ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my guide teacher Mr.S.P.Patel as

well as our H.O.D. Mr.V.B.Patel, who gave me the golden opportunity to do this wonderful
project on the HYBRID FOLDING CYCLE, which also helped me in doing a lot of Research
and i came to know about so many new things.
I am really thankful to them.
Secondly i would also like to thank my parents and friends who helped me a lot in finishing
this project within the limited time.

I am making this to increase my knowledge.

THANKS AGAIN TO ALL WHO HELPED ME.

1
 ABSTRACT

This project involved the design and manufacture of a prototype for a Hybrid folding cycle.
Throughout this project, a Hybrid folding cycle will be design and analyze in order to make
this project successful and reach the objective. Commonly, Hybrid folding cycle use different
type of electric motor as a power assist and with different method of fold mechanism. In this
project, there are two main consideration in order to design the bicycle which is power assist
(electric motor) and folding method. For power assist, this project is using hub motor that
attached at the front wheel. In order to design a small bicycle, a folding method and material
that will be used in this project need to be analyze. Based on this research, a small electric
bicycle will be design as a prototype and the motor performance and strength of bicycle
frame will be analyzed. The analysis on bicycle frame had been done by using Solidwork
software to know whether the frame design is acceptable.

2
 Index
Sr. No. Contents Page No.
Acknowledgement 1
Abstract 2
Index 3
List of figure 4
List of table 5
Problem formulation 6
1 Literature review 7
1.1 History of the Bicycle 7
1.2 The bicycle and its Application 9
2 Introduction 10
2.1 PROJECT BACKGROUND 10
2.2 OBJECTIVES 11
2.3 SCOPE 11
3. Methodology 12
3.1 Introduction 12
3.2 Design 14
3.2.1 Bicycle chain 15
3.2.2 Chain wheel 19
3.2.3 Pedal / Crank Assembly 20
3.2.4 Handle bar 23
3.3 Types of Battery 25
3.4 Types of Motor 25
4 Analysis 26
4.1 Modal Information 26
4.2 Study Properties 27
4.3 Units 28
4.4 Material Properties 28
4.5 Load and Fixture 29
4.6 Contact Information 29
4.7 Mesh Information 30
4.8 Resultant Forces 31
4.9 Study result 32
5 Conclusion 41
6 Appendix-A 42
7 Appendix-B 46

3
 List of figure
Figure No. Content Page No.
1.1 The Draisienne invented by 7
Baron van Drais
1.3 Bicycle Evolution 8
3.1 Block diagram 12
3.2.1 Bicycle chain 15
3.2.2 chain wheel 19
3.2.3 pedal/crank assembly 20
3.2.4 Handle bar 24
6.Appendix-A picture of cycle frame 43-46
7.1 Axial stress direction 47
7.2 Deformation 47
7.3 Bending moment in y direction 48
7.4 Bending moment in z direction 48
7.5 Von Mises stress 49
7.6 Von Mises Elastic Strain 49

4
 List of Table

Table No. Content Page No.

3.2.4 Actual & Maximum Stress 25
3.3 Types of Battery 26
3.4 Types of Motor 26
4.1 Model Information 27
4.2 Study Properties 28
4.3 Units 29
4.4 Material Properties 29
4.5 Load and Fixture 30
4.6 Contact Information 30
4.7 Mesh Information 31
4.7.1 Mesh Information-detail 31
4.8 Resultant Forces 32
4.9 Study Result 33

5
PROBLEM FORMULATION

Nowadays, a hybrid folding bicycle is become increasingly popular around the world. There
a lot of invention of folding electric bicycle in the market with different size, power assists
material usage and folding mechanism. However, not all the invention is perfect and suitable
for all situations. For example, larger size of bicycle have a better ride and better handling but
it difficult to carried into public transportation even in folding form and if the design too
small, it will sacrifice ride quality due to smaller wheel and to steering. Besides that, some of
the product in the market takes a longer time to fold into compact form. So, this will be part
to think the solution for related problem. Below is the listed of problem in this study.

