Your Friendly Neighbourhood Folding Bike Company

1. Your Friendly Neighbourhood Folding Bike Company

2. 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

3. 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.

4. 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

5. 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

6. Cost Analysis • Tubing • $315 • Machine Time • $675 • Recycled Parts • $386 • New Parts • $397.91 • Miscellaneous • $206.09 • Grand Total • $1980

7. The Kmax DFS

8. 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)

9. 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

10. 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

11. 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

12. 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

13. Technical Specifications The Folding Mechanism Aluminum C - clamp Frame Geometry Final Componentry & Peripherals

14. 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

15. The DFS Hinge

16. 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

17. DFS Geometry 10° 50° 59° 80° 30° 50° 49° 72° 10°

18. 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 Componentry

19. 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.

20. Model Mesh Element Size = 20 mm # of Nodes = 160

21. Imposed Constraints/Application of Loads

22. FEA Static Analysis Critical Areas Maximum Stress: 31.895 MPa Failure Strength: 813 MPa

23. FEA Dynamic Analysis Critical Areas Maximum Stress: 53.252 MPa Failure Strength: 813 MPa

24. 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.

25. 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.

26. 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

27. So this presentation is done then ? • 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.

28. So anyone have any questions ?