Commuter Bicycle

Nov. 2020 - June 2021

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I designed and manufactured a commuter bicycle over the course of two separate classes: Applied Finite Element Analysis (ME 404) and Single Track Vehicle Design (ME 441). As part of my ME 404 class, I compared the same frame with material, 4130 steel or 7005-T6 Aluminum, and sized in available bicycle tubes. The primary deflection measured was at the bottom bracket, while constraining at the rear axle and at the bottom of the headtube. This study provided insight into the material differences for a similar frame.

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In my ME 441 class, I was able to develop dynamic calculators to analyze geometry and its effect on the dynamic performance of the frame. Critical consideration was made to the trail fo the bike, this is controlled primarily by the head tube angle, wheel size, and rake of the fork. Dynamic analysis involved braking load transfer, Patterson control model (control spring and control sensitivity).

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Being built in the Spring quarter 2021, there were a lot of supply issues. Ended up having to buy a suspension adjusted fork (raising the height of the headtube and slackening the headtube angle). I also was unable to purchase a thru-axle that fit my dropouts, resulting in me making my own. 

Skills Developed

• FEA of static body​​

  • Mesh convergence study

  • numerous body constriants

• Dynamic analysis of bicycle and working with models

• Problem solving given tight constraints and resources

• TIG welding with thin-wall tubing