FEA ProjEct

MAE 533 : Finite Element Analysis -I
Contents
Finite Element Analysis of Bicycle Frame

1. INTRODUCTION: .............................................................................................................. 2
2. ANALYSIS: ........................................................................................................................ 3
2.1 Assumptions: .......................................................................................................................... 3
2.2 Analysis of an Aluminum frame (Conventional Frame): .......................................................... 3
2.3 Analysis of a Steel frame (Conventional Frame): ..................................................................... 6
2.4 Analysis of a Aluminum frame (Alternate Frame): .................................................................. 9
3. RESULTS AND DISCUSSION: ............................................................................................ 13
3.1 Comparison of the Steel frame with the Aluminum frame under similar loading conditions: 13
4. Conclusions: .................................................................................................................. 14
1.
INTRODUCTION:
A Bi-cycle frame is prominent part in a bicycle which is subjected to static and dynamic loads.
The dependency of the performance is directly proportionate to the weight of the cycle and frame

structural design. Optimization of weight and structure of the frame is the best scope of
optimizing the overall performance of the cycle.
Historically trial-and-error have played major roles in the evolution of today's diamond-shaped
steel frames. The design and manufacture of bicycle frames has largely been an art, performed
by skilled craftsmen and their efforts have resulted in reliable, efficient structures.
However, the limitations of trial-and-error become most apparent when new materials enter the
picture, and when new applications and demands are placed on the structure. Now that bicycle
frame builders are using materials such as aluminum, magnesium, titanium, and fiber
composites, a need exists to help the designer exploit the desirable properties of these materials.
Trial and error is costly and slow, and intuition does not always yield reliable results. A
promising solution is to turn to a proven tool of structural engineering: the finite-element
analysis (FEA) method.
The essence of FEA is to break a large stress analysis problem into many smaller ones, which are
then collectively solved by computer. Finite-element analysis is usually used to fine-tune the
geometry of a design that is still on the drawing board, before working models are built and
tested. FEA is also used to debug an existing prototype. The first approach is more cost-effective
and can open the door to more creative solutions at an early stage in the design process.
In our work, we compare the performance of a bicycle frame made of Aluminum with that made
of steel and then a comparison between two commercially available bicycle frames is also made
FEA Model Used: We have considered beam elements to analyze the system. We have
ignored the welding effects to simplify our analysis. Considering the welding will strengthen the
system. Hence, the model considered by us will give us conservative values.
2.
ANALYSIS:
Correct loading information is absolutely vital in producing reliable results. We use three load
cases to compare the overall safety and performance characteristics of various bike frames. For
every load case we refined the mesh by increasing the number of elements until we got
convergence in the maximum stress values. .
Assumptions:
We have assumed the bicycle components to be equivalent to beam element.
We have ignored the effects of welding.
We have assumed that all the loading is transferred to the points where wheels are
attached to the bicycle frame.
We have considered static equivalent of impact loads .
All loads acting on the bicycle frame are considered as point loads.
Analysis of an Aluminum frame (Conventional Frame):

(a) Static Start-Up:

A 100 kg rider is applying maximum effort to accelerate from a standing stop. The rider is "out
of the saddle" and inertial effects are significant. Aerodynamic, rolling, and gyroscopic forces
are assumed negligible. The bike is in vertical equilibrium with the front wheel pointed straight.
The finite element results are given below:
Figure 1:
(a) Stress distribution in Al frame
under static loading
(b)Convergence of stress upon
refining the mesh size
14
Maximum/stress/ (MPa)
12
10
8
6
4
2
0
0
10
20
30
40
50
60
No./of/divisions/per/line
Maximum/nodal/ displacement/ (mm)
Figure 2:
(a) Deflection distribution in Al
frame under static loading
(b)Convergence of nodal deflection
upon refining the mesh size
0.3
0.25
0.2
0.15
0.1
0.05
0
0
10
20
30
40
50
60
(b) Horizontal Impact:

