SPEED
Optimum speed for most

people is 55-85 rpm.
This yields the most
useful power output for a
given caloric usage (ref 3, pg 79)

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Human Power Output

■  Most adults can deliver .1 HP (75 watts)
continuously while pedaling which results in a
typical speed of 12 mph
■  Well-trained cyclists can produce .25 to.40 HP
continuously resulting in 20 to 24 mph
■  World champion cyclists can produce almost .6
HP (450 watts) for periods of one hour or more -
resulting in 27 to 30 mph
Why do the champion cyclists only go
about twice as fast if they can produce
nearly 6 times as much power?
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Human Power Output
The maximum power output that can be sustained for

various time durations for champion cyclists. Average
power output over long distances is less than 400 W.
used by permission of Human Kinetics Books, (ref 3. pg 112)
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The Forces Working Against Us

Drag Force due to air resistance: Fdrag =CdragV2 A
Cdrag = drag coefficient (a function of the shape of the body and the
density of the fluid)
A = frontal area of body
V = velocity
and since: Power = Force x Velocity

This means that, to double your speed requires 8 times
as much power just to overcome air drag (since
power ~ velocity3)
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Some Empirical
Data
Drag force on a cycle versus
speed showing the effect of
rider position. The wind
tunnel measurements are less
than the coast-down data
because the wheels were
stationary and rolling
resistance was absent.
(ref 3, pg 126)

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Forces - continued
§  Rolling Resistance Frr=Crr x Weight

§  typical values for Crr:
§  knobby tires .014
§  road racing tires .004
§  Mechanical Friction (bearings, gear train)
§  absorbs typically only 3-5% of power input if well maintained
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Other Energy Absorbers
§  Hills (energy storage or potential energy)

§  Change in Potential Energy = Weight x Change in elevation
(Δh)
Δh Here, the rider has stored up

energy equal to the combined
weight of rider and bike times
the vertical distance climbed.
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The First Law of Thermodynamics
§  Conservation of Energy, for any system:
Energyin = Energyout +Change in Stored Energy
Energy input Internal Energy

of System
Energy Output
SYSTEM
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Now Put it All Together:

Velocity = f [ power input (pedal rpm, pedal force), road slope,
rider weight, bike weight, frontal area, rider position, gear
ratio, tire type and inflation, maintenance ...]
Your task: (as homework, due in one week, use computer
(spreadsheet program like EXCEL) for analysis and presentation
of results)
1. Using first law of thermodynamics, derive the relation between the
relevant factors to calculate V (bike velocity). Clearly state all
assumptions.
2. Generate a graph relating speed to hill grade (from 0% to 20%) for
riders weighing 120, 140, 160, 180 and 200 pounds who are
exerting a continuous power of 0.1 HP.
3. Determine the terminal velocity of the 160 lb rider coasting going
down a 10% grade.
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Bicycle Construction and Design
from ref. 4, used by permission of Rodale Press, ©1994, all rights reserved
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Different Frame Construction

Philosophies
Bicycle companies tend to have different design
philosophies, to give them a unique market “niche”
Cannondale - welded aluminum frames, hand crafted

Specialized - steel or chrome-moly (a steel alloy), welded
Trek - glued aluminum frames, or welded steel
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Look at one simple subsystem -

frame tubing
■  This is an excellent example of the trade-offs inherent in the
design process and the sometimes arbitrary decisions (not
justifiable based on purely analytical terms) which are often
made
■  There are lots of possibilities (variables) for even this simple
element
–  material (steel, aluminum, titanium, composite, ...)
–  cross section shape
»  shape (square, round, oval or other)
»  hollow or solid
»  constant cross section, or variable
■  How do you handle all this information and make a proper
choice ?
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Design Process
1. My first step in design - ASK QUESTIONS
–  intended use of product
–  desired or important performance qualities
»  for bike - low weight, riding efficiency, comfort, durability,
low cost ...
–  potential failure modes
–  how does the part fit into overall system
2. Identify design variables (things you as the
designer can specify) make a list here
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Design Process - continued
3. Quantify the performance qualities in terms of

the design variables
4. Identify the constraints based on potential failure

modes and performance qualities
5. Formulate a measure of the design’s

“goodness” (quantitative if possible)
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Design Process - continued
■  6. Apply an appropriate design method for

choosing the actual values of the design
variables and then iterate
–  Trial and error (OK for simple problems)
–  Past experience (extrapolation or interpolation)
–  Intuition, dumb luck
–  Numerical optimization methods ( a necessity if the number of
design variables and constraints are large)
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Back to the Tube
Let’s assume that the most important qualities of

this tube are its:
–  Low Flexibility (= high stiffness)
–  Low Weight (want as light as possible)
–  High Bending and Crush Strength
–  Long Life
Design Variables:
–  Material
–  Wall thickness
–  Tube OD
–  Joining method (weld, glue, braze)
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Bike Tubing
plain gage tube
single-butted tube
Better tubes are
thicker at ends to
give greater
strength at joints
double-butted tube
How are these made?
triple-butted tube
from ref. 4, used by permission of Rodale Press, ©1994, all rights reserved
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Materials Issues
■  Why was aluminum used?

