Different Aspects Relating to the Bicycle Frame - Case Study Example

PRODUCTION OF THE BICYCLE FRAME THROUGH THE AGES By Production of the Bicycle Frame through the Ages Introduction The production of the bicycle has undergone a significant revolution through decades since its invention. People have involved technologies of varying standards to ensure that the quality of the bicycle produced is better than the preceding model at every time. The bicycle frame is the main part that determines the value of the complete machine. The wheels and the steering are embedded on the frame. Therefore, the development of the bicycle frame would imply the overall modification of the machine. This exercise will focus on different aspects relating to the bicycle frame, its efficiency and improvement (Wilson & Papadopoulos 2004). The report would discuss the materials that have been used in the manufacture of bicycle frame throughout the ages and their specifications. Products from the materials and the components fitted on the frame have been different and so to their performance. There are processes taking place during the operation of the bicycle and determine the bicycle efficiency (Galbiati & Ciravegna 1994). These processes would be addressed explicitly to foster criticality on the need and the effects of the frame improvements. Generally, the report will provide an overview on the bicycle frame from the time of the invention, the modification to the present status of the frame. There would be analysis of the processes where the procedures of making the frames would be examined. The materials’ description will entail the explanation of the specifications of the component materials. Research Objectives i. To analyze the materials which, have been used in making bicycle frame for different periods ii. To explain the use of appropriate material for the production of bicycle frame iii. To provide an explanation on the historical view on the materials and processes used in the manufacture of the frame iv. To evaluate the engineering significance of the choice of the materials and the processes v. To analyze the environmental effect and issues of sustainability related to the bicycle frame production Background The bicycle was discovered in the nineteenth century, was made of wood initially but currently many metals have been used in making the frames. In addition, metal alloys have been used with proportionate elements compositions to achieve best qualities. The bicycle frame consists of two frames, the main frame and the rare frame. This is the basic design known as the diamond design with doubled rare triangle. Bicycles are among the worlds most trendy modes of transportation. The ratio of bicycles to automobiles results into two to one. The bicycles are considered the most efficient for basic transportation due to their efficiency and little energy requirements (Galbiati & Ciravegna 1994). Bicycle users utilize about thirty-five calories in a single mile whilst the vehicles would consume over fifty times of the same calories in one mile. The uses of the bicycle include transportation, touring and competition. The development of the bicycle frames has modified the bicycle use into different specifications. The frames have assumed different forms as those to tolerate variant terrains, stationery and racing bicycles (Galbiati & Ciravegna 1994). Wood The bicycle was initially made of wood, which at was curved and joined at different points. The procedure included cutting the wood into appropriate shapes and sizes that would favor the diamond shape conformation. Stronger synthetic materials and strings were used to reinforce the joints. However, the method never lasted for long due to the desire for strength and durability. Imperatively, the idea emanated from the curving of the horse shaped boneshaker. http://www.bikerumor.com/wp-content/uploads/2009/08/renovo-wood-bicycle-rmbs2009l.jpg Bamboo The process also entailed cutting the bamboo rods at appropriate shapes and joining the pieces using glue. The outer parts of the joints were covered using stronger synthetic fibers or organic matter such as leather pieces. The joining of the current bamboo frames are epoxy materials and steel reinforcements. Therefore, significant portion of the frame is steel (Medina 2000). http://curate.tumblr.com/post/880187147/tanglad-building-bamboo-bikes-in-the Steel The use of steel as a material for modeling the bicycle frame then arose because of the material’s strength(Galbiati & Ciravegna 1994). Steel is a metal made from alloying iron with an element of carbon. The other elements include tungsten, vanadium, chromium and manganese. These alloying elements serve as hardening agents making steel stronger and harder than the original material, iron. The qualities of the steel produced from the alloying such as hardness, ductility and tensile strength; depend on the amount of the alloying elements applied. For instance, addition of more carbon results into harder and stronger steel but less ductile as compared to the iron (Wilson & Papadopoulos 2004). Alloys of steel that contains more than 2.1% of carbon reveals low melting points accompanied with appropriate casting hence, named cast iron. On the other hand, steel made from small amounts of carbon, added in the process of alloying as slag inclusions