This paper reports the design and construction of a prototype cycle frame intended for sprint racing. Initially, the bicycle was conceived as a 'one off'. Moreover, the work was undertaken in the context of an undergraduate student project, so that very little funding was available for tooling. It was decided, therefore, to manufacture the frame by hand lay up a foame core. This is necessarily a laborious process requiring hand finishing, but is a low risk route, allowing continual monitoring of quality. Wet lay up (dry fabric and liquid resin) was used, and vaccum bag processing gave good laminate consolidation. Aluminium bottom bracket shell and rear drop-outs, and carbon fibre tubes for the head tube and seat tube, were bonded to the foam core and integrally laminated in the frame. The finish frame was subjected to a series of static tests to verify its stiffness. These included vertical compliance, seat tube bending and overall torsional stiffness. The results were 'benchmarked' against two commercial frames and found to be of satisfactory performance. A detailed finite element model was under development at the time of writing this paper. A complete bicycle was assembled and raced by a member of the National Team of Greece in the 1994 World Championships. The rider succeeded in setting a new national record in the sprint event. Since then a number of bikes made for riders of national teams of Greece, Italy, Russia, Estonia and Latvia.


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    Title :

    Design and prototype manufacture of a composite bicycle frame


    Additional title:

    Entwicklung und Herstellung eines Fahrradrahmenprototyps aus Verbundwerkstoffen


    Contributors:
    Katsanis, D. (author) / Grove, S.M. (author)


    Publication date :

    1996


    Size :

    5 Seiten, 4 Bilder, 13 Quellen



    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




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