Design of a Racing Bike Frame

01.- Objetives & Description

Design a racing bike frame for amateur cyclists who run in amateur races. According to the road competiton regulations. According to the European safety regulations. Keeping the frame as ligth as possible. Reducing the cost.

02.- Design Process

A) Wireframe geometry. B) Material & Manufacturing process. C) Tubes dimensions.

03.- Wireframe Geometry

Body measurements Standard components UCI regulations

FRAME GEOMETRY

Bike use

Commercial bikes compartive

Biomechanical recomendations

03.- Wireframe Geometry

Body measurements: European average male anthropometric data. Bike use: Competition, recreational,... Biomechanical recomendations: Pedaling power and efficiency, aerodynamic position, avoid injuries. UCI regulations: Competition limitations. Standard components assembly: Avoid clashes. Commercial bikes comparative: Average frame dimensions.

03.- Wireframe Geometry

Final Geometry

04.- Material & Manufacturing

Materials used: Steel, Aluminium, Titanium, Magnesium, Carbon fiber, Wood, Bamboo... Weight and cost:

04.- Material & Manufacturing

Aluminum alloys:
6061-T6: USA manufacturers, good for extrusion, weldable, artificial aging. 7005-T53: EU manufacturers, weldable, slightly better mechanical properties, natural aging.

Manufacturing processes:
Tubes: Extrusion, butting, bending, cold forming, hydroforming, mittering. Welding: TIG. Corrosion preotection: Paint.

05.- Tubes Dimensioning

European Safety Norm

Standard Components Fitting

TUBES GEOMETRY

UCI Regulations

Commercial Tubes

05.- Tubes Dimensioning

Standard components fitting: Bottom bracket, Head tube, Seat tube. Commercial tubes: Extruded, triple butted, formed tubes (best weight to cost ratio; hydroformed tubes are more expensive). UCI regulations: Limitations over tubes maximum and minimum diameters, and bike weight.

05.- Tubes Dimensioning

European Norm:
EN 14781: Racing bicycles - Safety requirements and test methods. 2 Impact tests. 2 Fatigue tests. FEM analisys for the tests using ANSYS. Iterative process for optimization. Beam model: Tubes shape and thickness. Solid model: Joints and fittings checking.

05.- Tubes Dimensioning

Impact tests:
Dynamic solver: High computational cost. Static non-linear solver: Energy method.

Faliure criteria:
No visible cracks: Max. V.M. stress < Ult. Strength. Maximum plastic deformation: Between wheel axis < 15mm.

05.- Tubes Dimensioning

Impact tests:

05.- Tubes Dimensioning

Fatigue tests:
Static linear analisys. ANSYS Fatigue Tool: 100.000 cycles.

Faliure criteria:
Material fatigue strength: Whler curve. Failure criteria: Modified Goodman.

05.- Tubes Dimensioning

Fatigue tests:

05.- Tubes Dimensioning

Fatigue tests: