ENGINEERING COMPONENT DESIGN FINAL PROJECT

MONDAY, MAY 20th 2019

MECH 3312 A SPRING 2018/2019

FOLDABLE HELMET

Elin Rachmawati (2017360005)

Gloria Ellysian Aprilia(2017360006)
Wahyu Haykal Rahmanda (2017360015)

LECTURED BY:
Dr. Farid Triawan

MECHANICAL ENGINEERING
FACULTY OF ENGINEERING AND TECHNOLOGY
SAMPOERNA UNIVERSITY
2019
 Table of Contents

Table of Contents 1
CHAPTER 1: Introduction 4
1.1 Objectives 4
CHAPTER 2: Specifications of Needs 5
2.1 Specifications of Dimension 5
2.2 Specifications of Safety 6

2.3 Specifications of Strength 6

CHAPTER 3: Product Design 8

3.1 Three Rough Sketch of Mechanisms 8
3.1.1 Mechanism 1 8
3.1.2 Mechanism 2 9
3.1.3 Mechanism 3 10
3.2 Synthesis to Decide One Sketch 11
3.3 Design Requirement 11
3.4 Prototype of the Design 12
3.4.1 Three Parts of Outer Shell 13

3.4.2 Locking System on the Main Pivot / Primary Joint 15

3.4.2.1 Inner Support Joint Piece 17

3.4.2.2 Outer Handle Joint Piece 18

3.4.2.3 Cube-Key Joint Piece 19

3.4.2.4 Shaft Joint Piece 20

3.4.2.5 The Instalment and The Mechanism of The Joint Piece 21

3.4.3 Locking System between Two Outer Shell / Secondary Joint 22

3.5 Material of the Helmet 23

3.5.1 Inner Shell 24

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 3.5.2 Visor 24

3.5.3 Outer Shell 25

3.5.4 Primary Joint 26

3.5.5 Secondary Joint 27

CHAPTER 4: Technical Analysis 28

4.1 Design Factor 28

4.1.1 Assumption 28

4.1.2 Helmet Shell Analysis 28

4.1.2.1 Diagram 28

4.1.2.2 Calculation 30

4.1.2.3 Mean Load 31

4.1.2.4 Maximum Stress Analysis 32

4.1.2.5 Safety Factor 32

4.1.2.6 Load Range 33

4.2 Static Force Analysis in Critical Location 33

4.2.1 Primary Pin Joint 33

4.2.1.1 Diagrams 33

4.2.1.2 Calculations 35

4.2.1.3 Safety Factor 35

4.2.2 Secondary Fasteners Joint 36

4.2.2.1 Fastener Specifications 36

4.2.2.2 Calculation 36

4.2.2.2.1 Known Parameters 36

2
 4.2.2.2.2 Applied Force 37

4.2.2.2.3 Fastener Stiffness 37

4.2.2.2.4 Member Stiffness 37

4.2.2.2.5 Fasteners Factors 37

4.3 Volume Reduced Analysis 37

CHAPTER 5: Conclusion 41
References 42

3
 CHAPTER 1
INTRODUCTION

Helmets are items made from hard materials like Kevlar to protect all vital organs in the
head. Helmets are very important items in the field of security when riding a motorcycle. The
increase in the high-speed motorcycle industry, also triggered an increase in mortality due to
accidents in driving. Based on this phenomenon, C.F Lombard, a professor from the University of
South Carolina, made a breakthrough by designing a helmet as a safety device [1].

However, until now there are still many motorcycle riders who do not wear helmets while
driving and cause traffic accidents. Some reasons for not wearing a helmet when driving in
Indonesia are the close distance, and the design of a large and heavy helmet to carry [2]. Some of
these problems arise because of the inefficient helmet shape with a dense round shape but there is
a middle part of the helmet that still has a lot of space. A large helmet size can be anticipated by
making it foldable so that it can be easily carried everywhere and can be stored in a medium-sized
motorcycle luggage.

1.1 Objectives

Departing from these problems, our group decided to design a helmet for motorcycle
riders that could be folded up to 30% of its original volume and can be kept inside a medium-
sized motorcycle luggage, but did not eliminate the main function of the helmet as a head
protector when driving (satisfy SNI standard).

4
 CHAPTER 2
IDENTIFICATION OF NEEDS

There are minimum standards that must be achieved to make a helmet. The standard for
making this helmet is based on SNI or Indonesian National Standard. There are three aspects in
SNI that need to be achieved, that are minimum standards of strength and minimum standards of
safety on helmets as driving safety devices, as well as the standard size or dimensions of helmets
to be used by riders. The three standards are described in the following paragraph.

