Product Dissection Project

Bicycle

Prepared for:
Jim Hillier
April 19, 2010
Group:
Admir Mujanovic:
Harmeet Kaur: 5930524
Jamie Dilliott: 5775655
Maha Ali:
Table of contents

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INTRODUCTION:
The consumer product that we chose to analyze is the basic bicycle. The bicycle is a two
wheeled, human powered way of transportation. It is made up of a frame that sits on two wheels,
one behind the other. The pedals, which are connected to the crank shaft, are moved in a forward
motion by the rider. This moves a chain across the sprocket rotating in a continuous motion.
Because the chain is attached to the rear wheel the forward pedalling propels the rear wheel to
move ahead. The cyclist is able to control the bicycle by the use of the handle bars that are
extended above the forks of the front of the frame. Attached to the handlebars are the breaks that
allow him to safely stop the bike at any time. There is also a seat that sits on the top of the frame,
extended slightly over the rear tire, which allows the cyclist to comfortably sit on the bike while
operating it.

The two tires are connected to the frame with the use of an axle and a tightening mechanism to
hold the tire in place. The sprocket is connected by a shaft that goes through the centre hole of
the sprocket as well as the centre hole in the crankshaft. The use of a nut and threads at the end
of the shaft secure it into place. Threads are also used to keep the pedals in place at the end of the

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crank shaft. The chain is held on by the teeth on the sprocket which allow it to freely ride along
the sprocket. The chain needs to be tight enough to stay on the sprocket. The handle bars are held
on by a clamp with a bold. The breaks are normally held on to the frame using a bolt and treaded
hole that have been drilled into the frame or bracket that has been welded onto the frame. The
seat is held onto the frame by inserting the shaft of the seat into the frame tubing and the use of a
clamp with the same tightening mechanism that is used for the tires allows the seat to stay tightly
in place.

DISASSEMBLY
The bicycle is fairly simple to disassemble. The only tools you need to disassemble a bicycle are
a set of wrenches and possibly a set of Allen keys. Newer bicycles commonly have joining
methods which allow you do disassemble the bicycle to some degree with no tools required in
order to transport the bicycle. These are commonly found on the tires and on the seat. The
ability to easily disassemble a bicycle is a big selling feature to some riders. Not everyone has a
big enough vehicle to transport a bicycle so the ability to quickly disassemble and assemble a
bicycle is a nice feature.

FRAME AND FORKS

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FRAME:
A Bicycle frame is the main component of the bicycle, onto which the wheels and other
components are fitted. The frame comprises of the major of the body of the bicycle, which is
connected to wheels .The modern and most common frame design for an upright bicycle is based
on the safety bicycle and consists of two triangles, a main triangle and a paired rear triangle.

The Head Tube contains the head set, the bearings for the fork through the steerer tube. The top
tube connects the top of the head tube to the top of the seat tube. The down tube connects the
head tube to the bottom bracket shell. The seat tube consists of the seat post of the bike, which
connects to the saddle. The chain stays run parallel to the chain, connecting the bottom bracket
shell to the rear dropouts. The seat stays connect the top of the seat tube (often at or near the
same point as the top tube) to the rear dropouts. 

As its function suggest, the frame supports the whole weight of the person riding the bicycle. So,
it has to be strong enough to carry the load, for which a strong material should be used for
manufacturing it. In addition to this, the cost factor should also be taken care of. Generally, tubes
are made of steel. But other possible materials can be Aluminum alloys, Titanium, Carbon fibre
and even Bamboo. Steel frames are often built using various types of steel alloys. They are
strong, easy to work and often inexpensive but denser than many other structural materials.

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The method often used in building steel frames is called Lugged Steel Frame Construction,
which includes steel tubing and sockets called lugs. Lugged steel construction uses standard
cylindrical steel tubes which are connected with lugs, external fittings made of pieces of steel
(sometimes stainless steel) which fit over the ends of the tubing. 