makes the steel to resist rust and possible to weld. The welding process applies in the joining of tubular steel metals into the shapes that meet the demands of the design. http://www.almostcool.org/blog/ Aluminum alloy The process involves the combination of aluminum with other elements such as silicon, copper, chromium, manganese and titanium (Medina 2000). http://www.seekpart.com/company/44555/products/2011516145331593.html Carbon Fiber http://best-b2b.com/Sub-cat/1064/1092/bicycle-parts_14.html Historical Perspective The modification of the bicycle began by around 1700 when a Frenchman called Comte de Simrac discovered a crude wooden horse like structure with front and rare wheels. The rider would propel it through pushing the feet against the ground surface. Baron Karl made a hobbyhorse in 1816 that could be steered (Chamberlain 1998). The riders realized that they could ride without touching their feet on the ground. In 1840, Macmillan Kirkpatrick devised a bicycle mode that he used to travel a distance of 225 kilometers to Glasgow. Machux later modified a horse like boneshaker that had pedals, steering and tyre wheels with an iron frame. In 1866, various parts of bicycle such as the hubs and the ball bearings were discovered. Therefore, there was a critical step made in the bicycle modifications (Chamberlain 1998). The modification of bicycle with John Kemp developing a rover safety that was relatively safe for the users since the wheels were moderated well. In 1890, the bicycles had obtained a significant development and regarded among the prestigious means of transport. The Bicycle Material Case Study The case study highlights that the best design of the frame of the bicycle is achievable through correct material selection. The material selection skill is critical for the engineering designs and applications. Application Requirements Normally, the application requirements in bicycle selection are speed, comfort and endurance. Even though the weight of the bicycle is critical, requirement for a light bicycle should be comparable to speed, comfort and endurance. The frame is the main functional unit of the bicycle (Chamberlain 1998). Therefore, what is worth considering is the strength and weight of the fame. Thus, emphasis is on the type of tube frame that is applicable in frame making process. The Possible Materials Besides, the several materials applied in the manufacturing process of bicycles, the case study only focused on the current commonly used materials. These materials consist of steel alloys, aluminum alloys, titanium alloys and the composites (Medina 2000). The focus on the materials were based on the modulus of elasticity, the ultimate tensile strength, 0.2% proof stress at yield, the elongation at failure, fatigue limit per UTS and the density. Physical Principles The process of selecting the materials were guided by the following principles the case study viewed as crucial. Densification is applied as a matter of necessity in enhancing the tensile strength of products by lowering the degree of exposure of the matrix. The standard rule of the mixtures: In most cases, composite mixtures are widely used because they are adaptable hence, applicable in different types of applications. The selection of the different proportions of the mixture correlated to the attainment of optimal mechanical behavior of manufacturing hard materials. This process enables the change of power, continuity, the physical appearance, density and increasing the life span of the product. Alloying exists among the oldest techniques used in the processing of materials. The process gives the materials new and distinct properties from the individual elements (Medina 2000). Material Selection The case study analyses aspect in conjunction with and without cost, having examined the application requirements, the possible materials and the physical principles. The material selected for manufacturing frames without considering cost was titanium alloys, and that with cost was steel (Wilson & Papadopoulos 2004). The Bicycle Frame The raw materials Frame is the most vital part of the bicycle onto which all components are fixed. The frame contains the seat trays, the rare wheel and the chain trays on the hind triangle (Galbiati & Ciravegna 1994). The front triangle has top, down and head tubes. The frame was initially strong steel alloy but heavy. The current frame has been modified to meet the specifications such strength, durability and lightness. The developments that transpired on the 1970s led to the availability of stronger and versatile frames that were more durable and inexpensive (Medina 2000). The lightweight aluminum frames followed but could not be compared to steel in durability. More improvements by 1990s permitted the use of stronger materials in the manufacture of the bicycle frames such as carbon composites. The composite materials are strongest longitudinally in their fibers’ axes. Hence, the composite materials can be modified into one-piece frames that avail strength in the desired locations. The Manufacturing Process Seamless frame tubes are created through several stages, which involve piercing of solid steel blocks. These are normally superb to the seamed types made through drawing of drawing of flat steel strip stock before wrapping it into a tube and eventually