Project Report 2018.docx

A Mini Project Report on

Configuration and analysis of bicycle frames using ANSYS software Submitted in partial fulfilment for the Award of the Degree of

BACHELOR OF TECHNOLOGY in

MECHANICAL ENGINEERING by

SHUBHAM AGRAWAL (Registration No. 15BMEN009) Under the Guidance of MR. ANAND PRAKASH (ASST. PROFESSOR, MECHANICAL ENGINEERING DEPT.)

School of Engineering

JECRC UNIVERSITY JAIPUR, RAJASTHAN (DECEMBER 2018)

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CERTIFICATE

This is to certify that the Mini Project work titled “Configuration

and analysis of

bicycle frames using ANSYS software” that is being submitted by Shubham Agrawal (15BMEN009) is in partial fulfilment of the requirements for the award of Bachelor of Technology, is a record of bonafide work done under our guidance. The contents of this project work, in full or in parts, have neither been taken from any other source nor have been submitted to any other Institute or University for award of any degree or diploma.

Prof. M.M.S. Sodhi

Mr. Anand Prakash

(HoD, ME)

(Project Supervisor)

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APPROVAL This Project Report on “Configuration

and analysis of bicycle frames using

ANSYS software” by Shubham Agrawal (15BMEN009) is approved for the award of the degree of Bachelor of Technology in Mechanical Engineering.

Examiner (s)

Project supervisor (s)

HOD

Date: Place: Jaipur

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CANDIDATE’S DECLARATION I declare that this written submission represents my ideas in my own words and where other ideas or words have been included I have adequately cited and referenced the original sources. I also declare that I have adhered to all principles of academic honesty and integrity and have not mispresented or fabricated or falsified any idea/data/fact/source in my submission. I understand that my violation of the above will be cause of disciplinary action by the institute and can also evoke penal action from the sources which have thus not been properly cited or from whom proper permission has not been taken when needed.

SHUBHAM AGRAWAL Registration No – 15BMEN009

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ACKNOWLEDGEMENT

This mini report is submitted for partial fulfilment for the award of the degree of Bachelors of Technology in Mechanical Engineering at JECRC University. This has been an interesting challenge and a good learning experience for me. Throughout this mini project period, people have contributed directly or by providing support and guidance in the completion of the research.

I am most grateful to my supervisor Mr. Anand Prakash Asst. Professor, Mechanical Engineering Department for his support and guidance. I have been very fortunate to work under their supervision, and I thank them sincerely for the advice, encouragement and patience. I am extremely thankful to Prof. M.M.S. Sodhi, Head, Department of Mechanical Engineering and whole faculty and staff members, for their help and advice during the course of this work.

Last but not least, I am indebted to my parents, without whose support and encouragement I could not have achieved so much.

SHUBHAM AGRAWAL Registration No – 15BMEN009

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ABSTRACT

Bicycles continue to be the principal mode of transport for the low and middle income families. This is because the bicycle is both environment and people friendly. India is the largest producer of bicycles next only to China. It produces around 1.26 crore bicycles every year. Considering the rising fuels cost and pollution, the bikes are considered ideal. These can be maintained at low costs. Since their inception bicycles have provided society with a source of transportation, exercise, recreation and sport. New bicycle frames are generally motivated by weight and/or stiffness considerations and often incorporate the use of high performance engineering materials. Indeed, competitive bicycling has promoted the use of various advanced structural materials including non-ferrous alloys (e.g. primarily aluminum and titanium) and reinforced polymers (e.g. carbon and graphite reinforced epoxies). Both the frame design and the material contribute to rider’s energy consumption. Energy is expended for propulsion and elastic deformation of the frame. Therefore a minimization of frame’s total mass and deflection are essential. Frame is very important part of bicycle as all the important accessories are mounted on the frame. The frame need to be very strong, stiff and light in weight, which is obtained by combining different materials and optimizing its shapes. The strength of frame construction is correct design of a frame because it is the most important part that ensures safe riding. This report deals with the various design of bicycle frame. The modeling of bicycle frame is done in Computer Aided Design software CATIA and analysis of frame is done using the analysis software Ansys. This analysis is done by considering conditions like static start up, steady state paddling, vertical impact, horizontal impact, rear wheel braking etc. This report gives us the stress, strain, factor of safety of particular bicycle frame.