Samples of every manufacturer's frame design must pass certain physical tests to comply with
standards set in 1976 by the Bureau of National Affairs (BNA) and the Consumer Product Safety
Commission. The BNA's "Requirements for Bicycles" manual calls for a single compressive

loading test. A load of 1000 N is applied to the front dropouts horizontally, with the rear
dropouts constrained from any translational motion. The effect might be similar to a low speed,
head-on collision into a wall or curb. To pass the test, there must be no visible evidence of
fracture or frame deformation that significantly limits the steering angle over which the wheel
can be turned. The finite element results are given below:
Figure 3:
(a)Stress distribution in Al frame under
horizontal impact
(b)Convergence of stress upon refining the
mesh size
200
Maximum0stress0 (MPa)
180
160
140
120
100
80
60
40
20
0
0
10
20
30
40
50
60
70
80
No.0of0divisions0per0line0
Maximum0nodal0 displacement0 (mm)
Figure 4:
(a) Deflection distribution in Al frame under
horizontal impact
(b)Convergence of nodal deflection upon
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
No0of0divisions0per0line
(c) Vertical Impact:

Vertical impact loads are represented by multiplying the rider's weight by a certain "G factor".
An object dropped from an infinitesimal height onto a rigid surface would exert a 2G impact

load, assuming total energy transfer. The finite element results are given below:
Figure 5:
(a)Stress distribution in Al frame under
vertical impact
(b)Convergence of stress upon refining the
mesh size
Maximum.stress.(MPa)
25
20
15
10
5
0
0
10
20
30
40
50
60
No..of.divisions.per.line
Figure 6:
(a) Deflection distribution in Al frame
under vertical impact
Maximum0nodal0 deflection0 (mm)
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
0
10
20
30
40
No.0of0divisions0per0line
Analysis of a Steel frame (Conventional Frame):

All the load cases considered for the aluminum frame were repeated for the steel frame.
50
60

(a) Static Start-up:
Figure 7:
(a) Stress distribution in Steel frame under
static loading
(b)Convergence of stress upon refining
the mesh size
14
Maximum/stress/ (MPa)
12
10
8
6
4
2
0
0
10
20
30
40
50
60
Figure 8:
(a) Deflection distribution in Steel frame
Maximum/nodal/ deflection/ (mm)
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
0
10
20
30
40
50
60
Figure 9:
(a)Stress distribution in Steel frame
under horizontal impact
the mesh size
200
180
160
140
120
100
80
60
40
20
0
0
10
20
30
40
50
60
70
Figure 10:
(a) Deflection distribution in Steel
frame under horizontal impact
8
7
6
5
4
3
2
1
0
0
10
20
30
40
50
60
70
Figure 11:
(a)Stress distribution in Steel frame
the mesh size
Maximum.stress. (MPa)
30
25
20
15
10
5
0
0
10
20
30
40
50
60
No..of.divisions
Figure 12:
(a) Deflection distribution in Steel
frame under vertical impact
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
10
20
30
40
Analysis of a Aluminum frame (Alternate Frame):
50
60
Fig 13:Picture of the alternate bicycle frame considered for the analysis.
Fig 13 shows a different kind of bicycle frame available in the market. This kind of frame has a
monocogue design which facilitates manufacturing using modern manufacturing techniques such
as 3D- Printing. In this project we have tried to analyze this frame under same loading conditions
considered for the conventional bicycle frame and compared the performance of the two frames.
Figure 14:
(a) Stress distribution in Frame-2
(b)Convergence of stress upon
65
(a)Static Start-up:
64
63
62
61
60
59
0
10
20
30
40
50
60
70

Figure 15:
(a) Deflection distribution in Frame-2
5.262
5.26
5.258
5.256
5.254
5.252
5.25
5.248
5.246
5.244
0
10
20
30
40
50
60
70

Figure 16:
(a)Stress distribution in Frame-2 under
horizontal impact
the mesh size
200
198
196
194
192
190
188
186
184
0
10
20
30
40
50
60
70
80

Figure 17:
under horizontal impact
23.05
23.04
23.03
23.02
23.01
23
22.99
22.98
0
10
20
30
40
50
60
70
80

Figure 18:
(a)Stress distribution in Frame-2 under
vertical impact
the mesh size
132
130
128
126
124
122
120
118
0
10
20
30
40
50
60
70
80