1. Selecting the suitable size

2. Creating a folding mechanism that will decrease time to fold

3. Selecting the right material for frame to reduced weight but can support variable load.

4. Selecting of proper electric motor as a power assist

6
1. LITERATURE REVIEW

1.1 History of the Bicycle

The first predecessor of the bicycle that exists is a wooden horse developed in 1700’s
in France. A toymaker come up with the idea of placing a wheel on the bottom of his horse,
so that a child could propel himself forward with his feet. After this creation, in 1817 Baron
von Drais invented the Draisienne, a steerable bicycle. It was almost completely made of
wood, and having no pedals, riders propelled it by pushing their feet against the ground. The
purpose of this invention is to help him move around the Royal Gardens when he was in
hurry.

Figure 1.1: The Draisienne invented by Baron van Drais

The next appearance of a two wheeled riding machine was invented in 1865, pedals were
applied directly to the front wheel. This machine was known as the Velocipede, but was
popularity known as the bone shaker because it also made entirely from wood. Wooden
wheels clattering over cobblestone and dirt roads often lead to riders falling off and getting
injured. For this reason, a lot of modification and improvement in design of bicycle is done to
create a proper bicycle until in 1870, when the first all metal machine appeared. The pedals
were still attached directly to the front wheel with no freewheeling mechanism. Solid rubber
tires and the long spokes of the large front wheel provided a much smoother ride than its
predecessor. This machine was the first one to be called a bicycle (two wheels). After that,
the bicycle through a lof of modifications and improvements to satisfied the riders.

7
In the 1890s, electric bicycles were documented within various U.S. patents. For example, on
31 December 1895 Ogden Bolton Jr. was granted U.S. Patent 552,271for a battery-powered
bicycle with “6-pole brush-and-commutator direct current (DC) hub motor mounted in the
rear wheel.” There were no gears and the motor could draw up to 100 amperes (A) from a 10-
V battery. The electric bicycle is a bicycle with an attached motor used to power the vehicle,
or to assist with pedaling. This invention lead others inventor to produce other type of electric
bicycle by using a different types of power assist. The latest type of bicycle is the foldable
electric bicycle which is the frame can be fold into compact form to make it easier to store
and carried into building or public transportation.

Figure 1.3 Bicycle Evolution

8
1.2 The bicycle and its Applications

Throughout its history the most common use of the bicycle has been to transport a
single individual. Transportation can nevertheless take many forms as the needs of specific
scenario can greatly affect the design that would best fill those needs. Task specific bicycle
designs such as racing, mountain, touring, or utility bicycles have many refinements that
greatly improve performance for a particular situation.

One particular application of the bicycle that was of interest to our research was the
use of bicycle in military scenarios. In the late 19th century, several leading nations created
military units that took advantage of the mobility thy bicycle offered. In Italy in 1870, sharp
shooters were assigned to bicycle units which provided rapid and silent mobility to varied
terrain. By 1891, the United States had begun to adopt bicycle for many application within
the military as the maintenance and care advantages over horses became apparent. With the
advent of the automobile and the motorcycle the use of military bicycles has all but
disappeared but the need for a high compliance human powered transport has not.

The most common form of carrying cargo on a bicycle is by attaching baskets or

supports to which a package can be fixed at the front or rear of the frame. This method proves
to be ideal for small loads, usually no heavier than what an adult individual could carry by
hand or in a backpack. In order to increase the cargo capacity some manufactures produce
trailers that can be attached to a bicycle. These trailer systems make carrying large loads
possible but add length and additional wheels to the vehicle, changing its driving dynamics
even when cargo is not being carried.

