This research concerns the design, analysis and manufacturing method used in the making of a lightweight composite bicycle fork. This type of fork would be used on high end racing bicycles, where stiffness, strength and light weight are all critical design parameters. The design of a composite must be a combination of stiffness, strength, light weight, functionality and aesthetics. In the world of high end bicycles, all of the above parameters are essential. The functionality and aesthetics are achieved through the use of CAD software tools. Based on the geometry and suitable stiffness and strength must be achieved through the use of carbon fiber materials. However, metallic inserts are used as interfaces to the rest of the bicycle structure and are desirable for safety reasons. Both woven and unidirectional carbon fiber are used in the design and titanium is used at the extremities. The choice of titanium is logical in this application since it is a lightweight metal that is compatible with carbon fiber. The next step is to analyze the proposed structure using finite element analysis techniques. Finally, the fork is manufactured and tested. Development of a Resin Transfer Molding (RTM) technique is demonstrated and proven to be successful in this application. Difficulties in perfecting the manufacturing technique require some back-and-forth iterations between the theoretical design and a design that can be manufactured. Early prototypes are tested in the laboratory in order to compare fork stiffness and strength with theoretical predictions. Thus the three main aspects involved in the design of a complex composite structure are presented- design, analysis and manufacturing. Each plays an important role in the success of the final structure.
Design of a lightweight composite bicycle fork
Entwurf einer leichten Fahrradgabel aus Verbundwerkstoff
2001
8 Seiten, 9 Bilder, 1 Tabelle, 4 Quellen
Aufsatz (Konferenz)
Englisch