Abstract
The objectives of this study were: (i) to determine the stresses as a result of assembly and the stress concentration of a clamped connection, (ii) to demonstrate the importance of the effects of assembly in fatigue life predictions and (iii) to verify the accuracy of fatigue life predictions by measuring fatigue life experimentally. A stem-handlebar assembly used in off-road bicycles was chosen for the study because it is a critical assembly for which structural reliability must be insured to prevent serious injury. Assembly stresses in the handlebar exceeded 200 MPa and stress concentration because of the attached stem increased the applied stress by 40%. A stress-life prediction indicated that assembly effects would reduce predicted fatigue life of the handlebar by a factor of approximately 20. The measured fatigue lifetime of the handlebar was longer than that predicted by using the stress-life approach, but was much shorter than that predicted when assembly effects were ignored. Therefore, assembly effects have a significant effect on fatigue life predictions and should be included in lifetime assessments for clamped mechanical assemblies.
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