9
2. INTRODUCTION
2.1 PROJECT BACKGROUND

As we know, bicycling is becoming an increasingly more popular form as

transportation. Besides that, the bicycle is used for recreation, transportation and competition.
It let you get where you are going a lot faster and using less energy than walking or running.
Basically, bicycle is made of just a few parts that we can immediately see and identified and
it is a pedal driven or human powered vehicle with two wheels attached to frame, one behind
and another which is required balancing by the riders.

According to the data of the China Bicycle Association, a government-chartered

industry group, in 2004 China's manufacturers sold 7.5 million electric bicycles nationwide.
An electric bicycle is simply a bicycle with an attached motor which assist the riders. Electric
bicycles use rechargeable batteries, electric motors and some form of control for powering
the rear wheel. An electric power assist system may be added to almost any pedal cycle using
chain drive, belt drive, hub motors or friction drive. However, the frame of prior electric
bicycle is fixed and its storage may occupy a relatively large space and difficult to carried
into building, workplace oronto public transportation. So, it’s not convenient for living
environment of the big city nowadays. Thus, based on that problem, the folding electric
bicycle was created.

Earlier invention of folding bicycle was recorded in early 1900. A folding bicycle
incorporates special design features enables the bike to fold into a compact form. When
folded, the bikes can be more easily carried into buildings, into workplace or onto public
transportation. Folding mechanisms themselves are highly variable, with each design offering
a unique combination of folding speed, folding ease, compactness, engineering, ride, weight,
durability and price.

The foldable electric bicycle uses a combination of folding frame and powered assist
by electric motors. Thus it will give advantages because it not required human energy to drive
it, reduced storage space and being ease of movement. Besides that, this type of bicycle is
suitable for living environment at the big city. Another advantage for this type of bicycle is
based on energy cost.

10
2.2 OBJECTIVES

The main objectives of this project are:

1. To design a small electric bicycle
2. To analysis the performance of motor starter
3. To analysis the strength of proposed bicycle frame

2.3 SCOPE

The focus of this study is to do a researching and developing a foldable electric bicycle in
order to reduced storage space and being ease of movement. In this project making there are
several things which are been considerate and which are not been considered. This research
will focus on several aspects.

1. Ergonomic design of bicycle frame

2. Performance analysis of electric motor (maximum speed and motor efficiency)

3. Material selection for bicycle frame

4. Analysis on reaction force on proposed bicycle frame

11
3. Methodology

3.1 Introduction

• As name suggest hybrid means dual power,

1.Man power by pedal

2.Electric power by battery

• And folding means folds into a much smaller size when you’re finished using it.

There is one block diagram to understand the how the working of hybrid system.

Fig 3.1: Block diagram

The design project allows us to get a fundamental understanding of how materials and the
mechanics of those materials are used in real world situations, with real world application.
We were required to design a two-wheel bicycle that can safely withstand 90 kg and a
velocity of 15 km/hr. This design was done first, on the individual parts to ensure that each
portion of the bicycle was capable of supporting the stresses induced by the forces and
reactions acting on them. After making educated assumptions, analysis was performed on the
individual parts, and finally on the total design for the final testing. The bicycle performed as
expected from the assumptions and calculations.

12
In order to perform more accurate analysis the bicycle was broken down to familiar shapes
and members such as prismatic bars, hollow tubes, and bars with holes through the face. The
designing of the bicycle also required us to divide the bike into five portions: the bicycle
chain, the chain/wheel connection, the pedal/crank assembly, the bicycle frame, and the
handlebars. Treating the portions as free-body diagram like structures, the forces acting on
each portion were determined, and the stresses whether axial, shear, torsion, or bending
moment were determined and calculated. After solving how the bicycle would act in the
separate portions, they needed to be assembled to gain a full analysis to ensure that the
bicycle would act as expected after analyzing the parts. Also the parts were directly
associated with each other, such as the bicycle chain to chain/wheel connection, so it was
essential that the numbers were in agreement with each other as they shared the tension in the
chain.