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TABLE OF CONTENTS Page No. CERTIFICATE

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APPROVAL

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CANDIDATE’S DECLARATION

iv

ACKNOWLEDGEMENT

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ABSTRACT

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LIST OF TABLES

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LIST OF FIGURES

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LIST OF ABBREVIATIONS

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CHAPTER - I: INTRODUCTION

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1.1

Background

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1.2

Project Management

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1.2.1

Plant layout

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1.2.2

Maintenance Schedule

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CHAPTER - II: LITERATURE/ THEORETICAL FRAMEWORK

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2.1

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Historical Development

CHAPTER - III: EXPERIMENTAL METHODS/ MODELING/ANALYSIS

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3.1

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CHAPTER - IV: RESULTS AND DISCUSSION

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4.1

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CHAPTER - V: CONCLUSION

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6

5.1

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REFERENCES

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LIST OF TABLES Table No.

Table Title

Page No.

Table 1.1

Indian Railway Train

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Table1.2

Mechanical workshop, Secunderabad.

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Table 2.1

Schematic layout of air brake system

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Table 2.3

Cut Off Angle Cock

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LIST OF FIGURES Figure No.

Figure Title

Page No.

Figure 1.1

Indian Railway Train

1

Figure 1.2

Mechanical workshop, Secunderabad.

2

Figure 2.1

Schematic layout of air brake system

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Figure 2.3

Cut Off Angle Cock

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Figure 2.4

Brake Cylinder

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Figure 2.5

Dirt Collector

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Figure 2.6

Sectional view of dirt collector

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LIST OF ABBREVIATIONS

LHB

Link Hofmann Busch

ICF

Integral Coach Factory

WSPS

Wheel Slide Protection System

HE

Heat Exchanger

PFHE

Plate Fin Heat exchanger

TFHE

Tube Fin Heat Exchanger

FTMHE

Finned Tube Matrix Heat Exchanger

CFTMHE

Circular Finned Tube Matrix Heat Exchanger

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CHAPTER – 1 INTRODUCTION The innovation in the design of bicycle frame is still going on, the reason behind this is that the manufacturers and construction designers have innovative ideas related to minimize aerodynamic drag, to improve comfort, minimizing the mass of the frame, maximizing lateral stiffness in the load transfer from the hands and feet to the drive, maximizing the strength capabilities of the frame to allow for a higher load capacity or better load distribution, and adjusting the vertical compliance of the frame to tune the softness of the ride [1,2] that are needed to provide rider comfort and safety ride. Most modern bicycle frames have the simple form. This shape emerged in about 1895 following several decades of vigorous development and evolution and it remained as basically unchanged since that time [3]. The trial and error method is used at that time but this method does not provide the relevant result and the intuition made is not necessarily all time correct so there is need of software that provide a way to get direct and appropriate result. This ultimately saves the cost and time of manufacturer. The solution is provided by Finite Element Analysis (FEA). FEA is a computational technique used to obtain approximate solutions of boundary value problems in engineering. Simply, a boundary value problem is a mathematical problem in which one or more dependent variables must satisfy a differential equation everywhere within a known domain of independent variables and satisfy specific conditions on the boundary of the domain. Boundary value problems are also sometimes called field problems. The field is the domain of interest and most often represents a physical structure. The field variables are the dependent variables of interest governed by the differential equation. The boundary conditions are the specified values of the field variables on the boundaries of the field. Depending on the type of physical problem being analyzed, the field variables may include physical displacement, temperature, heat flux, and fluid velocity to name only a few [4].