Frame tubes are constructed from solid blocks of steel that are pierced and drawn into tubes
through several stages. Steel tubes can be manufactured using extrusion process and can be of
any length because before assembly, the frame builder cuts the tubes to desired length and
precisely mitres their ends, so that they fit closely together. The ends of the tubes are inserted
into the lugs and are then brazed together with a silver or brass filler metal.

Lugs used today on higher performance bicycles are investment cast (lost wax process). Copies of
the lugs are made in wax, and they are attached together into a "tree". The tree is surrounded by
ceramic and fired in a kiln, thereby melting the wax and setting the ceramic. Finally, molten steel
is poured in to produce the lug. Cast lugs have many advantages over stamped lugs: they allow
much finer detail, tighter tolerances, and more accurate angles and they can be made from
superior materials. Lugs can also be made by stamping, in which stamped lugs are formed by
pressing sheet metal over mandrel, bending them to shape, and then welding the seams. A
relatively recent trend is using stainless steel for investment cast lugs. Lugs are usually brazed
with the steel tubes to keep them precisely joined together.

The critical features for the bike frame can be the material of choice for its manufacturing.
Because the material’s weight decides how easy it is to ride the bike. For example, Steel frames
go soft with age, but they have a nicer ride quality. Also, Aluminum frames have a harsh ride
and titanium ones have a soft and whippy one.

The frame as we know is the outer body of the bicycle which is always exposed to all kinds of
weather conditions while riding. So, the frames are painted, not only to create a more finished
appearance, but also to protect the frame. The frame is first primed with an undercoat and then
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painted with a colored enamel. Paint may be applied by hand-spraying or by passing the frames
through automatic electrostatic spraying rooms.

FORKS:
A Fork is a portion of the bicycle that holds the front wheel and allows the rider to steer and
balances the bicycle. A fork consists of two dropouts which hold the front wheel axle, two blades
which join at the fork crown and a steering tube to which the handle bars attach, allowing the
user to steer the bicycle.

Forks are made from steel, aluminum, carbon fibre, titanium, magnesium and various
combinations.  For example, a fork may have carbon fibre blades with an aluminum crown, steer
tube, or dropouts.

Moulding processes can be used to manufacture bicycle forks. Talking about the critical features,
in rigid forks the material, shape, weight, and design of the forks can noticeably affect the feel
and handling of the bicycle. Carbon fibre forks are popular in road bicycles because they are
light and also because they can be designed to lessen and absorb vibrations from the road
surface. The similar finishing methods as in frame can be used in forks, even chrome plating can
be used in parts such as fork blades.

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TIRES AND RIMS

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TIRE
A Tyre is a ring shaped covering that fits around a rim to protect it and enable better vehicle
performance by providing a flexible cushion that absorbs shock while keeping the wheel in close
contact with the ground. The fundamental materials of modern tires are rubber and fabric along
with other compound [Link] the vast majority of tires are pneumatic (air filled).
Pneumatic ire is made of an airtight inner core filled with pressurized air. A tread, usually
reinforced with steel belting or other materials, covers this inner core and provides the contact
area with the road. The pressure of the air inside the tire is greater than atmospheric air pressure,
so the tire remains inflated even with the weight of a vehicle resting on it.

Pneumatic tires are manufactured according to a relatively standardized process and machinery.
This process involves many important steps like:

 Compounding and Mixing:

Compounding is the operation of bringing together all the ingredients required to mix a
batch of rubber compound. Each component has a different mix of ingredients according
to the properties required for that component.
Mixing is the process of applying mechanical work to the ingredients in order to blend
them into a homogeneous substance.
 Component Preparation:
Components fall into three classes based on manufacturing process - calendaring,
extrusion, and bead building. The extruder machine consists of a screw and barrel, screw
drive, heaters, and a die. The extruder applies two conditions to the compound: heat and
pressure. The extruder screw also provides for additional mixing of the compound
through the shearing action of the screw. The compound is pushed through a die, after
which the extruded profile is vulcanized in a continuous oven, cooled to terminate the