After determining what forces and stresses the bicycle would experience the next step was to
choose materials able to securely withstand these effects. After choosing a factor of safety
(FS) of 2, the material for each component was chosen, which could withstand the maximum
stresses of each portion of the bicycle with the FS enforced.

13
3.2 Design

A bike chain is constructed with many small links. These small links are like bars but
with two holes drilled into them. It can be assumed that there is constant tension all
throughout the entire chain. Also, there are normal stresses acting upon the outer and inner
links within the chain. The tension of the chain is in relation to the radius of the chain wheel
and the force applied on the pedals. Along with nor-mal stresses, there are shear and bearing
stresses acting in the chain. All the shear and bearing stresses are placed upon the pins
holding the links together.

In the chain wheel, we assume that there is little or no friction. We also as assume that the
radius is even and the same throughout the entire wheel.
In the pedal and crank assembly, it is assumed that the biker presses down with a force of 60
lbs on each pedal. Upon looking at all the forces in a pedal crank, it is expected to break or
split the crank into two different and simple bars. The forces acting upon the crank is an
assumed combination of bending moment and torsion. It can be assumed all the torsion and
bending moment comes from the force applied upon the pedal. In this project we are
assuming no friction between parts and for the force on the pedal to be constant.
In the bicycle frame, we assume that all of the rider’s weight is placed on the seat. We
assume that all the reaction forces are equal to the weight.

Before we begin our analysis of various components, it first necessary to find the
required force applied on the pedal, such that the bicycle will accelerate at a rate of 4.572
m/s2. To do this first the inertial force is found.

Since this is the resisting force of the motion of the bicycle, this is also the force
resisting the motion of the gear, or the tension in the chain. Now the required force applied on
the pedal is found.

TR (518 N)(89 mm)

∑ Mc = 0 = FLC − TR and F = = = 259.72 N
LC 177.5 mm

14
3.2.1 Bicycle chain

Fig 3.2.1: Bicycle chain

The tensile force in the chain, which is equal to inertial force of the bicycle, was found to
be

𝑇= 518 N

Since the links contain holes in the stress in the link is not distributed evenly, but reaches
a maxi-mum near the hole. The maximum stress acting on the outer links in the chain is
found by

Where K, the stress-concentration factor, was found to be 2.4

15
The shear stress acting on the pin holding the links together is given by

Speed of the driving sprocket is 150 rpm.

No. of teeth on driving sprocket Z1=44

No. of teeth on driven sprocket Z2=18

speed ratio i=n1/n2 =Z2/Z1

i=18/44

i=0.409

n1/n2 =Z2/Z1

n2=n1Z1/Z2

n2= (150×44)/18

=366.78rpm

n2 ≈367rpm

• Now, pitch of the chain drive is as per the ISO std. chain no 06 B-1

 Specification of chain:-

• ISO chain no 06 B-1

• Pitch of the chain =9.525mm

• Roller diameter=6.35mm

• Width b=5.72mm

• Weight of chain=0.41 Kg/m

16
• Breaking strength=8900N

Now,

diameter of the driving sprocket(D)

D=P/sin(180/Z1)

= 9.525/sin(180/44)

=133.51mm

D≈134mm

Now,

diameter of the driven sprocket(d)

d=P/sin(180/Z2)

= 9.525/sin(180/18)

=54.85mm

d ≈55mm

Chain velocity

V=(Z1×P×n1)/60×10^3

V=(44×9.525×150)/60×10^3

V=1.0477m/s

Chain in tension P1= (1000×kw)/v

= (1000×0.47)/1.0477

P1 = 448.58N

Now factor of safety

(fs)=breaking load/chain in tension

=8900/448.58

17
 (fs)= 19.84

• Center distance between 2 sprocket (a)= 610 mm

For, no of link(Ln)

Ln=2(a/P)+(z₁+z₂/2)+(z₁-z₂/2∏)*(p/a)

=2(610/9.525)+(44+18/2)+(44-18/2∏)*(9.525/610)

=79.5

≈80links

Now, total length of the chain

L=2×Ln×p

=2×80×9.525

L=1524mm

18
3.2.2 Chain wheel

Fig3.2.2: chain wheel

The spokes on the chain wheel which pull on the chain links, experience a shear stress on the
area between the base of the spoke and the chain wheel. The area on the base of each spoke is
roughly 1/8 in by 3/8 in.