2.1 Specifications of Dimension

After doing several discussion, our group want to create a helmet with “bogo” type and
it is foldable. To create the helmet, there are several dimension requirements for a helmet
based on SNI standard that should be fulfilled, which are:
a. The height of the helmet at least 114 mm is measured from the top of the helmet to the
main plane, which is the horizontal plane through the ear hole and the lower part of the
eyeball holder.
b. The circumference of the inner circle of the helmet is XXS (510 mm - 520 mm), XS
(530 mm - 540 mm), S (550 mm - 560 mm), M (570 mm - 580 mm), L (590 mm - 600
mm), XL (610 mm - 620 mm), and XXL (620 mm - 640 mm).
c. There should be no outward protrusions that exceed 5 millimeters from the outer surface
of the shell and each bulge must be covered with soft material and there should be no
sharp edges.
d. Wide viewing angle of at least 105 degrees on each side and vertical viewing angle of
at least 30 degrees above and 45 degrees below the main plane.
The common size of helmet in society is in M size, so our group will create between M
size (570 mm - 580 mm) for our foldable helmet prototype, because our targets are teenagers
and adults. The other points of specifications will be realized to increase the comfort and
strength of the helmet.

5
2.2 Specifications of Safety

As one of the safety tools in riding a motorcycle, helmet is necessary to fulfill several
safety specifications. This specifications are specially made, so that the user’s head will be
totally safe when the helmet is used properly. The safety specifications of a helmet are listed
in the following:
1. The shell needs to be made from hard and strong material, has the same thickness and
homogen at any points.
2. The shell should not in one part with the face protector nor eye protector.
3. The shell should protect the ears and the nape of the user.
4. Collision reducer thickness should be at least 10mm from the shell.
5. The chin strap should have minimum width of 20mm and work properly.
The helmets will be made to satisfy the minimum standards of strength in order to
protect the head of a motorcycle rider when driving. The helmet consists of the outer shell
(hard and strong material), inner shell (foam) and the visor to protect the face. The material of
each part in helmets also homogen at any point (visor, outer shell, inner shell).

2.3 Specifications of Strength

There is one main requirement for a helmet to meet the SNI standard in term of the
strength, which is the capability of the product to absorb the impact and it can be tested through
impact test. This test is intended to examine the ability of the helmet to absorb impact. The
helmet will be placed in a place called a metal plate, then the helmet is dropped from a height
of 2.5 meters with a speed of 20.8 km / hour directly hit the iron surface below. Iron surface
can be flat, and tapered (like a triangle). This test is carried out several times on 4 sides of the
helmet, namely the forehead (crown), the back side, the right side of the helmet, and the left
side of the helmet. Furthermore, the value of the test results will be obtained which determines
whether the helmet has passed or not.

6
 Figure 2.3.1 Impact Test for Helmet

The protruding shape of the head on the iron surface combined with the accelerometer
aims to measure the strength of the G (G force peak) peak or acceleration measured in units
called "G" Gravitational units. Impact energy (height when dropped and mass of helmet), or
how hard the helmet is affected, and this will have different results for each standard.
However, for each correct test, if the effect of the 'G force Peak' on the helmet exceeds a
certain limit value (around 300 G or almost equal to 3000 N, depending on the standard and
type of test), the helmet does not pass the test. So, at the end the helmet will be tested in a
software to check whether the helmet can withstand loads of 3000 N.

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 CHAPTER 3
PRODUCT DESIGN

The designs needed to make helmets will be discussed in detail in this chapter. The reason
for using the final mechanism, the prototype of the design used, and the material used to make the
helmet. The calculation and deeper analysis ini strength and factor of safety will explained in the
next chapter. The final design used is based on the agreement of the members to achieve the desired
goal, that are the volume of the helmet can be greatly reduced and the strength and factor of safety
of the helmet. More detailed explanation of the final prototype is as follows.

3.1 Three Rough Sketch of Mechanisms

The ideas come from several sources on the internet and also our own thoughts. There
are three mechanisms that we think are possible to develop. Each mechanism has several
advantages and disadvantages. In this subchapter, the advantages and disadvantages of each
mechanism plan will be discussed in more detail.

3.1.1 Mechanism 1

Figure 3.1.1.1 Mechanism 1

Mechanism 1 is the first idea for our foldable helmet. In this mechanism, the shell
divided into three parts. The first part become the main part, and the other parts can be
8
 slided. Then after we did analysis, mechanism 1 has advantage and disadvantage. The
advantage is the helmet is quite strong because the shell and foam are one part (rigid).
In addition, the locking system is safer and stronger when impacted from behind or side,
because the affected part is the whole part not centered in one part. But the disadvantage
is the volume doesn't decrease much. The height is reduced but the length and the
thickness are slightly increased.

3.1.2 Mechanism 2

Figure 3.1.2.1 Mechanism 2

In the mechanism 2 the shell and the foam is divided part. The shell divided into
four parts. One of the parts become the main part, which is near the neck. To fold the
shell, there is one pivot in the right and left side. After we did analysis for mechanism
2, it has some advantages and disadvantages. The advantages are the volume is smaller
than the mechanism 1. In addition, the shell locking system is more simple and resistant
if it is impacted from behind or side. That is because the locking system is shifted from
bottom up at the locking center (1 point on the right and left side of the helmet). Even
though foam and shell are separate parts, both are easy to wear, but it needs more time
9
 than mechanism 1. The disadvantages of this mechanism are slightly weaker than
mechanism 1, because there is a gap or distance between the outer shell and inner shell.
Also, for the inner shell, the mechanism for folding foam is a little more difficult.

