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FEA project report

1.Background
In the traditional realm of Finite Elements, there are very few practical
applications where the
finite code can be compared to direct measurements. At best, Engineers can
usually only
compare their computer analysis with the results predicted by established
mechanical formulae. At worst, Engineers must rely on their experience and
intuition to guide them towards a workable “right” answer.

The FEA modeling process requires three types of input data: geometry,
material properties, and loading. For the bicycle frame, "geometry" means
the overall frame dimensions (such as tube lengths, intersection points, and
angles) as well as the tubing specifications (diameters, wall thickness, etc.).
The purpose of this analysis is to formulate a finite element model of a
bicycle frame and compare theoretical results with those revealed by ANSYS.
Eventually, redesigning the structure for safety reasons.

2. Geometry and discretization


The bicycle frame shown in figure is constructed from aluminum tubes.
The main part of the frame is made of tubes of a minimum outer diameter
of 12mm and 2mm wall thickness.
Figure 1: 3D bicycle frame

2.12D model

Keypoint x(m) y(m) z(m)


1 0 0.325 0
2.00E-
2 0.4 0
02
3 0.52 0.4 0
4 0.4 0 0
5 0.825 0 0
Table 1 : Key points’ coordinates

Connectivity table
Elemen
i j Θ°
t
1 1 2 75.06
2 2 3 0
3 3 4 76
4 4 1 140.906
5 5 4 0
6 3 5 129
Table 2 : Connectivity table

L1(m) L2(m) L3(m) L4(m) L5(m) L6(m)


0.078 0.500 0.418 0.515 0.425 0.503
Table 3 : Length of elements

2.23D model

Keypoint x(m) y(m) z(m)


1 0 0.325 0
2.00E-
2 0.4 0
02
3 0.52 0.4 0
4 0.4 0 0
5 0.4 0 0.02
6 0.4 0 -0.02
7 0.825 0 -0.05
8 0.825 0 0.05

Table 4 : Keypoints’ coordinates

Connectivity table
Element i j Θ°
1 1 2 75.06
2 2 3 0
3 3 4 76
4 4 1 140.906
5 4 6 0
6 6 7 0
7 8 5 0
8 5 4 0
9 3 7 129
10 3 8 129
Table 5 : Connectivity table

3.Hand calculations
To validate the ANSYS simulations, we will need to calculate the nodal
displacements and stresses and compare them to the ANSYS results. For the
first loading case, the loads are assumed to be applied on the saddle and on
the pedal. These are applied by the rider who sits down on the bike. Hence,
the problem becomes dynamic. To overcome this issue, we are going to
multiply the loads by a dynamic load factor G=2. We can then consider the
problem as static and we can use static point forces on the nodes. For the
second loading case, we will consider a force of 1000 N applied on the front
dropout of the bike frame.
3.1 Boundary Conditions and applied forces

Given the above assumptions on loading, we can further assume that the
boundary conditions will not change over time. We know from the problem
description that the left hand support is fixed by a ball joint and that the rear
dropouts have sliding conditions as in Figure 2 .

1800

Figure 2: Boundary conditions for vertical loading

3.2Calculations

y1212
x
Θ1
u
v
Θ 600 N
U
U
U
Figure 3 : Local displacements on element 1 Figure 4 : Global
displacements on element 1
Y
U U
Angle Θ1 Θ3 Θ4 ΘX6
Θ
Degrees 75.068 76.000 140.906 U 129.000
Radians 1.310 1.326 2.459 2.251
Table 6 : Angles of orientation of the elements

Din(m) Dout(m) A(m2) E(Pa) σ(Pa) ρ(kg/m3) I


6.28319E- 70000000 21000000 8.16814E-
0.008 0.012 05 000 0 2580 10
Table 7: Material and geometry parameters of the pipes

-
5.67E+07 0 0 0 0
5.67E+07
0 1.47E+06 5.69E+04 0 -1.47E+06 5.69E+04
0 5.69E+04 2.95E+03 0 -5.69E+04 1.47E+03
[k1] -5.67E+07 0 0 5.67E+07 0 0
= -
0 -1.47E+06 -5.69E+04 0 1.47E+06
5.69E+04
0 5.69E+04 1.47E+03 0 -5.69E+04 2.95E+03
0.2576724 0.9662323
79 19 0 0 0 0
-
0.9662323 0.2576724
2 79 0 0 0 0
0 0 1 0 0 0
[R1]
0.2576724 0.9662323
= 0 0 0 79 19 0
-
0.9662323 0.2576724
0 0 0 19 79 0
0 0 0 0 0 1