Figure 19:
10.535
10.53
10.525
10.52
10.515
10.51
10.505
10.5
10.495
0
10
20
30
40
50
60
70
80
3.
RESULTS AND DISCUSSION:
Comparison of the Steel frame with the Aluminum frame under similar
loading conditions:
245
Static loading
Horizontal impact
Vertical impact
Max.
Max.
Max.
Max.
Max.
Max.
stress
stress
deflection
deflection stress deflection
(Mpa)
(MPa)
11.6754 0.247757 189.015 21.062 23.3508 1.68656
300
12.7659
0.32289
183.372
6.97498
245
64.64
5.26
199.1
23.04
E
Yield
(Young's
Material
Strength
Modulus)
(MPa)
(MPa)
Al (6601) 70E+03
Mild
210E+03
Steel
Alternate
70E+03
Frame
24.4645 0.603998
129.81
10.52
Table 1: Table showing comparison of maximum stress and displacement for different load cases and
frames.
As seen from Table 1, the stress values for the Al and SS frames are comparable. The deflection
for SS frame is less for all the load cases, because of its high elastic modulus. While designing a
bicycle frame the deflections are not too significant. Knowing that the density of Al is 1/3 that of
SS, we can significantly reduce the weight of the bicycle, by choosing Al frame, without
compromising the structural strength of the bicycle.
The results for the alternate frame show significantly higher stresses (esp. in vertical impact
loading case). It is clear form the results that the bicycle frame does not perform well under

vertical impact loads. Although, this frame will be easier to manufacture, but it is not advisable
to use such kind of frames for performing stunts (where one can see large vertical impact loads).
4.
Conclusions:
In this project we have tried to analyze two different bicycle frames, as well as the conventional
bicycle frame for two different materials. The bicycle frames were found to be within the safety
limits with a decent factor of safety. However, we should note that one of the weakest points of
any bicycle are its wheel spokes. For future study we can analyze different kind of spokes, esp.
the ones used by bicycle racers, to understand the load bearing capacity of different types of
bicycles.
APPENDIX A
(Proposal)
Introduction
A Bi-cycle frame is prominent part in whole racing cycle system, which is subjected to static and
dynamic loads. The dependency of the performance is directly proportionate to weight of the
cycle and frame structural design; Optimization of weight and structure of the frame is the best
scope of optimizing the overall performance of the racing cycle
The aim of this project is to analyze various commercially available bicycle frames under
loading conditions normally encountered during their operation. We intend to analyze the
common factors considered while designing a bicycle; e.g.: the weight of the bicycle, its
maximum load carrying capacity and its impact toughness.
Next, we intend to increase the number of nodes in our model to the point we reach convergence.
Then, we will be able to define the minimum number of nodes required to get results with
sufficient level of accuracy.
Lastly, we intend to compare the results achieved by increasing the number of nodes against
those achieved by increasing the number of elements.
Engineering Assumptions
-
The bicycle is modeled using beam elements in ANSYS.

DYNAMIC loading will not be considered in this analysis.
Point loads will be considered in the analysis.
The points where the frame is attached to the real wheel will be considered fixed.
Anticipated Results
-
The commercially available bicycles are expected to have a reasonable factor of safety.
We will be able to identify the critical areas in the bicycle frame.
Timetable
We intend to submit the results in the first week of December.

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MAE 533 : Finite Element Analysis -I

Finite Element Analysis of Bicycle Frame

Finite Element Analysis of Bicycle Frame

Analysis of an Aluminum frame (Conventional Frame):

Finite Element Analysis of Bicycle Frame

Maximum/nodal/ displacement/ (mm)

(b) Horizontal Impact:

Finite Element Analysis of Bicycle Frame

Maximum0nodal0 displacement0 (mm)

(c) Vertical Impact:

Finite Element Analysis of Bicycle Frame

Analysis of a Steel frame (Conventional Frame):

Finite Element Analysis of Bicycle Frame

Maximum/nodal/ deflection/ (mm)

(b) Horizontal Impact:

Finite Element Analysis of Bicycle Frame

Maximum0nodal0 displacement0 (mm)

(c) Vertical Impact:

Finite Element Analysis of Bicycle Frame

Maximum0nodal0 displacement0 (mm)

Analysis of a Aluminum frame (Alternate Frame):

Finite Element Analysis of Bicycle Frame

Finite Element Analysis of Bicycle Frame

Maximum1nodal1 deflection1 (mm)

(b) Horizontal Impact:

Finite Element Analysis of Bicycle Frame

Maximum2nodal2 deflection2 (mm)

(c) Vertical Impact:

Finite Element Analysis of Bicycle Frame

Maximum2nodal2 deflection2 (mm)

RESULTS AND DISCUSSION:

Finite Element Analysis of Bicycle Frame

Finite Element Analysis of Bicycle Frame

The bicycle is modeled using beam elements in ANSYS.

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