19
3.2.3 Pedal / Crank Assembly

Fig3.2.3: pedal/crank assembly

Since the stresses acting on the crank are a combination of the torsion and bending
moment, the total state of stress is given by

20
Fr= 9.8×80

=784N

Fr ≈800N Fr = Radial force acting on the bearing

Fa = 9.8×90

=882N

Fa ≈900N Fa = Axial force acting on the bearing

Now,

(Fa/Fr )>e here,e=0.22

= 0.88>e

X=0.56

Y=1.4

P=(XFr + yFa)

=(0.56×784) +(1.4×900)

P=1673.84N

Now, L10 =60nL10h/10^6

=(60×150×5000) /10^6

L10 =45 million revolutions

here,

L10 =life of bearing for 90% survival at 1 mr

L10h =life of bearing in hours

n=revolutions per minute of pedal shaft

21
  Dynamic load carrying capacity of bearing:

c=P×(L10) ^1/3

=1673.84×(45) ^1/3

c =5953.67 N

c =5.95 KN

From above calculations we can select a bearing for mfg. Catalogue

• Bearing designation is 6202

• Inner diameter of bearing =15mm
• Outer diameter of bearing =32mm
• Width of the bearing =11mm
• Dynamic load carrying capacity of bearing =7800N

22
3.2.4 Handle bar

fig 3.2.4 Handle bar

23
 • To analyze the maximum state of stress acting on the handlebar

Tabulated below are the results for the maximum stresses experiences by various components
on the bicycle. With a factor of safety of two, the maximum stresses are doubled.

Table 3.2.4 Actual & Maximum Stress

Component Actual stresses Maximum stresses

Chain Link 32.72 N/mm2 65.44 N/mm2

Chain Wheel 17.12 N/mm2 34.25 N/mm2

Pedal Crank 256.94 N/mm2 513.88 N/mm2

Handle Bars 12.07 N/mm2 24.14 N/mm2

24
 3.3 Types of Battery

Battery Type Advantages Disadvantages

Lithium-Ion 1. Highest energy 1. Can damage easily by

density to weight over(dis )charge.
ratio. 2. All lithium-ion
2. Eliminates need for technologies require
periodic care for a protection circuit to
long life. prevent overheating.

Lead-Acid 1. Inexpensive and 1. Low energy density

simple to — poor weight-to
manufacture. energy density.
2. Low maintenance 2. Environmentally
requirements. unfriendly.

Ni-CD 1. Fast and simple 1. Environmentally

charge. unfriendly —the Ni-
2. Economically priced Cd contains toxic
— the Ni-Cd is the metals.
lowest cost battery in 2. Some countries are
terms of cost per limiting the use of the
cycle. Ni-Cd battery.

3.4 Types of Motor

Motor Type Description

Brushed Hub Motors In a brushed hub motor, electrical energy is transferred

through small metal "brushes"' that contact a rotating
part of the motor called the commutator. Because there is
physical contact between stationary and moving parts,
wear will occur, and over time the brushes will have to be
replaced. Brushed hub motors require less complex
controllers , so the systems are less expensive.

Brushed Hub Motors Brushless motor, there is no contact between any of the
parts inside the motor. Brushless motors are more
efficient at converting electricity into mechanical power
than brushed motors.

