Experimental Development of Composite Bicycle Frame

Abstract

This article focuses on the development of a carbon composite bicycle frame using various experimental methods of structural analysis. Two types of frame specimen were used. The complete frame specimen was tested in accordance with ISO test load cases with the addition of an ergometer test in order to refine the operational strain envelope of such a frame. Resistive strain gauges and optical Fiber Bragg Grating (FBG) sensors were used for this analysis. The FBG sensors were embedded inside the head tube joints during the manufacturing process. The head connection was designed as a geometrically precise form–connection of wound composite tubes, reinforced with a wrap of high-strength unidirectional carbon tapes and carbon fabrics. Additional structural strength laboratory tests were conducted using simplified frame specimens, in order to evaluate the range of the limit case strain ranges. The digital image correlation method was used for the evaluation of the strain distribution in the head tube area. Resistive strain gauges were used for local strain analysis in critical areas. The acoustic emission method was used to detect structural defects before they could influence the stiffness response of the frame. It was found that the joints of the frame tubes are crucial for the strength and safety of the frame. Therefore, attention was also focused on the strengthening of the head tube joint, and on its experimental verification. A positive effect on the strength of the reinforced frame was found by doubling the thickness of the carbon fabric in the head tube joint area.