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 vulcanization process, and either rolled up on a spool or cut to length. The calendar is a
set of multiple large-diameter rolls that squeeze rubber compound into a thin sheet.
 Tire Building:
Tire building is the process of assembling all the components onto a tire building drum.
 Curing:
Curing is the process of applying pressure to the green tire in a mold in order to give it its
final shape, and applying heat energy to stimulate the chemical reaction between the
rubber and other materials. In this process the green tire is automatically transferred onto
the lower mold bead seat, a rubber bladder is inserted into the green tire, and the mold
closes while the bladder inflates.
 Final Finish:
After the tire has been cured, there are several additional operations involved, like tire
uniformity measurement, tire balance measurement etc. In the final step, tires are
inspected by human eyes for numerous visual defects such as incomplete mold fill,
exposed cords, blisters, blemishes, and others.

The critical features of tires can be the variation in air pressure and tire performance. The air
pressure in the tires should be maintained; neither should it be low nor high, for the excellent
performance of the bicycle.

RIMS:

The rim is a large hoop attached to the outer ends of the spokes of the wheel that holds the tire
and tube. It is commonly a metal extrusion that is butted into itself to form a hoop, though may
also be a structure of carbon fibre composite, and was historically made of wood. Metallic
bicycle rims are now normally made of aluminum alloy. Rims designed for use with rim brakes
provide a smooth parallel braking surface, while rims meant for use with disc brakes or hub
brakes sometimes lack this surface.

A standard automotive steel wheel rim is made from a rectangular sheet metal. The metal plate is
bent to produce a cylindrical sleeve with the two free edges of the sleeve welded together. The
sleeve is then shaped to obtain the rims on each side with a radially inner cylindrical wall in the
zone of the outer seat and with a radially outer conical wall inclined at an angle corresponding to
the standard inclination of the rim seats. The rim is then calibrated. One-piece rim and wheel
assemblies may be obtained by casting or forging.

Sprocket

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A Sprocket is a wheel with teeth around the outside circumference which a chain rides on. A
sprocket and a gear are commonly mistaken. A sprocket is never meshed together with another
sprocket like gears are. The purpose of the bicycle’s sprockets is to provide a pathway for the
chain to ride which allows the bicycle to move. There are different sprocket sizes for bicycles
each performing in a different way. The larger the diameter of the driven sprocket, the easier it is
to peddle the bicycle. The smaller the diameter of the driven sprocket, the harder it is to peddle
but the bicycle is able to travel at faster speeds.

The area on the sprocket that will absorb the most workload is the teeth. The teeth are in constant
contact with the chain and the friction along with the load causes the teeth to wear over time.
This mean that the material the sprocket is made out of should be hard enough to withstand the
wear caused by the chain.

Like the rest of the bicycle, the sprocket is exposed to the outdoors. It must be protected with
some kind of finish and be properly taken care of in order to prevent rust and allow it to perform
better, as well as have a longer life span.

There are several materials a bicycle sprocket can be made of. It all depends on the style of
bicycle and the amount of money you want to spend. A standard bicycle’s sprocket would be
made out of a plain carbon or alloy steel. Higher end bicycles or after market sprockets could
come in a variety of materials giving the sprocket less weight or a stronger structure. An example
of one of these materials would be aluminum. There are a few critical features about the sprocket
that would need to be more precise than others. One is the diameter of the sprocket. The diameter
of the sprocket affects the speed that the bike can travel and the amount of effort needed to pedal
the bicycle. The second part of the sprocket that needs to be precise is the teeth. The chain must
be able to smoothly ride over the sprocket without any problems at all. The chain will not be able

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to do this if the sprocket is not accurate and precise and the rider will have a difficult time
pedaling the bicycle. All sprockets will have a protective finish on them to prevent rust and other
damage from harsh conditions such as rain, gravel, and mud. It could be some kind of paint,
powder coat, clear chemical protector, or a galvanized coating.