3.1.3 Mechanism 3

Figure 3.1.3.1 Mechanism 3

In mechanism 3 design, it has a simpler folding mechanism by push-pull

movement in vertical direction. Yet, it needs a sophisticated and advanced locking
system to make sure the helmet is strong enough to keep its shape while get impact.
Therefore, the strength of the overall component joint of the helmet is arguably weak.
Also, there is no significant volume reduced after the helmet is folded.

3.2 Synthesis to Decide One Sketch

Each mechanism has their own advantages and disadvantages. There are some
considerations to choose the most suitable mechanism. Some considerations are needed based
on the purpose of the design project that are the amount of volume reduced from the helmet,
and the strength of the helmet. The most reduced volume when the helmet has been folded is
on the second mechanism because the empty part can be filled with foam separately. while in
10
 the first and second mechanisms, the top of the shell is still solid so it is hard to fill the foam
in the empty part after folding.
The strength of the helmet after being solid (not folded) on mechanisms 2 is little bit
smaller than mechanism 1 and 3 because there is a small gap between the outer shell and the
inner shell. Mechanism 3 has the potential to be destroyed if it is affected by the top or in the
direction when folding the helmet (depending on the locking system on the helmet).
Mechanism 1 also has the potential to be destroyed if it is impacted on the back or in the
direction when folding the helmet if the locking system is not strong enough. While
mechanism 2 can absorb a large impact based on its round shape because the impact is evenly
distributed, and based on the location of the locking system on the helmet which is located on
the side. So that if affected by the back and side will not be affected by the locking system
because the locking on the helmet is shifted or perpendicular to the impact from the side of
the helmet.

3.3 Design Requirement

In the designing process, this group decided to focus on several vital part of the foldable
helmet to achieve minimum strength and safety standards based on SNI.. Considering the data
collection and the objectives of the project, the parts that need to be developed are:

1. The outer shell of the foldable helmet

2. The locking system on the pivot point (primary joint)

3. The locking system between two outer shell (secondary joint)

The improvement of the design is briefly described in the following script.

Table 3.3.1 Design Requirement

Outer Shell It should be able to be fold into three parts

Primary Joint The locking system in the pivot point should be able to make
the helmet in solid and folded condition easily.

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 Secondary Joint The locking system between the two outer shell should be able
to hold the outer helmet in solid shape.

The role of the locking system is important to withstand the big impact. So, the locking
system should be designed and analyzed carefully. The locking system on the helmet is made
into two important parts, that are in the helmet pivot and in the middle of the helmet (locking
between the two outer shell parts of the helmet) to increase the strength of the helmet so that
it can withstand greater impact if only using one locking system.

3.4 Prototype of the Design

In this part, our group decide to focus on the outer shell design. The outer shell is divided
into three big parts (upper shell, middle shell, and lower shell). Since the helmet is based on
an armadillo flipped design, therefore it requires a pivot to move the parts. There are two main
locking system which are located in the pivot and in some location in outer shell of the helmet.

Figure 3.4.1 Front view of the helmet.

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 Figure 3.4.2 Side view of the helmet

The outer shell is consists of three part (upper, middle and lower part) aiming for
more optimal helmet strength if only 3 parts are like in armadillo design. The originality
of the foldable helmet design is the locking system design that is located at the pivot
point and in the middle of the helmet (between the two outer shells). The three parts of
outer shell and the locking system is explained in detailed in the following sub-chapter.

3.4.1 Three Parts of Outer Shell

The outer shell is divided into three parts, the upper shell, the middle shell, and
the lower shell. The design of the outer shell is shown below.

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Figure 3.4.1.1 Upper Shell

Figure 3.4.1.2 Middle Shell

14
 Figure 3.4.1.3 Lower Shell

When the helmet is folded, the outermost part is the upper shell. So the helmet
volume is reduced, that is, the middle shell and lower shell part is entered into the helmet
volume on the upper shell. In this case, the volume can be found by calculating the upper
shell only to find out whether the foldable helmet can be inserted into the motorcycle
luggage or not.

3.4.2 Locking System on the Main Pivot / Primary Joint

The locking mechanism in the pivot is able to lock all motion of the main parts to
stand still either in helmet mode or in flipped mode. The mechanism is inspired by the
locking mechanism of car’s door but simpler, since it is used in small component in a
helmet. if the mechanism in car’s door is press-pull mechanism, in this lock for the pivot
is using switching motion to do locking.

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 Figure 3.4.2.1 Isometric view of the helmet.