joining it along the tube of the length through welding. Through butting or modification of the thickness of tube walls, the seams tubes are altered to enhance their strength and lessen their weight. The butting process incorporate thinning of the frame near the joints where there is much stress and thinning the middle if the frame tube where the stress is lowered substantially. Generally, the buttering process enhances the strength and resiliency according to the applied degree of metal thickness (Galbiati & Ciravegna 1994). Hand brazing or machine welding methods are employed in the assembly of tubes to form a diamond frame. However, hand brazing is labor intensive and relatively expensive as compared to machine welding. Plastic binders and glue that is more adhesive are used in joining composite frame components. Proficient experts make moderations finally on the frame (Galbiati & Ciravegna 1994). Assembling the Frame Parts Tailoring There is annealing of the metal through heating process and hollowing to form tube. Scales are then removed by pickling and the metal is lubricated. The metal tubes are measured and cut according to standard dimension provided in the specifications. The cutting allows the metal measurements to fit adult or children bicycles. The tubes are fitted on the mandel embedded on the draw bench. The drawing process enables the hollows to attain the specified gauges. Cold brewing enables the hollows to stretch through dyes and get thinned. The taper gauge fox blades shapes the tubes into variant shapes to attain desirable designs. Joining (Brazing, welding, and gluing) The tubes can be connected into a frame using hand or machine welding. The methods would include gluing, brazing or welding. Brazing involve welding at a temperature of about 1600oF or low. Brazing filler is applied on the joint and the joint subjected to high temperatures that make the filler melt and flow around and seal the joint. Aligning and Cleaning Appropriate alignment is checked and attained by putting the joined frame into jigs. Modifications are made on the frame whilst the frame is malleable. Cleaning of the flux and the surplus metals are cleared by acid picking. Advance precision and configurations are made after cooling the metals (Wilson & Papadopoulos 2004). Finishing The protection of the frames is maintained through painting. The painting of the frame makes two coats with the undercoat first and the final colored enamel. The painting of the frame may take place manually spraying or by passing the aligned frame through an automatic electrostatic sprayer. The frame attains a negative charge while the paint attains a positive charge hence attraction between the paint and the frame until the frame is fully painted. Fixation of the paint is then performed through supplication of transfers, lacquers and spreaders (Wilson & Papadopoulos 2004). Information on appropriate and inappropriate engineering use of this material/product/process The engineers have applied an appropriate use of steel and the composite carbon materials in the production of the bicycle frame. Seeding of the metal is done to ensure efficiency in the metal structure and reinforce the frame structure. Picking is also appropriate on the hollow metals to eliminate flux and the metal flaws that would cause weaknesses in the frame. The resultant product is a light, strong and durable bicycle frame. The engineers have used inappropriate materials in designing the previous diamond frames through inappropriate use of proportions of metals in making the aluminum in creating metal alloys. The inappropriate alloys do not provide desired density of the resultant products hence undesirable weight of the frame (Wilson & Papadopoulos 2004). Environmental impact and issues of sustainability This report promotes the enhancement of sustainability of the engineering processes, products and methods. Several products in the engineering provisions uphold the research in environmentally compassionate production or chemical procedures. The environmental sustainability schedule support examinations that would execute environmental requirements beyond the physical processes (Smith 1997). The issue also recommends comprehensive approaches that encourage conformations with environmental demands through products and manufacturing processes. Environmental sustainability also supports the areas that will remodel the effects of production processes to the surrounding (World Bank 2008). Other vital areas of research would also incorporate recycling and avoidance of misuse of the natural resources such as the mineral metals (Jha & Murthy 2006). Bibliography Chamberlain G.1998, "Shocker of an Idea." Design News. pp. 90-2 Galbiati, F & Ciravegna, N. 1994, “Bicycles (Le Biciclette).” San Francisco: Chronicle, Jha, R & Murthy B., V, 2006, Environmental Sustainability: A Consumption Approach, Volume 0, Issues 415-36342. Paris: Taylor & Francis, 2006 Medina, K. 2000, "Aluminum/carbon fibers team up." Modern Metals, pp. 87 Smith F., 1997, Environmental Sustainability: Practical Global Implications, New York: St. Lucie Press Wilson, D. G., & Papadopoulos, J. 2004, Bicycling Science. New York: MIT Press World Bank, 2008, Environmental Sustainability: An Evaluation of World Bank Group Support. New York: World Bank Publications Read More