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Composite Cross-Country Bike Frame Design and Development under Static and Dynamic Loads

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The finite element analysis of a cross-country bicycle frame is performed using a shellbased structure under several different types of loads. The simulation considers the implementation of orthotropic materials known as carbon-fibers in two different patterns. Thefirst is the unidirectional (UD) and the second is the 2 x 2 twill weave, which are combined in different laminate configurations to generate the ten individual components of the frame. Other constituents of the complete bicycle are taken into account in the simulation, but their individual analysis is not described. A primary stackup configuration for the shell model is chosen with five layers of the 2 x 2 twill weave ply and, under different load conditions, the IRF (inverse relation to the failure envelope), displacements, natural frequencies, modes and other characteristics are extracted. A total of eight cases are assumed considering International Standards procedures, field scenarios and possible misuse. Two of them are dynamic analysis carry out using time-integration during impacts tests. The other two contemplate failure due to fatigue tests, while the remaining ones are associated with climbing circumstances, possible side loads at the saddle and, finally, forces perpendicular to regions of the frame. Assumptions and simplification are described for a proper interpretation of the outcome. The study shows the results in the most critical areas of the structure which will need to be mechanically enhanced. At these regions, the definition of new layups based on the stresses and IRF are computed. A total of eleven configurations of laminate are created to cover the thirty-three surfaces of the frame and minimize the stress conditions. The optimized geometry and the related results are presented showing a decrement of the mechanical stresses/IRF at almost all the components. The IRF does not surpass 0.5 in all of them except at the head tube. This element presented IRF between 0.5 and 0.9 at three different loads, but some consideration about the boundary conditions and initial assumptions are given demonstrating that they worsen the stresses at those regions; therefore, from the project standpoint, this final design could be manufactured and tested to visualize the possible failure modes and chances of improvements.

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