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LITERATURE REVIEW As far back as 1986, Peterson and Londry (1986) used FEA to fine tube the design of the Trek 2000 aluminium frame using two other designs (steel, aluminum) as performance benchmarks for mass, strength and stiffness characteristics. The model used beam elements to represent the tubular frame structure (excluding forks) with a variety of loading conditions to all frames to calculate their response characteristics [5]. In 1999,D. Arola et.al. explained the method used for an experimental evaluation of unique Prototype Bicycle motocross (BMX) frame [6]. In 2009, Thomas Jin-Chee Liu, Huang-Chieh Wu in their discussed the fiber direction and stacking sequence design for the bicycle frame of the carbon/epoxy composite laminates [7]. Alexandre Callens, André Bignonnet the methodology used for validation of bicycle frames and the fatigue strength prediction is excellent when compared to the standard tests [8]. The work presented by Derek Covill, et.al. outlined a FE model using beam elements to represent a standard road bicycle frame. The model simulates two standard loading conditions to quantify the vertical compliance and lateral stiffness characteristics of 82 existing bicycle frames [9]. Recently in 2014, M. V. Pazare deals with the stress analysis of bicycle frame by using Finite Element Method. The analysis of frame is carried out in ANSYS software, and the F.E.A. results are compared with theoretical results. And it is found that there is good agreement between analytical and F.EA results [3]. METHODOLOGY The methodology used in this paper consists of modeling the bicycle frame in CATIA software and analyze the frame using the analysis software Ansys. In this paper the sample analysis of frame of Falcon Avon is presented here. CATIA is software which is used for creation and modifications of the objects. In CATIA, the design and modeling feature is available. Design means the process of creating a new object or modifying the existing one. Drafting means the representation or idea of the object. Modeling means creation 2D to 3D model. By using CATIA software, create the model of the bicycle frame. The modeling of various frames in CATIA is as follows. 3.1. Modeling of bicycle frame II.

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Figure 3.1: Modeling of Falcon Avon bicycle frame 3.2: Modeling of Sunami bicycle frame

Figure 3.3: Modeling of Foster bicycle frame Modeling of Miss India Hero bicycle frame

Figure

Figure 3.4:

3.2. Analysis requirement After modeling the analysis of frame is done in Ansys Software, for that purpose After preparing the model in CATIA it is improved to ANSYS, the file is imported from CATIA by file>import>IGES. To carry out the analysis various conditions are consider like, Static start up, Steady state pedaling, Vertical impact, Horizontal impact, Rear wheel braking. The input data for the analysis of bicycle frame Material IS2039 is as follows: Young’s modulus: 2.e+005 MPa Poisson’s ratio = 0.31 Density = 7.75e-006 kg/m3 Tensile Yield Strength =320 MPa Tensile Ultimate Strength= 400 MPa Physics type = Structural Analysis type= Static structural, Solver target= Ansys mechanical

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Force applied in various conditions:

(A) (B)

(C) (D)

(E) Figure 3.5 (A)Static start up (B) Steady state pedaling (C)Vertical impact (D)Horizontal impact (E)Rear wheel braking III. RESULT

ANALYSIS

The analysis of bicycle frame named Falcon (Avon) size 50.5cm (20") is done using following condition as follows: 4.1. Static start up

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(A) (B)

(C) (D) Fig. 4.1(A) Deformation (B) Vin Mises Stresses (C) Strain (D) Factor of safety

4.2. Steady state pedaling

(A)

(B)

(C) (D) Figure 4.2 (A) Deformation (B) Von Mises stress (C) Strain (D) Factor of safety 4.3 Vertical Impact 15

(A) (B)

(C) (D) Figure 4.3 (A) Deformation (B) Von Mises stresses (C) Strain (D) Factor of safety 4.4. Horizontal impact

. (B)

(A)

(C) (D) Figure 4.4 (A) Deformation (B) Von Mises stress (C) Strain (D) Factor of safety 4.5. Rear wheel braking

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(A) (B)

(C) (D) Figure 4.5 (A) Deformation (B) Von Mises stress (C) Strain (D) Factor of safety Results in tabular form: TABLE I Conditions

