Topological Optimisation of Bicycle Frame Connections Using 3D Printing Design
Font i Codinachs, Roc; Zurita Sánchez, Raúl (2023)
2023
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2023060923343
https://urn.fi/URN:NBN:fi:amk-2023060923343
Tiivistelmä
This thesis discusses the Additive Manufacturing design, optimisation and 3D metal printing of the union nodes of a bicycle frame. A first prototype was already developed, hence this second model had to improve the previous in terms of visual aspects and weight reduction.
The components were printed using the Prima Additive - Print Sharp 250 printer installed in the laboratory, using Stainless Steel 316L as the material. The joint tubes between the union nodes were made of Aluminium 6060 and assembled through an engineered mechanical joint.
The average reduction of 50% of the components’ mass was achieved using Design for Additive Manufacturing techniques in Altair and nTopology software. The head tube experienced an 81% mass reduction while the seat tube weight increased by 28%, the maximum and minimum accomplished. The complexity of the parts, with an estimated cost of 15,800€, made it impossible to print them in metal because of the more than 200 hours of printing time, the limitations of the machine, and the high demand for the equipment used, which led to limited printing sessions.
Potential improvements that could be applied to this project are a change of printing material or the use of a more advanced machine model that allows more complex structures to be printed.
The components were printed using the Prima Additive - Print Sharp 250 printer installed in the laboratory, using Stainless Steel 316L as the material. The joint tubes between the union nodes were made of Aluminium 6060 and assembled through an engineered mechanical joint.
The average reduction of 50% of the components’ mass was achieved using Design for Additive Manufacturing techniques in Altair and nTopology software. The head tube experienced an 81% mass reduction while the seat tube weight increased by 28%, the maximum and minimum accomplished. The complexity of the parts, with an estimated cost of 15,800€, made it impossible to print them in metal because of the more than 200 hours of printing time, the limitations of the machine, and the high demand for the equipment used, which led to limited printing sessions.
Potential improvements that could be applied to this project are a change of printing material or the use of a more advanced machine model that allows more complex structures to be printed.