In the above figure, the pivot is located in the below part that has a hole go through
all the way of all parts. The hole would shaped as a 20 x 20 mm square that will be fit
with a cube-key joint piece to lock the movement of the shells through the square hole.
The appearance of the primary joint without the shells would be as follow:

Figure 3.4.2.2 Front view of the joint pieces

Figure 3.4.2.2 Isometric view of the joint

pieces.

It is later will be described as 4 pieces to become one mechanism of primary joint

to keep the all 3 shells at its position and still allowing them to folded. They are defined
as outer handle, shaft, cube-key, and inner support pieces as follow:

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Figure 3.4.2.4 The outer handle, inner support, shaft, and cube-key as the primary
joint pieces.

3.4.2.1 Inner Support Joint Piece

The part is attached to the inner side of the lower outer shell by applying
thread mechanism. It provides a fix position for a foundation to all the other
pieces to be a pivot due to the lower shell.

Figure 3.4.2.1.1 The installed inner supporting part to the lower shell.

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 Figure 3.4.2.1.2 The detail dimension information of the inner supporting joint
piece.

3.4.2.2 Outer Handle Joint Piece

The handle is attached with the cube-key joint piece by thread

mechanism. It is used as the extension of the cube-key to ease the operator to
rotate the cube-key due to its pivot point.

Figure 3.4.2.2.1 The detail dimension information of the outer handle joint
piece.

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3.4.2.3 Cube-Key Joint Piece

The cube-shaped key is attached to the outer handle joint piece by

applying thread mechanism. It would fit with the 20 x 20 mm square hole on
the shells and locked it in a fix position while it still can be moved in a
longitudinal direction.

Figure 3.4.2.3.1 The installed cube-key part to the outer handle joint piece.

Figure 3.4.2.3.1 The detail dimension information of the cube-key joint piece.

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3.4.2.4 Shaft Joint Piece

It is attached with the inner supporting joint piece by thread mechanism.

It is used as the support and the path of the cube-key to move in longitudinal
direction (in & out or locked & unlocked mechanism).

Figure 3.4.2.4.1 The installed shaft part to the inner supporting joint piece.

Figure 3.4.2.4.2 The detail dimension information of the shaft joint piece.

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3.4.2.5 The Instalment and The Mechanism of The Joint Piece

With the inner supporting parts is bolted to the lower shell by its thread
mechanism, it becomes the the fix base foundation to make the pivot to the
locking mechanism. As the shaft is also bolted to the inner supporting part, the
pivot is now established. The mounted cube-key and the outer handle part is a
moving part that moves in a longitudinal direction of the shaft. The role of this
moving part to lock and unlock the square-shaped hole in the shells is illustrated
as the following:

(a) (b)
Figure 3.4.2.5.1 (a) The illustration of the initial unlocked position of the
locking mechanism, and (b) The illustration of the locked position of the
locking mechanism.

Figure 3.4.2.5.2 (a) The locking position, and (b) The unlocking position.

The folded helmet is able to reach reduction of volume approximately

until 25% from its initial full form. Based on the design drawing, the upper
shell can rotate until 60 degree and the middle shell can be rotated until 45
degree from its initial full form due to the reference point of the lower shell.

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 (a) (b)

Figure 3.4.2.14 (a) The folded form looked from an isometric view, and (b) The
folded form looked from side view.

3.4.3 Locking System between Two Outer Shell / Secondary Joint

The locking system on the outer shell is defined by the sets of bolt to lock the
motion of the 3 main part of the outer shell when it is assembled in a full form. the
mechanism is just a normal bolt mechanism using thread principle. The use of bolt is
due to the minor role of the secondary locking system to only keep the shape of the
helmet when in its full form.

(a) (b)
Figure 3.4.2.15 (a) Bolt installation front view, and (b) Bolt installation side view.

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 (a) (b)
Figure 3.4.2.16 (a) Bolt piece, and (b) The detail dimension information of the bolt
piece.

3.5 Material of the Helmet

A full helmet is consists of 5 different materials which is found in several parts of the
helmet. The material of the part in the helmet is homogen, made of materials commonly used
to make helmets and not made of metal. The material of the helmet is explained in detail in
the following paragraph.

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3.5.1 Inner Shell

Figure 3.5.1.1 Polystyrene (Styrofoam) [3]

The inner shell is consist of styrofoam and comfort padding. Inside the outer layer
are layers that are equally important for the impact of the buffer coating. Usually made
from Polystyrene (Styrofoam). This thick layer provides a cushion that functions to
withstand shocks when the helmet collides with hard objects while the head is still
moving. When there is a collision that bumps the head with a hard object, the hard outer
layer and the inner layer of the helmet spread pressure throughout the helmet material.
The helmet prevents collisions that can break the skull. It is the inside which consists of
soft material and cloth to place the head in a right and right in the helmet cavity. Sponge
material also used for the earmuffs and neck

3.5.2 Visor

A visor is a surface that protects the face (eyes, nose, mouth) from the bright light
or protecting the face from flying debris. Usually visor are transparent. There are two
primary materials that visors are made from, acrylic and polycarbonate. The acrylic and
polycarbonate visor has their own advantages and disadvantages.

