Design Validation Methodology for Bicycle Frames Using Finite Element Analysis

Abstract

Abstract The general industrial practice for bicycle frame design is to do a prototype testing based on the results from linear static structural finite element analysis (FEA). But many times simulation results are not be in line with laboratory test results such as “fast vibration test rig” used validating the prototype frame structure. Hence, an effort has been made for identifying a FE methodology that would reduce the development time and the test is reliable. In this work, two simulation methodologies were studied – linear static analysis considering test rig boundary conditions and fatigue using harmonic analysis. Both methodologies were compared with laboratory test rig results. The stress amplitude calculated using harmonic fatigue analysis was one third of test rig (experimental) stress amplitude. Also, the stresses calculated using FE static analysis was in line with experimental results. Therefore, a fatigue using harmonic stress calculations is recommended prior to prototype testing using “fast vibration test rig” for reliability. With bicycle industry expected to expand multi-fold and its design validation criteria could include more constraints, these results could help the industry benchmark its design and testing