25
 4. Analysis
4.1 Modal Information

Model name: Assem1

Current Configuration: Default
` Treated As Volumetric Properties Document Path/Date
Modified
Boss-Extrude21 Solid Body Mass:0.00822065 kg D:\folding
Volume:1.04615e-006 m^3 cycle\Part4.SLDPRT
Density:7858 kg/m^3 Nov 19 14:36:28 2013
Weight:0.0805624 N

Combine5 Solid Body Mass:6.05304 kg D:\folding

Volume:0.000770302 m^3 cycle\Part4.SLDPRT
Density:7858 kg/m^3 Nov 19 14:36:28 2013
Weight:59.3198 N

Combine8 Solid Body Mass:13.0571 kg D:\folding

Volume:0.00166165 m^3 cycle\Part4.SLDPRT
Density:7857.91 kg/m^3 Nov 19 14:36:28 2013
Weight:127.959 N

Cut-Extrude14 Solid Body Mass:0.222789 kg D:\folding

Volume:2.83518e-005 m^3 cycle\Part4.SLDPRT
Density:7858 kg/m^3 Nov 19 14:36:28 2013
Weight:2.18333 N

Combine2 Solid Body Mass:1.94303 kg C:\Users\Harry\Deskto

26
 Volume:0.000247268 m^3 p\solidworks\fork.SLD
Density:7858 kg/m^3 PRT
Weight:19.0417 N Nov 19 14:45:52 2013

4.2 Study Properties

Study name Study 1

Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SolidWorks Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SolidWorks document
(c:\users\harry\appdata\local\temp)

27
 4.3 Units

Unit system: SI (MKS)

Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2

4.4 Material Properties

Model Reference Properties Components

Name: AISI 4130 Steel, SolidBody 1(Boss-
normalized at 870C Extrude21)(Part4),
Model type: Linear Elastic Isotropic SolidBody 2(Combine5)(Part4),
Default failure criterion: Max von Mises Stress SolidBody 3(Combine8)(Part4),
Yield strength: 4.6e+008 N/m^2 SolidBody 4(Cut-
Tensile strength: 7.31e+008 N/m^2 Extrude14)(Part4)
Elastic modulus: 2.05e+011 N/m^2
Poisson's ratio: 0.285
Mass density: 7850 kg/m^3
Shear modulus: 8e+010 N/m^2
Curve Data:N/A

28
 4.5 Load and Fixture

Fixture name Fixture Image Fixture Details

Fixed-1 Entities: 2 edge(s), 19 face(s)
Type: Fixed Geometry

Resultant Forces
Components X Y Z Resultant
Reaction force(N) 0.012924 800.048 0.00807436 800.048
Reaction Moment(N·m) 0 0 0 0

Load name Load Image Load Details

Force-1 Entities: 1 face(s), 1 plane(s)
Reference: Top Plane
Type: Apply force
Values: ---, ---, -200 N

Force-2 Entities: 1 face(s), 1 plane(s)

Reference: Top Plane
Type: Apply force
Values: ---, ---, -600 N

4.6 Contact Information

Contact Contact Image Contact Properties

Global Contact Type: Bonded
Components: 1
component(s)
Options: Compatible
mesh

Component Contact-1 Type: Bonded

Components: 3 Solid Body (s)
Options: Compatible
mesh

29
 4.7 Mesh Information

Mesh type Solid Mesh

Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 5 mm
Tolerance 0.25 mm
Mesh Quality High
Remesh failed parts with incompatible mesh Off

4.7.1 Mesh information – detail

Total Nodes 253998

Total Elements 157386
Maximum Aspect Ratio 21.681
% of elements with Aspect Ratio < 3 98.7
% of elements with Aspect Ratio > 10 0.0197
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:36

30
 4.8 Resultant Forces

Reaction forces

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N 0.012924 800.048 0.00807436 800.048

Reaction moment

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N·m 0 0 0 0

31
 4.9 Study result

Name Type Min Max

Stress1 VON: von Mises Stress 7.96611 N/m^2 1.48523e+007 N/m^2
Node: 42263 Node: 212031