A bicycle sprocket can be made a couple of different ways. Depending on the size and quality of
the sprocket, it can either be stamped out of a sheet of material or it can be machined using a mill
or a CNC machine. A higher quality sprocket will be made out of a more expensive material
such as aluminum and will be CNC machined which will allow the rider to perform better due to
the higher precision and quality of the part. A standard bicycle sprocket will most likely be
stamped out of a steel alloy. This method is more cost effective and the average rider or child
will not be as interested in the performance of the bicycle, so it does not need to be as precise.
Their main priority is getting from one place to the other. The design of a sprocket on the bicycle
is such that it is made of one piece of material that is formed into its appropriate shape and size.

Chain

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The bicycle chain is a key part of the bicycle. Without the chain the bicycle would not be able to
move. The bicycle chain’s job is to transfer power from the pedals to the rear wheels, thus
allowing the bike to move. The bicycle chain is known as a roller chain which is a chain that is
used for the transmission of mechanical power.

The most important quality a bicycle chain should have is a good tensile strength and low fatigue
rate. Wear, over a period of time, causes the chain to stretch. The higher the tensile strength of
the chain the longer it takes the chain to stretch which results in a longer life span for the chain.
Fatigue also causes the bicycle chain to fail. The gearing on a bicycle causes the chain to twist.
The lower the fatigue rate of the chain, the quicker it will need to be replaced. Proper
maintenance of the bicycle and the environmental conditions also have an effect on the chains
wear and life time. If you store a bicycle outside and the chain is not properly lubricated on a
regular basis, the chain will start to rust, cease up and will not properly function. However, if a
bicycle is stored inside and not out in the rain and snow, and the chain is properly lubricated, the
chains life time will be much longer and the bicycle will perform a lot better. The sustainability
of the chain depends on the environment conditions as well as the quality of the material it is
made of.

There are a variety of materials that bicycle chains are made of. Like everything it all depends on
what you would like to spend. Most bicycle chains are made from plain carbon or alloy steel.
These are your cheapest and most commonly seen option for a chain. However, some bicycle
chains are chrome plated or made of stainless steel in order to prevent the chain from rusting.
Some of the higher end bicycles will even have titanium chains. The type of material all depends
on what the bicycle is being used for and what you would like to spend on it.

The critical features of a bicycle chain are the inner links. These are the links on the chain that
come in contact with the sprocket. The inner links require a smooth surface finish so they travel
easily on the sprocket.

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Another critical feature is the outer links. This is the piece that is used to connect the inner links
together. They do not come in contact with the sprocket so they do not need as smooth of a finish
as the inner links.

The pins are put into the holes of the inner and outer links to connect them together. They have
to have a high tolerance in order to slide into the holes and fit snugly. They also require a high
shear strength to withstand the pulling forces in opposite directions.

All parts must be kept well lubricated regardless of the quality of material used.

The retaining rings and spacers are used.....

Depending on the material being used the manufacturing of the bicycle chain may be different.
The most common material used for a bicycle chain is plain carbon or alloy steel so this is the
manufacturing method that will be described.

 A punch press is used to cut steel into the shape of the inner links or the chain
 The links are then baked in an oven. This process hardens the steel.
 The inner links then get polished using ceramic and abrasive powders mixed with water.
 A chemical bath is the next process. This helps the links to resist corrosion and gives it a
smooth texture which allows the chain to travel easily over the gear sprockets of the
bicycle.
 The chains outer links are manufactured the same way except they have a different finish
because they do not have to travel over the bicycle’s sprockets.
 Then the chain is ready to be assembled using an assembly machine.
 The links, along with the use of retainer rings and spacers, are used to form a long chain
when the machine presses pins into the links holes.
 The long chain then is inspected to make sure there are no defects.
 The chain is placed in hot oil to lubricate the links.

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  Finally a laser is used to determine the exact length the bicycle chain needs to be and a
blade is used to cut the chain.

The finishing methods include a chemical bath to help resist corrosion and give the inner links as
smooth finish. Also, once the pieces are assembled the completed chain is dipped in hot oil
which lubricates the chain.