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 Figure 3.5.2.1 Polycarbonate Visors [4]

The acrylic visor is cheap to replace, and it does pick up scratches very easily.
But, over time, acrylic visors can turn a slight yellowish shade or hazy. Polycarbonate
visor is more expensive than acrylic visor. Polycarbonate visors are harder to scratch
and better in terms of distortion than acrylic visors. So, based on several considerations,
our group choose polycarbonate as the visor material on helmet. This is because the
price is still affordable and have good quality than acrylic visor.

3.5.3 Outer Shell

Shell or the outer helmet is the most important component in the helmet. the
material used to make the shell must be strong against impact but not too heavy. There
are popular materials used for making the shell include fiberglass (composite fiber),
polycarbonate, and carbon fiber or kevlar. Each material has their own advantages and
disadvantages.
Shell that made of polycarbonate is require more foam padding to meet safety
standards because the polycarbonate is not the hardest material. the amount of foam will
affect the shape and weight of the helmet. But helmets made from polycarbonate are
cheap and easy to make [5].

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 Fiberglass shell is more expensive than polycarbonate shell because it is hard to
make. But, in the end, the shell is harder and more lightweight than polycarbonate shell.
It also has a high stiffness and a good impact flexibility which spreads the force across
a wider area of foam. The fiberglass shell will absorb more force before the foam layer
even comes to play. The fiberglass shell has excellent strength to weight ratio, compared
to other materials, suitable for complex designs. So fiberglass helmets do not require
much foam padding. It will gives lighter and smaller shapes of helmets but stronger
compare with polycarbonate shell [5].
Kevlar shell has the similar process like fiberglass but different fibre cloth. Kevlar
shell is strong and do not need to use many fibers to achieve the same result with the
fiberglass shell. Kevlar shell is 20% lighter than fiberglass shell. The kevlar shell is more
expensive than fiberglass shell but the size and the weight is much less than fiberglass
shell [5].
Based on several considerations, our group chose Glass Fiber Reinforced Polymer
(GFRP) as a shell material on the helmet. This is because the price is affordable,
excellent strength to weight ratio, and does not require much foam padding. The
thickness of the outer shell is 1 cm. The thick of the outer shell is believed to be able to
hold the minimum impact in accordance with SNI standards.

3.5.4 Primary Joint

The primary joint is located at the center which makes it easier for the helmet to
fold. based on several considerations such as the strength of the material, materials
commonly used to make helmets, and the safety factor if affected, the material used is
Glass Fiber Reinforced Polymer (GFRP).

This material is strong enough to withstand 3000 N of impact (based on SNI) and
has high yield strength. The safety factor of the primary joint is 7.51. This number of
safety factor will make this primary joint hard to break and it is very safe for the helmet
as the safety device when driving a motorcycle. The detail calculation of the strength
and the safety factor of primary joint is calculated in the Chapter 4: Technical Analysis.

26
3.5.5 Secondary Joint

The secondary joint is also important because this joint holds the outer shell in a
solid condition. If the joint is not strong enough, then the helmet will be easy to curl
when exposed to impact from the outside. To prevent secondary joints from being
destroyed during impact, the material used is Glass Fiber Reinforced Polymer (GFRP).
This material is strong enough to withstand 3000 N of impact (based on SNI standard).
The calculation of the strength and the safety factor is explained in detail in the next
chapter (technical analysis).

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 CHAPTER 4

TECHNICAL ANALYSIS

4.1 Helmet Shell Analysis

4.1.1 Assumption

The assumptions for calculating the design factor are:

1. The helmet is equally divided into three part;

2. The upper body of the helmet is a perfect semi-circular arc;

4.1.2 Helmet Shell Analysis

4.1.2.1 Diagrams

The size diagram of the helmet part is presented below:

Figure 4.1.2.1.1 Size diagram of a helmet part

The free body diagram (FBD) of the system is depicted below:

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 Figure 4.1.2.1.2 Free-body diagram of a helmet part

The shear force diagram (SFD) is presented below:

Figure 4.1.2.1.3 Shear-force diagram of a helmet part

The bending moment diagram (BMD) is presented below:

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 Figure 4.1.2.1.4 Bending-moment diagram of a helmet part

4.1.2.2 Calculation

4.1.2.2.1 Method 1

1
1 − 𝑢𝑛𝑐𝑒𝑟𝑡𝑎𝑖𝑛𝑡𝑦 𝑜𝑓 𝑙𝑜𝑠𝑠 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
𝑛𝑑 =
1
1 + 𝑢𝑛𝑐𝑒𝑟𝑡𝑎𝑖𝑛𝑡𝑦 𝑜𝑓 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟

1 + 𝑢𝑛𝑐𝑒𝑟𝑡𝑎𝑖𝑛𝑡𝑦 𝑜𝑓 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟

𝑛𝑑 =
1 − 𝑢𝑛𝑐𝑒𝑟𝑡𝑎𝑖𝑛𝑡𝑦 𝑜𝑓 𝑙𝑜𝑠𝑠 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟

20
1 + 100 1.2
𝑛𝑑 = = = 1.333
10 0.9
1 − 100

4.1.2.2.2 Method 2

Table 4.1.2.2.2.1 Design factor consideration

No Aspect Score

1 Accuracy of load knowledge 0

2 Accuracy of stress calculation -1

3 Accuracy of strength knowledge -1

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 4 Need to conserve -2

5 Seriousness of failure consequences +2

6 Quality of manufacture 0

7 Condition of operation 0

8 Quality of inspection/maintenance in -2
operation

Total -4

Design factor calculation

(10 + 𝑡𝑜𝑡𝑎𝑙 𝑠𝑐𝑜𝑟𝑒)2

𝑛𝑑 = 1 +
100

(10 − 4)2
𝑛𝑑 = 1 +
100

𝑛𝑑 = 1 + 0.36

𝑛𝑑 = 1.36

4.1.2.3 Mean Load

𝑃 = 300𝐺 = 3000𝑁

𝑃𝐿 (3000)(0.115)
𝑀= = = 172.5𝑁𝑚
2 2

𝐴 = (0.01)(0.0763) = 763𝑥10−6 𝑚2

𝑃 3000
𝜎0 = = = 3.93 𝑀𝑃𝑎
𝐴 763𝑥10−6

1 3 (0.0763)(0.01)3
𝐼= 𝑏ℎ = = 63.58𝑥10−10
12 12

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 𝑀𝑐 (172.5)(0.005)
𝜎𝑚 = = = 135.3 𝑀𝑃𝑎
𝐼 63.58𝑥10−10

Maximum tensile stress:

𝜎𝑡𝑒𝑛𝑠𝑖𝑙𝑒,𝑚𝑎𝑥 = 𝜎0 + 𝜎𝑚 = 3.93 + 135.3 = 139.23 𝑀𝑃𝑎

Maximum compression stress:

𝜎𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛,𝑚𝑎𝑥 = 𝜎𝑚 − 𝜎0 = 135.3 − 3.93 = 131.37 𝑀𝑃𝑎

4.1.2.4 Maximum Stress Analysis

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑡𝑟𝑒𝑠𝑠
𝑛𝑑 =
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑆𝑡𝑟𝑒𝑠𝑠

𝜎𝑚𝑎𝑥 = 𝑛𝑑 ∙ 𝜎𝑎𝑙𝑙𝑜𝑤 = (1.33)(139.23) = 185.179𝑀𝑃𝑎

Maximum load:

𝜎𝑡𝑒𝑛𝑠𝑖𝑙𝑒,𝑚𝑎𝑥 185.179 × 106

𝑃= = = 3990𝑁
𝐿𝑐 1 (0.23)(0.005) 1
+ +
4𝐼 𝐴 1(63.58 × 10−10 ) 763 × 10−6

4.1.2.5 Safety Factor

Load that cause the failure calculation is shown below, with

material ultimate tensile strength of 194 MPa:

𝜎𝑡𝑒𝑛𝑠𝑖𝑙𝑒,𝑚𝑎𝑥 194 × 106

𝑃= = = 4169𝑁
𝐿𝑐 1 (0.23)(0.005) 1
4𝐼 + 𝐴 +
1(63.58 × 10−10 ) 763 × 10−6

The safety factor of the helmet shell are:

𝐿𝑜𝑎𝑑𝑚𝑎𝑥𝑖𝑚𝑢𝑚 4100
𝑛𝑠 = = = 1.37 𝑓𝑜𝑟 3000 𝑁
𝐿𝑜𝑎𝑑𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 3000

𝐿𝑜𝑎𝑑𝑚𝑎𝑥𝑖𝑚𝑢𝑚 4100
𝑛𝑠 = = = 1.05 𝑓𝑜𝑟 3990 𝑁
𝐿𝑜𝑎𝑑𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 3990

32
 The safety factor of this helmet is very small. This part should
have more design improvement so that the failure can be prevented
fairly.

4.1.2.6 Load Range

According to the standard of SNI helmet, the minimum load

should be 3000N. Besides, from the calculation, it is known that the
maximum load is 3990N. Although the helmet can withstand load
until 4100N, this group limits the maximum load at 3990N to give
space between the maximum load and failure-causing load so the
helmet will not immediately break after the load exceed the
maximum. Therefore, the load range is lies between 3000N-3990N.