-
0.2576724 0.9662323
79 2 0 0 0 0
0.9662323 0.2576724
19 79 0 0 0 0
0 0 1 0 0 0
[R1]T -
= 0.257672 0.9662323
0 0 0 48 2 0
0.966232 0.2576724
0 0 0 32 79 0
0 0 0 0 0 1

- - - -
14600653. 1417630.8 55018.2527 14600653 1417630.8 55018.25
89 36 3 .9 36 27
- -
54750215. 378050.33 14672.1335 54750215 378050.33 14672.13
09 54 1 .1 54 351
[K1e] -
= 56941.018 2946.50792 56941.018 1473.253
0 92 6 0 92 963
- -
14600653. 1417630.8 55018.2527 14600653 1417630.8 55018.25
89 36 3 .89 36 273
- - - -
54750215. 378050.33 14672.1335 54750215 378050.33 14672.13
09 54 1 .09 54 35
-
56941.018 1473.25396 56941.018 2946.507
0 92 3 0 92 926

[K1e]= [R1]T*[k1]* [R1]


Horizontal loading
Boundary Conditions and applied forces

Figure 5 : Boundary conditions and loading

2000
4.ANSYS Simulation 2D

4.1Vertical loading

4.1.1 Units

SI system is the default system of units in ANSYS and is the system used to model
the problem. The d

4.1.2 Element Type

Given the 3D nature of the structure it should be clear that a 3D analysis is


required. The bicycle frame is made of a number of long beams that would
be expected to bend due to the applied loads so a truss analysis would not
be appropriate. A 3D pipe16 is the most suitable geometric model here. A 3D
solid model would overkill and would not estimate bending stress correctly.

4.1.3 Material Properties

As known, the bicycle frame is constructed from aluminum. We will assume a linear
material model for aluminum. This is valid considering the problem, as a bicycle
would not be expected to deform significantly or yield under operating conditions.
We will, however, take a note of the assumed yield stress and use this to ensure
that our linear elastic model is valid and to determine the load that causes yielding
of the structure.

4.1.4 Meshing

As a first attempt to get preliminary results, we are going to mesh the elements
with 3 subdivisions.

4.1.5 Boundary conditions


Ball-joint boundary conditions are used for the front dropout (location1) and sliding
conditions for the rear dropouts (location 5). All the translation movements along z
are constrained. Node number 1 is constrained from any translational movement
and node number 5 is constrained from translation along the y axis.

4.1.6 Results

Figure 6 shows the deformed shape of the structure due to the applied loading. It is
clear from the figure that both the saddle and pedal points are displacing
downwards and forwards, while the rear wheel attachment point is moving
forwards. This deformation seems reasonable considering the loads and boundary
conditions applied. In order to quantify the deformation Figure 7 shows a nodal
distribution of displacement vector sum. It can be seen here that the maximum
displacement is and occurs at the saddle point and at the front o f the top bar.
Again, this level of displacement and its locations seem reasonable based on the
applied loads. One would expect the displacement of a bicycle frame when the rider
sits on it not to be noticeable to the rider and a deformation of 0.0079 mm would
certainly not be noticed by the rider.

Figure 6 : Deformed and un-deformed edge


Figure 7: Nodal displacement sum

shows an elements plot of the distribution of Von-Mises stress in the pipe model.
This figure is rather difficult to read, as is normally the case for such pipe models, so
in order to aid visualization the stress distribution has been converted into a bar
graph and mapped onto the pipe model, as shown in . It can be seen from the figure
that the maximum stress is and it is located around the front of the bicycle frame.
Von mises contour plot

Von mises magnitude


Axial stresses

The results around the front of the frame and indeed at all of the joints give some
cause for concern as stress is changing too rapidly from high values to low values
across the joints. This is an indication that a finer mesh is required in these
locations and this will be discussed in the next section.

4.2Horizontal loading

4.2.1 Units

SI system is the default system of units in ANSYS and is the system used to model
the problem. The distances are entered in mm and the stresses will be given in MPa.

4.2.2 Element Type

Given the 3D nature of the structure it should be clear that a 3D analysis is


required. The bicycle frame is made of a number of long beams that would
be expected to bend due to the applied loads so a truss analysis would not
be appropriate. A 3D pipe16 is the most suitable geometric model here. A 3D
solid model would overkill and would not estimate bending stress correctly.

4.2.3 Material Properties


As known, the bicycle frame is constructed from aluminum. We will assume a linear
material model for aluminum. This is valid considering the problem, as a bicycle
would not be expected to deform significantly or yield under operating conditions.
We will, however, take a note of the assumed yield stress and use this to ensure
that our linear elastic model is valid and to determine the load that causes yielding
of the structure.

4.2.4 Meshing

As a first attempt to get preliminary results, we are going to mesh the elements
with 3 subdivisions.

