Your Friendly Neighbourhood Folding Bike Company

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Your Friendly Neighbourhood Folding Bike Company
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Our Team

• 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

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Mission Statement

• 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.

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Timeline of Events

• 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

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Timeline of Events The Sequel

• 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

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Cost Analysis

• Tubing
• 315
• Machine Time
• 675
• Recycled Parts
• 386
• New Parts
• 397.91
• Miscellaneous
• 206.09
• Grand Total
• 1980

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The Kmax DFS
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Frame Construction

• 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)

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Rear Triangle

• 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

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Cable and Brake Mounts

• 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

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Locking Mechanism

• 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

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Changes and Finishing Touches

• 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

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Technical Specifications

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

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The DFS Hinge

• 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

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The DFS Hinge
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The C-Clamp

• 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

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DFS Geometry
10
50
59
80
30
50
49
72
10
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Componentry

• 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

• 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

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Finite Element Analysis

• 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.

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Model Mesh
Element Size 20 mm of Nodes 160
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Imposed Constraints/Application of Loads
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FEA Static Analysis
Critical Areas
Maximum Stress 31.895 MPa
Failure Strength 813 MPa
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FEA Dynamic Analysis
Critical Areas
Maximum Stress 53.252 MPa
Failure Strength 813 MPa
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So You Did an FEA

• 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.

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So you've got a folding bike

• 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.

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So you mean its not perfect

• 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

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So this presentation is done then ?

• In conclusion the Kmax Designs Team believes that
  weve 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.

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So anyone have any questions ?