4.2 Static Force Analysis in Critical Location

4.2.1 Primary Pin Joint

4.2.1.1 Diagrams

The size diagram of primary pin joint is presented below:

Figure 4.2.1.1.1 Size diagram of primary pin joint

33
The free body diagram (FBD) of the primary pin joint is presented below:

Figure 4.2.1.1.2 FBD of primary pin joint

The shear force diagram (SFD) of the primary pin joint is presented below:

Figure 4.2.1.1.3 SFD of primary pin joint

The bending moment diagram (BMD) of the primary pin joint is presented
below:

34
 Figure 4.2.1.1.4 BMD of primary pin joint

4.2.1.2 Calculations

𝑃 = 1995𝑁

𝑃𝐿 (1995)(0.038)
𝑀= = = 9.47625𝑁𝑚
8 8

𝑏ℎ3 𝜋𝑅 4 (0.02)4 𝜋(0.006)4

𝐼= − = − = 1.228 × 10−8
12 4 12 4

𝑀𝑐 (9.47625)(0.01)
𝜎= = = 7.7168𝑀𝑃𝑎
𝐼 1.228 × 10−8

4.2.1.3 Safety Factor

The safety factor of the primary pin joint is in accordance to the material
properties of Glass Fiber Reinforced Polymer with yield strength of 58.1MPa.
Therefore, the safety factor of the pin joint will be:

𝜎𝑚𝑎𝑥 58.1
𝑛𝑠 = = = 7.51
𝜎𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 7.7168

35
4.2.2 Secondary Fasteners Joint

4.2.2.1 Fastener Specifications

The helmet parts fasteners specification are listed below:

● Fastener type: M10x1.5 Single Thread

● The material is Glass Fiber Reinforced Polymer (Yield Strength of 58.1
MPa and Ultimate Tensile Strength of 194 MPa)

4.2.2.2 Calculation

4.2.2.2.1 Known Parameters

The given parameter are:

𝑑 10
𝑙 =ℎ+ =5+ = 10𝑚𝑚
2 2

𝐻 = 8.4𝑚𝑚

𝑤 = 16𝑚𝑚

𝑝 = 1.5𝑚𝑚

𝑑𝑚 = 10𝑚𝑚

𝐴𝑡 = 58.0𝑚𝑚2

𝑆𝑝 = 194𝑀𝑃𝑎

𝐿 = ℎ + 1.5𝑑 = 5 + 15 = 20𝑚𝑚

𝑙𝑑 = 6𝑚𝑚

𝑙𝑡 = 4𝑚𝑚

10 2
𝐴𝑑 = 𝜋 ( ) = 78.5398𝑚𝑚2
2

36
4.2.2.2.2 Applied Force

𝐹𝑖 = 0.75𝐹𝑝 = 0.75𝐴𝑡 𝑆𝑝 = 0.75(58𝑥10−6 )(194𝑥106 )

𝐹𝑖 = 8439𝑁

4.2.2.2.3 Fastener Stiffness

𝐴𝑑 𝐴𝑡 𝐸
𝐾𝑏 =
𝐴𝑑 𝑙𝑡 + 𝐴𝑡 𝑙𝑑
(78.5398𝑥10−6 )(58𝑥10−6 )(13.9𝑥109 )
=
(78.5398𝑥10−6 )(4𝑥10−3 ) + (58𝑥10−6 )(6𝑥10−3 )
63.319
= 𝑥109
662.15

𝐾𝑏 = 95.63𝑥106

4.2.2.2.4 Member Stiffness

0.5774𝜋𝐸𝑑 0.5774𝜋(13.9𝑥109 )(0.01)

𝐾𝑚 = =
0.5774𝑙 + 0.5𝑑 0.5774(0.01) + 0.5(0.01)
2 𝑙𝑛 (5 ) 2 𝑙𝑛 (5 )
05774𝑙 + 2.5𝑑 05774(0.01) + 2.5(0.01)
504.48𝑥106
=
𝑙𝑛(1.7505)

𝐾𝑚 = 901.01𝑥106

4.2.2.2.5 Constanta and Unloading Load

𝐾𝑏 95.63
𝐶= = = 0.095952
𝐾𝑚 + 𝐾𝑏 901.01 + 95.63

𝑃 = 1995𝑁, half of maximum load since there are two fasteners in a

helmet part

4.2.2.2.6 Fasteners Factors

Proof strength factor:

𝑆𝑝 𝐴𝑡 (194𝑥106 )(58𝑥10−6 ) 11252

𝑛𝑝 = = = = 1.3
𝐶𝑃 + 𝐹𝑖 (0.095952)(1995) + 8439 8630.42
37
 Load factor:

𝑆𝑝 𝐴𝑡 − 𝐹𝑖 (194𝑥106 )(58𝑥10−6 ) − 8439 2813

𝑛𝑙 = = = = 14.6
𝐶𝑃 (0.095952)(1995) 191.42

Joint separation load factor:

𝐹 8439 8439
𝑖
𝑛0 =𝑃(1−𝐶) = 1995(1−0.095952) = 1803.57 = 4.6

4.3 Volume Reduced Analysis

The foldable helmets have benefits, that is the helmet volume can be reduced so that the
shape becomes smaller. To analyze the reduced volume of the original helmet into a folded
helmet, we need the original dimensions of the helmet and the dimensions of the helmet when
folded.

