Integrated Handlebar Clamp Plastic Triple Tree/Yoke Design,

Analysis and Development

for Motorcycle
Anish Kumar
LARPM-CIPET
Abstract: This paper presents the design and substitution of metal part of automobile with plastic part. Plastic components in automotive has become popular
over the last decades. Plastic components are used for body interior as well as exterior. The most important advantage of plastics part is its lower weight, more
anish83007@yahoo.com
economical design and low manufacturing cost. In this project, a new model of motorcycle triple tree made of plastic material has been designed and developed.
A triple tree/yoke attaches the fork tubes to the frame via steering head bearings, which allow the fork assembly to pivot from side to side, and therefore steer the
motorcycle. Most bikes have upper and lower triple trees, providing two solid clamping points that keeps the fork tubes parallel, while also connecting the forks to
the frame via the steering head bearings. Triple clamp converts the steering force applied by rider on handlebar into steering torque which steers the front wheel
of motorcycle. The currently used triple tree of general purpose motorcycle is made of metal and its alloys having four or more assembling components. In this
improved design introduced here, assembling components are integrated to achieve better mechanical reliability and performance of new model. Motorcycle
handling and stability have also been analysed during design of the model. The dimensions of model have been optimized to achieve maximum allowable stress.
The steering torque and steering force have been analysed, simulations and experimental tests are carried out in order to validate the performance of new model.
The durability and performance of new designed model is parallel to the metal and alloys triple tree currently used in motorcycles. The present redesigned model
of plastic triple tree is as reliable as metal triple tree.

INTRODUCTION PROBLEMS DEFINITION

A triple tree/yoke attaches the fork tubes to the Figure(1) shows a schematic representation of triple tree
frame via steering head bearings, which allow model. This design features two vertical clamps for mounting
the fork assembly to pivot from side to side, handlebar on the top of triple tree.
and therefore steer the motorcycle. This design is then attempts to redesign the integrated
Most bikes have upper and lower triple trees, handlebar clamps triple tree. In an attempts to integrate these
providing two solid clamping point that keeps clamps, these are fixed with the base plate of the triple tree.
the fork tubes parallel, while also connecting This is shown in figure (2).
the forks to the frame via the steering head In order to avoid the twisting of clamps and achieving
bearings. maximum steering torque in front forks during application of
With the tendency to employ fork tubes with force on handlebar, the two ribs of height 25 mm and
single action damping, fork triple trees need to thickness 3 mm are provided. These ribs also provide strength
be reinforced more than when the forks shared to the base plate when rider apply load on handlebar. This
both damping roles, because the rigidity of the design is depicted in figure (3).
triple trees are relied upon to distribute the The focus of preliminary design is to determine steering
forces within the forks without flex. torque, load limit, stresses developed and other physical
The existing triple tree used in most motorcycle characteristics for an optimum triple tree design, which best
is made of metal and its alloy having four and maximize scores for competition.
more connecting components. The complexity of the operating variable can be simplified by
The newMODELS
designedFORmodel of plastic
TRIPLE TREE triple tree taking(1) appropriate assumption.
(2) This help (3)
to develop a
has integrated assembly components which
Steering torque preliminary design.
have only one connecting component for RESULTS
Stress Analysis
attaching handlebar.

Dynamic load on front wheel (Nf), Normal Trail (tn)

Stress in Handlebar Connectors

Von Mises stress on application Von Mises stress on
of steering torque application
of force
Deformation Analysis

Design parameters
Loads on Baseplate Component Symbol Quantity Unit

Length (l) 58 mm

Width (b) 25 mm
Total deformation on application Total deformation on
Height (h) 35 mm
Handlebar
connector of load application
w
Shear stress at A (A) 3.575 MPa

Shear stress at B (B) 9.431 MPa CONCLUSION of steering

Torque (T) 112 N-m In this project, the triple clamp has beentorque
redesigned to provide better
Overall length 220 mm mechanical reliability and performance. This has been achieved by
Baseplate Overall Width 92.5 mm replacing the connecting components with integral connectors. The
Offset (O )f 42.5 mm dimensions of the triple tree have optimized to provide maximum
Wheelbase (W) 1255 mm allowable stress. Different types of load acting on the triple clamp
Front wheel radius (R )f 431.8 mm through handlebar and fork has analysed and stresses are calculated,
Caster angle () 26.5 degree the maximum shear stress in handlebar clamp is 9.5 MPa at a torque
Others
Steering angle () 20 degree of 112 N-m. The forces and torque have been analysed and compared
Spring deflection (x) 120 mm with metal part. The design is validated in a digital simulation and
Front centre of mass (w) 70 kg mathematical analysis. The durability and performance of new design
is parallel to the metal and alloys triple clamps currently used in
7. V. Cossalter, R. Lot, M. Massaro and M. Peretto, Motorcycle Steering Torque Decomposition, Proceedings of the World Congress on
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