4.2.5 Boundary conditions

Ball-joint boundary conditions are used for the rear dropout (location 5) and no
translation along y-axis for the front dropouts (location 1). All the translation
movements along z are constrained.

4.2.6 Results
5.Result Verification

5.1Comparison with calculations

Table 8 and Table 9 show a comparison of the displacements previously


calculated and the results given by ANSYS simulation. The error is generally
around 7% which is a reasonable result for a preliminary study using a coarse
mesh with 3 subdivisions. Generally, the ANSYS results tend to slightly
underestimate the theoretical results in both loading cases.

Table 8 : Comparison of results for vertical loading case

DOF ANSYS Theory Err


U2 -0.0055446 -0.0060 -8%
V2 0.0014724 0.0016 -8%
U3 -0.0056491 -0.0060 -6%
V3 -0.0026222 -0.0029 -11%
U4 -0.0026462 -0.0028 -6%
V4 -0.0034917 -0.0037 -6%
U5 -0.0025435 -0.0027 -6%
Table 9: comparison of results for the horizontal loading case

DOF ANSYS Theory Err


U1 0.002588 0.0027 -4%
U2 -0.002236 -0.00230 -3%
V2 0.0012812 0.00130 -1%
U3 -0.0023258 -0.00240 -3%
V3 -0.0019129 -0.00210 -10%
U4 0.00013707 0.00013 4%
V4 -0.0027396 -0.00280 -2%

5.2Convergence analysis

1. ANSYS Simulation 3D
The structure and loading are symmetrical about the mid-plane; however,
given the simple nature of the geometry it would probably take more time to
build a symmetric model than the full model, so in this case the full
geometry will be modeled.

2.Design optimization
2.1Failure criteria calculations

Equivalent Von-Mises stress

σaxial=FxA

σb= -M*CcI

M : applied bending moment

I : moment of inertia of cross-section about neutral axis

Cc : distances from neutral axis

σx= σaxial+σb
Maximum shear stress

τxy=2*FyA

In 2-D

σ=σx2+σxσy+σy2+3τxy2

σy=0

σ=σx2+3τxy2

In 3-D

σ=((σx-σy)2+(σy-σz)2+(σz-σx)2+6(τxy2+τyz2+τzx2))/2

Yielding

We will assume that the yielding takes place once the von mises stress
exceeds the uniaxial yield stress for the material σy.

Given the axial yield strength σy=210 MPa and a safety factor n = 1.5

σmax= σy1.5

σmax=2101.5=140 MPa

Buckling

B=Sy* l2C*π2*E

k= IA

Sy : yield strength of column

k: Radius of gyration of column

I: Moment of inertia of column

A: Area of column cross-section

C=4 (Welded joints)


Conclusion
Appendices
Element N⁰2
-
8796459. 8796459.
43 0 0 43 0 0
-
5488.9906 1372.247 5488.9906 1372.247
0 84 67 0 8 67
-
1372.2476 538.1363 1372.2476 228.7079
0 71 42 0 7 45
[K2e] -
= 8796459. 8796459.
43 0 0 43 0 0
- - -
5488.9906 1372.247 5488.9906 1372.247
0 8 67 0 84 67
-
1372.2476 228.7079 1372.2476 538.1363
0 71 45 0 7 42

Element N⁰3

-
1.05E+07 0 0 0 0
1.05E+07
0 9.42E+03 1.37E+03 0 -9.42E+03 1.37E+03
0 1.37E+03 5.48E+02 0 -1.37E+03 2.74E+02
[K3]= -1.05E+07 0 0 1.05E+07 0 0
-
0 -9.42E+03 -1.37E+03 0 9.42E+03
1.37E+03
0 1.37E+03 2.74E+02 0 -1.37E+03 5.48E+02

0.2419218 0.9702957
96 26 0 0 0 0
-
0.9702957 0.2419218
3 96 0 0 0 0
0 0 1 0 0 0
[R3] 0.2419218 0.9702957
= 0 0 0 96 26 0
-
0.9702957 0.2419218
0 0 0 26 96 0
0 0 0 0 0 1

-
0.2419218 0.9702957
96 3 0 0 0
0.9702957 0.2419218
26 96 0 0 0
0 0 1 0 0
-
[R3]T=
0.241921 0.9702957
0 0 0 9 3
0.970295 0.2419218
0 0 0 73 96
0 0 0 0 0

- - - -
625277.41 2470063.0 1331.486 625277.4 2470063.0 1331.486
35 7 05 13 7 05
- -
2470063.0 9916303.3 331.9767 2470063. 9916303.3 331.9767
8.53E+06 7 0 87 0 58 - 07 0 9 0 58
- 8.53E+06 -
0
1331.4860 5.01E+03
331.97675 1.29E+03
547.6722 0
1331.486 -5.01E+03
331.97675 1.29E+03
273.8361
0 5 1.29E+0378 83
4.44E+02 0 05 8
-1.29E+03 41
2.22E+02
- -
-8.53E+06 0 0 8.53E+06 0 0
625277.41 2470063.0 1331.486 625277.4 2470063.0 1331.486
0 3 -5.01E+03 7 -1.29E+03
05 0 13 5.01E+03
7 - 05
- - - 1.29E+03-
0
2470063.0 1.29E+03
9916303.3 2.22E+02
331.9767 0
2470063. -1.29E+03
9916303.3 4.44E+02
331.9767
7 9 58 07 87 58
- -
1331.4860 331.97675 273.8361 1331.486 331.97675 547.6722
5 78 41 05 8 83

[K3e]
=

Element N⁰4

[K4]=
-
0.766044 0.6427876
44 1 0 0 0 0
- -
0.642787 0.7660444
61 43 0 0 0 0
0 0 1 0 0 0
-
0.7660444 0.6427876
0 0 0 43 1 0
- -
0.6427876 0.7660444
0 0 0 1 43 0
0 0 0 0 0 1

[R4]=

[R4]
= - -
0.766044 0.642787
44 61 0 0 0 0
-
0.642787 0.766044
61 44 0 0 0 0
0 0 1 0 0 0
[R4]T - -
= 0.7660444 0.642787
0 0 0 4 61 0
-
0.6427876 0.766044
0 0 0 1 44 0
0 0 0 0 0 1
- - - -
5009806. 4199521. 830.1396 5009806. 4199521. 830.1396
659 76 92 66 757 92
- - - -
4199521. 3528828. 989.3219 4199521. 3528828. 989.3219
76 675 6 76 68 6
- -
830.1396 989.3219 443.7484 830.1396 989.3219 221.8742
92 6 38 92 599 19
- -
5009806. 4199521. 830.1396 5009806. 4199521. 830.1396
66 757 92 66 76 92
- -
4199521. 3528828. 989.3219 4199521. 3528828. 989.3219
757 68 6 76 675 6
- -
830.1396 989.3219 221.8742 830.1396 989.3219 443.7484
92 6 19 92 599 38

[K4e]
=

Element N⁰5

-
10348775 10348775
.8 0 0 .8 0 0
-
8937.904 1899.304 8937.904 1899.304
0 636 74 0 64 74
-
1899.304 538.1363 1899.304 269.0681
0 735 42 0 74 71
[K5e] -
= 10348775 10348775
.8 0 0 .8 0 0
- - -
8937.904 1899.304 8937.904 1899.304
0 64 74 0 636 74
-
1899.304 269.0681 1899.304 538.1363
0 735 71 0 74 42
Element N⁰6

-
[K6] 8.74E+06 0 0 0 0
8.74E+06
= 0 5.39E+03 1.36E+03 0 -5.39E+03 1.36E+03
0 1.36E+03 4.44E+02 0 -1.36E+03 2.27E+02
-8.74E+06 0 0 8.74E+06 0 0
-
0 -5.39E+03 -1.36E+03 0 5.39E+03
1.36E+03
0 1.36E+03 2.27E+02 0 -1.36E+03 4.44E+02

-
0.629320 0.7771459
39 61 0 0 0 0
- -
0.777145 0.6293203
96 91 0 0 0 0
0 0 1 0 0 0
[R6] -
= 0.6293203 0.7771459
0 0 0 91 61 0
- -
0.7771459 0.6293203
0 0 0 61 91 0
0 0 0 0 0 1
- -
0.6293203 0.777145
9 96 0 0 0
-
[R6]T 0.7771459 0.629320
3466264. - - - 4273822. -
= 61 39 0 0 0
434 4273822. 1053.753 3466264. 314 1053.753
0 31 0 76 1 43 0 0 76
- 5283122. - 4273822. - - - -
4273822. 386 853.3129 0.629320
31 0.777145
5283122. 853.3129
31 0 0 66 0 39 39 96 66
- - 443.7484 1053.753 -
853.3129 227.3438
[R6e] 1053.753 853.3129 38 0.777145 661
76 0.629320 82
= 76 0 66 0 0 96 39
- 4273822.
0 1053.753
0 3466264.
0 0 - 1053.753
0
3466264. 314 76 43 4273822. 76
43 31
- -
4273822. 5283122. 853.3129 4273822. 5283122. 853.3129
314 39 66 31 386 66
- -
1053.753 853.3129 227.3438 1053.753 853.3129 443.7484
76 66 82 76 661 38

References

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