■  What are its advantages and disadvantages?
■  Other possibilities:
–  Steels
»  Low Carbon, High Carbon, Chrome-molybdenum,
Stainless ...
–  Titanium
–  Magnesium
–  Carbon fiber composite (Carbon Fiber, Kevlar)
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Important Material Properties
■  Weight (density)
■  Stiffness (elastic modulus)
■  Strength (tensile strength, endurance limit)
■  Impact resistance (hardness)
■  Corrosion resistance
■  Joining
■  Recycling potential
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Material Properties Comparison

Elastic Yield Tensile Density Brinell Cost
Material Modulus Strength Strength lb/in3 Hardness $/lb
Mpsi Kpsi Kpsi
Aluminum
6061 T6 10 40 45 .10 95
7075 T6 10 72 82 .10 150
Steel
1040 HR (med carbon) 30 42 76 .283 149
1040 CD 30 71 85 .283 170
4140 HR (chrome/moly) 30 63 90 .283 187
4140 CD 30 90 102 .283 223
Graphite/Epoxy* 1-20 N/A 30-200 .06
HR = Hot Rolled CD=Cold Drawn

* Actual properties depend on the amount of reinforcing material
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Static Strength
results from a typical tensile

test of a steel sample
from Manufacturing Engineering and Technology, by S. Kalpaakjian,

used by permission of Addison Wesley, ©1992, all rights reserved
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Cyclic Strength
80
The fatigue properties are
500
highly dependent on the
1045 Steel
Stress Amplitude, S (MPa)

material type. Steels have
an endurance limit - a stress Endurance Limit
level which can be
endured for an unlimited
Kpsi
number of cycles (no
fatigue). Aluminum does
not have an endurance 2014-T6
limit and fatigues no matter Aluminum alloy
what the stress level. An
aluminum bike must be built 0 0
with extra strength to 103 1010
account for fatigue effects. Number of Cycles, N
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Cannondale Tube
Cannondale chose: aluminum tubing, 1.75” OD, .085” constant wall
thickness - a good compromise between weight and flexibility
OD - 1.75”
WEIGHT
FLEXIBILITY
0 0.05 0.1 0.15 0.2 0.25
WALL THICKNESS - inches

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Bicycle Reverse Engineering

Let’s say we are trying to get a quick start in the bicycle
business. We could buy a bunch of new bikes and
“reverse engineer” them to:
■  learn how to build them ourselves (without

paying royalties for the design)
■  improve on existing designs if possible
■  another reason for reverse engineering - need to
replace a part for which you have no drawing or
technical information
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Reverse Engineering Process
■  Document the design (usually in the form of

detailed engineering drawings)
–  Dimensions (metrology)
–  Materials (destructive or non-destructive measures)
–  Manufacturing processes
–  Estimate costs (materials, labor, etc)
■  Attempt to understand the design constraints and

reasons for various design decisions
bike1.ppt - 43 of 5

Bike Project Complete

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product dissection 03.12.

Used by permission, Cannondale Corp, ©1996

Bicycle Module Contents

1. Introduction, History and Development of

1839 Treadle cycle by Kirkpatrick

1861 Velocipede by Pierre

In the quest for more speed, the velocipede

Bicycle Evolution - continued

1885 Rover “Diamond Frame”

1888 Pneumatic tire by John Boyd Rover Safety Bicycle

1895 Derailleur gears

1895 - 1970 Nothing significant

Modern Rear Derailleur

The Revolution since 1970

The Bicycle Today

§ The world’s 1 Billion bikes outnumber cars by

Bicycle Facts - continued

§ Each mile of highway consumes about 25 acres

§ Basic Terminology (fill in the details as a class)

Things I’ve always

Newton’s Second Law

External Forces acting on Bike

GROUND REACTION FORCES

L3 F1 Purpose of bike transmission

A clock diagram showing the

used by permission of Human Kinetics Books,

Pedal Force Components

Fr = Total Foot Force

The total foot force can be resolved

Effective Pedal Force

CRANK ANGLE (Degrees)

Optimum speed for most

used by permission of Human Kinetics Books,

Human Power Output

Human Power Output

The maximum power output that can be sustained for

The Forces Working Against Us

and since: Power = Force x Velocity

used by permission of Human Kinetics Books,

§ Rolling Resistance Frr=Crr x Weight

Other Energy Absorbers

§ Hills (energy storage or potential energy)

Δh Here, the rider has stored up

The First Law of Thermodynamics

§ Conservation of Energy, for any system:

Energyin = Energyout +Change in Stored Energy

Energy input Internal Energy

Now Put it All Together:

Bicycle Construction and Design

Different Frame Construction

Cannondale - welded aluminum frames, hand crafted

Look at one simple subsystem -

Design Process - continued

3. Quantify the performance qualities in terms of

4. Identify the constraints based on potential failure

5. Formulate a measure of the design’s

Design Process - continued

■ 6. Apply an appropriate design method for

Back to the Tube

Let’s assume that the most important qualities of

plain gage tube

How are these made?

■ Why was aluminum used?

Important Material Properties

1.  Introduction, History and Development of

§  The world’s 1 Billion bikes outnumber cars by

§  Each mile of highway consumes about 25 acres

§  Basic Terminology (fill in the details as a class)

§  Rolling Resistance Frr=Crr x Weight

§  Hills (energy storage or potential energy)

§  Conservation of Energy, for any system:

■  6. Apply an appropriate design method for

■  Why was aluminum used?

■  learn how to build them ourselves (without

■  Document the design (usually in the form of

■  Attempt to understand the design constraints and