Total Equivalent Equivalent (von-Mises) Deformati Elastic Strain Stress on

Static start 1.9931eup 002 mm

8.1359e005 mm/mm

16.272 MPa

Steady state pedaling

1.554e002 mm

1.0228e004 mm/mm

20.456 MPa

Vertical impact

4.1937e002 mm

2.7646e004 mm/mm

55.292 MPa

3.1421e004 mm/mm

62.842 MPa

2.7345e004 mm/mm

54.689 MPa

Horizontal 0.10109 impact mm Rear wheel braking

1.6719 mm

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CONCLUSION From the results of FEA, it is apparent that the stresses induced in the bicycle frame of Falcon Avon is least and the factor of safety is also well above the limit. Also the Von Mises stresses are less than ultimate strength for the material. Thus the design of bicycle frame is sturdy. The use of Ansys software makes the process of calculation fast and several iterations are permissible to arrive at the best possible results. The results are relevant provided the assumptions and boundary conditions are perfect. The inner and outer diameter of top tube, seat tube and down tube is 33 mm and 29 mm with a thickness of 2mm. The inner and outer diameter of seat stays and chain stays are 23 mm and 21 mm with a thickness of 1mm. The lengths of the tubes are taken in accordance to the rider’s height. The lengths are close to industry standard. Modeling of the designed bike frame is done in NX Unigraphics 7.5 software. The bike frame is designed in 2 different material alloys so as to analyze and compare the frame material according to one’s need. For these 2 frames, 5 different load cases are defined in order to make out the stress and deformation in each frame. Normal stress analysis along x-axis is also performed in ANSYS software with the same loading cases. The stresses obtained from both the theoretical (analytical) and ANSYS are compared and a difference of 0% to 42.6% is seen in the results but the average difference is around 5% which can validate the ANSYS results as there is difference in meshing standard in both the analysis. Equivalent (von-Mises) stress analysis for all material alloys for all load cases is performed in ANSYS to make a comparative study. Results of all cases reveal that the maximum stress in the member of the bike frames is less than the yield strength in tension for the material selected. A comparative study is also made for the total deformation in the members of alloys for all load cases. Aluminium alloys are light weight but are easily deformed.

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References [1]

[2]

[3]

[4]

Andrew L. Hastert, Benjamin F. Barger, and Justin T. Wood,“Finite Element Analysis of a Sandwich Composite Bicycle Frame”.www.labmilwaukee.com/wpcontent/uploads/2011/08/bikef ea.pdf Mr. M. V. Pazare “Stress Analysis of Bicycle Frame”, International Journal of Engineering Science and Technology (IJEST), ISSN: 0975-5462 Vol. 6 No.6 Jun 2014, Pages 287-294. David. V. Hutton, “Fundamental of Finite Element Analysis” .published by McGraw hill publication, International edition ISBN0-07-112231-1, copyright 2004. Leisha A. Peterson and Kelly J. Londry, “Finite-Element Structural Analysis: A New Tool for Bicycle Frame Design The Strain Energy

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[5]

[6]

[7]

[8]

Design Method”, Bike Tech Bicycling Magazine's Newsletter for the Technical Enthusiast, 1986 Vol 5, No. 2. D. Arola, P. G. Rainhall, M .G. Jenkins, S.C. Iverson, An Experimental analysis of hybrid Bicycle frame”, May- June 1999, Experimental techniques. Type CEA06-125UR 120, Measurement Group, Releigh NC Pages 21-24. Thomas Jin-Chee Liu, Huang-Chieh Wu, “Fiber direction and stacking sequence design for bicycle frame made of carbon/epoxy composite laminate”, 23 October2009, www.elsevier.com/locate/matdes, Pages 19711980. Alexandre Callens, André Bignonnet, “Fatigue design of welded bicycle frames using a multi axial Criterion”, 2012, 9th Conference of the International Sports Engineering Association. Pages 640-645. Derek Covill, Steven Begg, Eddy Elton, Mark Milne, Richard Morris, Tim Katz,” Parametric finite element analysis of bicycle frame geometries”, The 2014 conference of the International Sports Engineering Association. Pages 441-446.

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