Figure 4.3.1 Side view of the helmet

38
 Figure 4.3.2 Side view of folded helmet

The the reduced volume from the solid helmet to the folded helmet can be roughly seen
in Figures 4.3.1 and 4.3.2. Based on the Figures above, the volume of the solid helmet can be
assumed as ¾ volumes of ball. While, the folded helmet can be assumed as ¼ volumes of
ball. The radius of the helmet is 115 mm. The calculation of the reduced volume of the helmet
is calculated below.

Volume of solid helmet (¾ volume of a ball):

𝑉 = (4/3 𝜋 𝑟 3 ) 3/4

𝑉 = 4/3 𝜋 (115)3 3/4

𝑉 = 4777969,727 𝑚𝑚3

Volume of folded helmet (¼ volume of a ball):

𝑉 = (4/3 𝜋 𝑟 3 ) 1/4

𝑉 = (4/3 𝜋 (115)3 ) 1/4

𝑉 = 1592656,5756 𝑚𝑚3

𝑉 = 1592,6566 𝑐𝑐

The total reduced volume:

𝑉𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑠𝑜𝑙𝑖𝑑 − 𝑉𝑓𝑜𝑙𝑑𝑒𝑑

39
 𝑉𝑡𝑜𝑡𝑎𝑙 = 4777969,727 𝑚𝑚3 − 1592656,5756 𝑚𝑚3

𝑉𝑡𝑜𝑡𝑎𝑙 = 3185313,1513 𝑚𝑚3

𝑉𝑡𝑜𝑡𝑎𝑙 = 3185,3131 𝑐𝑐

Percentage of reduced volume:

𝑉𝑓𝑜𝑙𝑑𝑒𝑑
% 𝑅𝑒𝑑𝑢𝑐𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑥 100%
𝑉𝑠𝑜𝑙𝑖𝑑

1592656,5756
% 𝑅𝑒𝑑𝑢𝑐𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑥 100%
4777969,727

% 𝑅𝑒𝑑𝑢𝑐𝑒𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 33.33%

From the calculation above, the percentage of the reduced volume is 33.33%. This
number of reduction can provide benefits, one of which is that it can be inserted into a
medium-sized motorcycle luggage.

40
 CHAPTER 5

CONCLUSION

Helmets are the important items for safety riding. It used for protecting the vital organ in
the head. Indonesia have the standard for producing standard, or called as Indonesian National
Standard. There are three aspects need to be achieved, which are the dimension, the strength, and
the safety of the helmet.

In the beginning, there are three design plans for this foldable helmet. Finally, after did a
synthesis, it comes up with one main design. This design was divided into three major parts, which
are the outer shell, the inner shell (or foam), and the visor. This report was more focused on the
outer shell. This outer shell was divided into three parts and supported with two different joint
(primary and secondary joint).

There are three calculations explained in this report, which are for the shell, the primary
joints, and the secondary joints. All of the calculations were under the static load. By considering
several aspects, the design factor for this helmet is 1.33. The shell of the helmet has maximum
stress of 185.179 MPa with safety factor 1.05. The primary joints of the helmet have maximum
stress of 7.7168 MPa with safety factor 7.51. The last is the secondary joints of the helmet have
1.3 for proof strength factor, 14.6 for load factor, and 4.6 for joint separation load factor.

There are several benefits and limitation for this foldable helmet. The benefits are: this
foldable helmet can withstand up to 3990 N, which is more than SNI standard; this helmet also
can be folded up to 30% and can be stored on medium-size of motorcycle luggage, which fulfill
the initial goal of this project. The weakness is it needs more time to construct the foldable helmet
become the full helmet because the helmets has several secondary joints.

41
 References

[1] “Sejarah Lahirnya Helm, Dipacu Tingginya Angka Kematian Saat Bekendara,” kumparan,
14-Mar-2019. [Online]. Available: https://kumparan.com/@kumparanoto/sejarah-lahirnya-
helm-dipacu-tingginya-angka-kematian-saat-bekendara. [Accessed: 18-May-2019].

[2] “Reasons Not To Wear a Motorcycle Helmet,” Bikers Of America, Know Your Rights!
[Online]. Available: https://bikersofamerica.blogspot.com/2010/06/reasons-not-to-wear-
motorcycle-helmet.html. [Accessed: 18-May-2019].

[3] “Expanded Polystyrene Sheet ( Eps ),” indiamart.com. [Online]. Available:

https://www.indiamart.com/proddetail/expanded-polystyrene-sheet-eps-4642204862.html.
[Accessed: 18-May-2019].

[4] “Helmet visor Material: polycarbonate Surface treatment: hardening and fog proof,” Global
Sources. [Online]. Available: https://www.globalsources.com/si/AS/Foshan-
Liangyu/6008835721385/pdtl/Helmet-visor-Material/1057933289.htm. [Accessed: 18-
May-2019].

[5] “FortNine,” English, 17-Jan-2017. [Online]. Available: https://fortnine.ca/en/materials-used-

in-motorcycle-helmets/. [Accessed: 18-May-2019].

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