Assem1-Study 1-Stress-Stress1

Name Type Min Max

Displacement1 URES: Resultant Displacement 0 mm 0.069668 mm
Node: 67115 Node: 75302

32
 Assem1-Study 1-Displacement-Displacement1

Name Type Min Max

Strain1 ESTRN: Equivalent Strain 4.07195e-011 5.34468e-005
Element: 14854 Element: 62070

Assem1-Study 1-Strain-Strain1
Name Type Min Max
Stress2 SX: X Normal Stress -1.32e+007 N/m^2 1.15345e+007 N/m^2
Node: 212016 Node: 191142

33
 Assem1-Study 1-Stress-Stress2

Name Type Min Max

Stress3 SY: Y Normal Stress -9.91697e+006 N/m^2 7.78472e+006 N/m^2
Node: 212058 Node: 186025

Assem1-Study 1-Stress-Stress3

Name Type Min Max

Stress4 SZ: Z Normal Stress -9.91697e+006 7.78472e+006 N/m^2

34
 N/m^2 Node: 186025
Node: 212058

Assem1-Study 1-Stress-Stress4
Name Type Min Max
tress5 P1: 1st Principal Stress -4.63384e+006 1.29661e+007 N/m^2
N/m^2 Node: 221133
Node: 253062

Assem1-Study 1-Stress-Stress5

Name Type Min Max

35
Stress6 P3: 3rd Principal Stress -1.83192e+007 N/m^2 2.19754e+006 N/m^2
Node: 253405 Node: 232642

Assem1-Study 1-Stress-Stress6

Name Type Min Max

Displacement2 UX: X Displacement -0.000898429 mm 0.0428042 mm
Node: 55232 Node: 75296

Assem1-Study 1-Displacement-Displacement2
Name Type Min Max
Displacement3 UY: Y Displacement -0.0592852 mm 0.00402652 mm

36
 Node: 65791 Node: 55387

Assem1-Study 1-Displacement-Displacement3

Name Type Min Max

Displacement4 UZ: Z Displacement -0.0253672 mm 0.0251905 mm
Node: 165627 Node: 184689

Assem1-Study 1-Displacement-Displacement4

Name Type Min Max

37
Strain2 EPSX: X Normal Strain -5.72799e-005 5.49892e-005
Node: 212016 Node: 191142

Assem1-Study 1-Strain-Strain2

38
Name Type Min Max
Strain3 EPSY: Y Normal Strain -5.24785e-005 5.37373e-005
Node: 217923 Node: 221133

Assem1-Study 1-Strain-Strain3

Name Type Min Max

Strain4 EPSZ: Z Normal Strain -3.54464e-005 3.14065e-005
Node: 212062 Node: 201778

39
 Assem1-Study 1-Strain-Strain4

Name Type Min Max

Factor of Safety1 Max von Mises Stress 19.0331 3.5486e+007
Node: 212031 Node: 42263

Assem1-Study 1-Factor of Safety-Factor of Safety1

40
5. Conclusion

By performing this simulation, design and mathematical formulation we can conclude

that our design for folding cycle is safe and reliable so now we can successfully
implement in our production domain.

41
 6.Appendix-A

In this section some picture of cycle frame.

42
43
44
45
 7.Appendix-B

In this section the FEA analysis in Ansys.

Fig 7.1: Axial stress direction

Fig 7.2: Deformation

46
Fig 7.3: Bending moment in y direction

Fig 7.4: Bending moment in z direction

47
 Fig 7.5: Von misses stress

Fig 7.6: Von misses elastic strain

References:

1. http://depts.washington.edu/matseed/mse_resources/Webpage/Bicycl
e/Bicycle%20Materials%20Case%20Study.htm
2. http://www.bikeforums.net/archive/index.php/t-477073.html

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3. http://www.ibiscycles.com/support/technical_articles/metallurgy_for_
cyclists/steel_is_real/

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