Your Friendly Neighbourhood Your Friendly Neighbourhood Folding Bike CompanyFolding Bike Company

• Kmax Design Team Members:• Jake Kaupp• Pete Mckay• Jared MacInnis• Peter MacLennan

• Team Supervisor:• Dr. Alex Kalamkarov

• Client:• Kmax Designs

• Team Sponsor:• True Temper Sports

• The goal of our project is to build and create a full size mountain bike that folds into a much smaller size when your finished using it.

• Typically these bikes are small and unable to provide the stability and comfort for variable riding conditions.

• September 2002– Established Kmax Designs– Chose our project and finalized our

client and supervisor requirements• October 2002

– Acquired True Temper Sports as a sponsor

– Began Brainstorming• November 2002

– Finalized Design

• January 2003• Worked out all final design problems

• February 2003• Started fabrication

• March 2003• Completed fabrication• Painted, rigged and tested prototype• Completed an FEA analysis

• Tubing• $315

• Machine Time• $675

• Recycled Parts• $386

• New Parts• $397.91

• Miscellaneous• $206.09

• Grand Total•$1980

Cost Analysis

Tubing16%

Machine time35%

Recycled Parts19%

New Parts20% Misc

10%

• Manufacturing Processes– TIG Welding

•All frame tubes, rear dropout, hinge and bottom bracket

– Silver Soldering•Brake and gear cable mounts

(damage from intense heat, high strength not a requirement)

Rear triangle and dropouts– Aluminium cylinder used to align rear

dropouts– Brace for top of rear triangle

fabricated from extra tubing– Lower tubes cut and bent on inside

then welded• unable to produce curved sections

– Top tubes did not require bending

• Cable mounts were positioned so as to avoid tension when folding

• All mount locations were strategically placed and marked prior to soldering

• Jig was required to locate position of rear brake mounts

•U-shaped aluminum block– Small clearance between block and

hinge

– Hole drilled through block and hinge with clearance for faster assembly

– Quick release through block and hinge to hold hinge closed

• Angle of head tube changed• Original angle too large

• Internal grinding of seat tube due to excess material

• Small groove in seat tube to increase forces on seat post

• The Folding Mechanism• Aluminum C - clamp• Frame Geometry• Final Componentry & Peripherals

• The focal point of the Kmax DFS• A standard industrial door hinge was

utilized• Hinge originally had 6 pre-drilled bolt holes• Technicians filled the holes to increase strength

• One single centered hole drilled for Quick Release Pin

• Bearing surface provided by weather stripping lining

• Design credit goes to Albert who envisioned the design

• Aluminum clamp/bracket provides rigid support, yet is a flexible safety device

• Increased clamping area provides greater closing force, increasing the stability of the DFS

49°

59°

72°

50°

50°

80°

10°

30°

10°

• Frame• True Temper OX Platinum

• Headset• Dia-Comp

• Bottom Bracket• Shimano

• Front Changer• Shimano XT Bottom Pull

• Front Shifter• Shimano Deore

• Front Brake• Avid V Brake

• Fork• Rock Shock Judy XL

100mm travel

• Pedals• MKS FD6 Folding

• Rear Changer• Shimano STX-RC

• Rear Shifter• Shimano 7 Speed

• Rear Brake• Shimano Alvio V Brake

• Tire Size• 26 x 2.1 Inch

• ANSYS 6.0 was used for the FEA of the Frame.

• Two analyses were completed• Static Analysis• Semi-Dynamic Analysis

• Frame was modeled as a collection of line elements possessing the characteristics and properties of the individual frame elements.

Element Size = 20 mm

# of Nodes = 160

Critical Areas

Maximum Stress: 31.895 MPa

Failure Strength: 813 MPa

Maximum Stress: 53.252 MPa

Failure Strength: 813 MPa

Critical Areas

• Illustrates the validity of the frame design

– Maximum Stress never exceeds the UTS of the Material, in both Hinge and Frame

– Proves the frame possesses stable geometrical characteristics

• Depicts potential failure areas• Validates the folding method.

• Kmax feels that we have reached our goal in producing what was intended, The Casablanca is a full size folding mountain bike that will fit in the trunk of a car.

• The design also incorporates a widened wheel base to improve stability, an initial concern caused by the ‘dip’ in the frame due to the hinge.

• There are some areas that the Kmax design team has identified that could be improved.

– Dimensions of Rear Triangle– Dimensions of the Front Segment– Alignment of the Drop-Outs

• Also a full Three Dimensional FEA should be undertaken by a professional to determine a precise FMEA and determine the wear and fatigue to which the frame will be subject to

• In conclusion the Kmax Designs Team believes that we’ve produced an innovative bike frame that hopefully increases interest in cycling due to its unique portability, making it easier to have a rip, anytime, anyplace.