The Brake Assembly

The brake on a bicycle is one of the key features that you will need to stop other then
jumping off. There are many types of brakes since the invention of the bike. The three main
types of brakes are: rim brake, disk brake and not so common drum brakes. Almost all of these
brakes work on the same principal; this principal consists of converting the kinetic energy of
your bike to heat, sound, and even light energy this energy is dissipated by the brake. The brake
functions by force acting on the wheel or the gears, the rider of the bike applies this force. This
force is transferred either by mechanical or hydraulic power, by the riders hand or feet. The rim
brake is the most common these days, but the disk brakes is slowly becoming more popular due

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to its better performance and stopping power. The rim brake as with others consists of similar
parts the handle, the cable and the shoes.

THE HANDLE

Brake handle

The handle on the brake assembly is what the rider of the bike uses to transfer the action
of squeezing his hand to the shoes squeezing the rim of the tire. The handle is not is not just a
handle it consists of more than one part. The parts of the handle consist of the main lever, lever
housing adjustable screw, and adjustable cable screw. The lever on the brake handle is usually
made from plastic, this plastic is a high density plastic it probably injection molded as with the
rest of the handle. Other than just plastic these parts can be made from aluminum for greater
strength for serious riders and they are casted. Tolerances on the handle are not that great, except
the threads for the adjustable screws. Tolerances would not be accepted greater than 0.1 of an
inch. Tolerances are not that great due to that everything can be adjusted anyways to fit the right
position in the rider’s hand.

BOWDEN CABLE

Bowden cable

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 A Bowden cable is the way mechanical energy is transferred from the brake handle to the
actual braking mechanism. The Bowden cable consists of four main materials: protective plastic
coating, steel structure, and inner sleeve to reduce friction, inner cable (usually made form steel
or stainless steel). The protective plastic coating has to be made from a material that is resistant
to water and sun. Water because to protect the cables inside and sun so that it doesn’t ware out
over time and start to crack because of the long exposure to the sun. The steel structure is made
in a helix construction this causes the cable to be flexible and hold its shape when the cable is
moving inside. The inner plastic could be made from a low friction materials maybe Teflon due
to its low friction. The tolerances are of this cable must be close due to their close moving parts
and the less the gap the better the performance of the cable.

V-BRAKES

A V-brake

THE V - BRAKE
The V-brake is one of the more common breaks due to its simplicity. Other brakes follow
the same principal. Pulled by a cable the two half’s close exerting force on the rim of the tire,
this is how almost all types of brakes work. A V-brake is made from aluminum, to keep the
weight down, some can be made from steel to gain strength. The V-brake can be easily
disconnected, usually for those bikes that the tire can be removed. To adjust the brakes turn the
two screws on the side to increase the tension on the springs. The tolerance of this part is not that
critical due to the adjustment features. But the holes and threads of this part need to within
tolerance to achieve a tight fit and minimize ware on the shafts. The brake pads are the part that

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makes contact with the rim itself. Usually made from a harder rubber. An inside made from
metal holds the rigidity of the rubber and the rubber is injected around this frame.

The Seat
The seat is where the biker sits, the seat is designed to be ergonomic so that the biker can peddle
and not have the seat get in the way. Arthur Garford in 1892 was credited for the invention of
the padded bike seat. The most common type of seat is the hard-shell seat.

A normal hard-shell seat

The hard-shell seat is padded with usually closed or open cell foam and a vinyl or leather outer
layer so that no rain gets into the foam. Hard-shell part of the bike seat is made from a high
density plastic so that it retains its strength in this injection molding process the attachments are
molded as one part. The attachments are a solid metal bar stock ¼ of an inch thick on both sides.
These are in place to hold the bike seat to the bike with one more bracket. This bracket is made
from aluminum and had close tolerances due to the tight fitting of the bar that goes into the bike
frame. The tolerances can be really high here and the metal tube is sometimes heated and shrunk
onto this bracket.

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 The picture above illustrates how the seat assembly is put together.

The use of different fasteners on the seat is used raging from a normal bolt and nut to hex head.
All of these have their own purpose for being where they are. For example the bolt and but used
to lift and lower the seat is used because it had a high strength and only one is used. The hex
head screws are used because when disassembling the seat in the future you cannot use a bolt
because of the minimal clearance between the parts so that’s why the hex head is used in this
situation.

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