Composites in Bicycle Manufacturing

Overview
Basics of frame geometry Background and history Focus on:
Titanium frames Carbon Fiber frames Kevlar frames

Video of composite frame construction

Basics of Frame Geometry

Mountain Bike Frame Design Angled top tube Front/rear springs Heavier construction Relaxed rider position Aggressive fork rake angle Forgiving design for crashes! Greater rider movement about bike Road Bike Frame Design Springs are atypical Emphasis on less weight Top tube parallel to ground More aggressive rider position Less flexibility on rider movement Stiffer frame design for responsiveness

Basics of Frame Types & Geometry

Basic Frame Types: Diamond: The most common sport version Truss: Precursor to Diamond

Step Through: Commuter focus Monocoque: Typically Al, hollow shell Recumbent: Ergonomics and aerodynamics Penny-Farthing:

Bicycle Jig Construction: Common across all frame types, with monocoque & some composites the exception (molding instead)

Background Wood & Steel

Precursor to the modern bicycle The Draisienne Primarily wood construction Incidentally, the inventor is also credited with the first cycling traffic fine: for running over a pedestrian! Velocipedes and Penny-Farthings soon followed

From Penny-Farthing to today Penny-Farthing comprised of lowcarbon spring steel Followed a similar path as aircraft construction always moving to lighter, stronger alloy steels Common steels used today are often 4130, or Chromoly

Background - Aluminum

Aluminum Frame Construction: Far better strength-to-weight ratio, machinability, and lower stiffness than steel equivalents Introduced the use of TIG welding in bike manufacture, as well as hollow-tube forming such as with monocoque frames There are even CNC-machined Aluminum frames! Typical Aluminum alloys are 6061 and 7005

Background - Titanium Alloys

Titanium Alloy bike frame construction 6/4 and 3/2.5 the most common alloys Gaining steady popularity in recent years due to desire for lower weight vs. steel and higher stiffness vs. Aluminum

Focus on Carbon Fiber

Carbon Fiber-based tube frame construction: Is able to utilize all major forms of bicycle frame manufacturing: Tube-to-tube techniques Monocoque/molding techniques Latticework techniques Material type ranges from 1k to 15k tow, plain weave Preimpregnated epoxy is still uncommon, but gaining in popularity Bike material of choice for racers

Focus on Carbon Fiber

Carbon Fiber is also an excuse to pursue more esoteric designs: Recumbent racing bikes Ultra-lightweight folding designs Artwork/ off-the-wall designs These designs often retain full functionality!
Focus on Carbon Fiber

Focus on Kevlar Fiber

In Truth. This is a Kevlar/Carbon Fiber composite bike frame Utilizes a latticework construction with kevlar/carbon roving Three-dimensional triangulation for superior column strength and resistance to buckling/bending

Focus on Kevlar Fiber

Kevlar/ latticework manufacturing and research hook-and weave construction methodology (patented, of course!) 1:12 weight ratio vs. Steel of comparable strengths 1lb of lattice material supporting 11,600lb reinforced concrete block

Carbon Frame Construction Video!

http://www.youtube.com/watch?v=2nVbmcnsXXs&feature=related Manufacturer name is Trek Monocoque construction demonstration Sorry for the length (6 minutes), but its good stuff!

Thank You
Any Questions?

References
http://www.phred.org/~josh/build/design.html http://blog.velocite-bikes.com/carbon-fiber/ http://www.delta7bikes.com http://www.jamisbikes.com/usa/thebikes/road/xenith/nearnet_xenithsldi 2.html http://en.wikipedia.org/wiki/Bicycle_frame http://en.wikipedia.org/wiki/Bicycle