Design and Fabrication of A Bicycle Frame Under Static Loading Conditions

Abstract

The design and fabrication of a bicycle frame require a careful balance between strength, weight, and durability to ensure optimal performance and safety. This study focuses on the structural analysis and manufacturing of a bicycle frame under static loading conditions. A detailed design process is carried out using computer-aided design (CAD) software, followed by finite element analysis (FEA) to evaluate stress distribution, deformation, and factor of safety under different loading scenarios. The material selection plays a crucial role in achieving a lightweight yet strong frame, with considerations given to aluminium alloys, carbon fibre, and steel. Based on analytical results, a prototype is fabricated using suitable manufacturing techniques, such as welding or brazing, to ensure structural integrity. Experimental validation is performed through static load testing to compare theoretical predictions with real-world performance. The results provide insights into the structural efficiency and reliability of the bicycle frame, contributing to advancements in bicycle engineering and material optimization

Introduction

Objective:
The study investigates the structural behavior of a bicycle frame under static loading using CAD design, finite element analysis (FEA), and experimental testing, aiming to optimize performance, safety, and durability.

1. Design Methodology

• CAD Modeling: A 3D model of the bicycle frame is created using CAD software, considering geometry, ergonomics, and mechanical strength.

• Material Selection:

  • Aluminium Alloys: Lightweight and corrosion-resistant.

  • Carbon Fiber: High strength-to-weight, but expensive.

  • Steel: Durable and affordable, but heavy.

• Structural Steel Properties: Includes data like density, tensile strength, modulus of elasticity, and thermal expansion.

2. Finite Element Analysis (FEA)

• FEA simulates the frame under static loads such as:

  • Rider weight

  • Braking forces

  • Pedaling forces

• Outputs:

  • Identification of stress concentrations and deformation patterns.

  • Supports design refinement for better structural performance.

3. Fabrication Process

• Prototype construction is based on analytical findings.

• Joining Techniques:

  • TIG welding for aluminium.

  • Brazing for steel for better fatigue resistance.

4. Experimental Validation

The prototype undergoes real-world mechanical testing to validate simulation results:

Tests Performed:

• U-turn Test: Evaluates maneuverability, stability, and control.

• Bump Test: Tests suspension and comfort on uneven terrain.

• Brake Test: Assesses braking efficiency and safety.

• Pedal Stroke Test: Analyzes power transfer and drivetrain smoothness.

• Weight Test: Measures overall frame weight affecting speed and ride quality.

• Slow Cycle Test: Evaluates control and stability at low speeds.

5. Results and Discussion

• FEA Accuracy: Experiment results closely match FEA predictions with minor deviations due to manufacturing tolerances.

• Stress Analysis:

  • Max Von Mises stress: 4.309 × 10? Pa

  • Min Von Mises stress: 3479 Pa

Conclusion

This study presents a systematic approach to designing, analyzing, and fabricating a bicycle frame. The combination of CAD modeling, FEA, and experimental validation ensures an optimized design with enhanced structural efficiency. Future work may focus on dynamic loading conditions and fatigue analysis to further improve frame performance

References

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Copyright

Copyright © 2025 Kandasamy Ragupathi, S Bharathiraja, R Karthikeyan, M Santhosh, S Suvithan . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.