CYCLONE BIKE PEDAL

Final Report

Abby Dutke, Alex Patow, and David Villari

Boston University ENG EK156: Design and Manufacture

CYCLONE BIKE PEDAL

Final Report

Abby Dutke, Alex Patow, and David Villari

Boston University ENG EK156: Design and Manufacture

Abstract
! The Cyclone bike pedals are specically designed with the typical everyday rider in mind. Cast out of 6061 T-6 Anodized Aluminum, The Cyclone awlessly combines this lightweight material with strength and durability. The precision behind the Cyclones ergonomic design sets a new precedence for strapless bike pedals. Its structure considers the foots natural shape and form during peddling. By tting to the riders foot, no power is lost from shifting on the surface of the pedal, thus maximizing the riders overall efciency.

Boston University ENG EK156: Design and Manufacture

Table of Contents

Work Statement Initial Design Description Manufacturing Description and Design Changes Manufacturing Processes Used for Prototype Schedule Cost for One Prototype Pedal Material Selection for Manufactured Pedal
Pedal: Center Sha :

1 2 3 4 5 6 7 7 7 7 7 7 8 8 10 10 11 12 12 12
Cyclone Bike Pedal i

Material Selection for Prototype Pedal

Pedal: Center Sha :

Appendices
Physical Properties of 6061 T6 Aluminum: Physical Properties of 4130 Steel: Physical Properties of Acrylic: Physics Properties of Leaded Steel: Description of Parts for Manufactured Pedal: Pedal: Center Sha :
B o s t o n U n i v e r s i t y!

Bearings: Additional Components: Description of Parts for Prototype Pedal: Pedal: Center Sha : Bearings: Stand: Additional Components: Pictures of Manufacturing: CNC Milling of Mold: Belt Sanding of Mold: Heating and Bending of Curves: Turning of Center Sha : Design Verication: Completed Project:

12 12 12 12 12 12 12 12 13 13 13 14 14 15 15

B o s t o n U n i v e r s i t y! ii

Cyclone Bike Pedal

Work Statement
! We will furnish all materials and labor in order to design, manufacture, test, deliver and install the product to design specications. We guarantee its performance. It will be completed on or before the delivery date.

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Initial Design Description

! This pedal is going to function by using two sets of thrust bearings on either end of the center shaft made out of 4130 alloy steel. On the OD of the bearings will sit the pedal itself, so it is free to rotate without restriction. The items will be xed with appropriate sized nuts to ensure no slip or shifting of either bearings or the pedal. The bearings are corrosion resistant type 440 stainless steel and can handle a radial load as well as minor angular misalignment. The center shaft made of 4130 alloy steel provides a great strength to weight ratio and is the industry leader for pedal shafts specically for that reason. The pegs on the pedal are to increase gripping ability and allow for further efciency without compromising any freedom of movement. In addition the pedal is designed symmetrically so that there is no right side up allowing for further versatility. !

!
B o s t o n U n i v e r s i t y! Cyclone Bike Pedal

Manufacturing Description and Design Changes

! The overall design of our part changed from a functional pedal to a proof of concept after project evaluation with Mr. Sjostrom. To manufacture this pedal it would require investment casting using 3-D printed parts to create negative molds, a method of manufacturing not available to us. We used plastic instead of aluminum for the pedal, which increased the manufacturability. Instead of casting, a wooden open-faced mold was created using a CNC mill. It was cut in half then sanded using the belt sander. The Acrylic curves were heated then placed in the bends. After cooling, the acrylic was removed and cut using scissors. The circular tube in the center was made on a manual lathe out of Acrylic. The design was simplied to hold two sealed bearings instead of thrust bearings. This increased manufacturability by eliminating unnecessary angles. The bearings were inserted after the center shaft was turned. Holes were drilled into the plastic tube using an NC mill. The curves were assembled using glue. After, the vertical posts were also glued. The center shaft was turned on a manual lathe. The base was cut using a laser cutter and glued together. All glue was 414 Loctite. Pictures of the manufacturing processes can be found in the appendix.

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Manufacturing Processes Used for Prototype

CNC Vertical Mill: Mold GibbsCAM Ball End Mill Manual Lathe: Center Shaft and Circular Tube Left Hand Roughing Tool, Cutoff Tool, Boring Tool, Single Point Thread Tool File NC Vertical Mill: Hole Drilling on Center Shaft, Stand Prototype End Mill Laser Cutter: Final Stand Cutting and Etching Band Saw: Mold, Stand, Curves and Circular Tube Belt Sander: Mold Heat Gun: Curves Glue: Curves, Final Stand

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Schedule
Date
Friday, October 19 Monday, October 22

Goal
Project Presentation Finalize Manufacturing Methods and Design Meet with Joe Estano Purchase Materials Test Bending of Metal Begin and Finish Manufacturing of Mold, Curves and Center Tube

Location
Photonics Building Machine Shop/ESL Lab

Wednesday, October 24 Friday, October 26 Friday, November 2 Monday, November 19

Joe Estanos Ofce

Machine Shop

Tuesday, November 20

Begin and Finish Manufacturing of Center Shaft

Machine Shop

Monday, November 26

Finish Assembly Create Stand

Machine Shop

Saturday, November 26

Begin Project Report and Presentation Finish Project Report and Presentation

Friday, December 7

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Cost for One Prototype Pedal

Part
Bearings 1 Leaded Steel 1 1 Acrylic Tube 1 1/4-20UNC Nut (Box of 100) 3/8 Sheet Acrylic (18x24) Shipping Total We received all of our materials for free through BU.

Cost Per Number Item of Items

$13.03 $7.79 $7.84 $10.10 2 1 1 N/A

Vendor
McMaster-Carr Onlinemetals.com McMaster-Carr McMaster-Carr

Total
$26.06 $7.79 $7.84 $10.10

$23.49 $7.50

1 Estreetplastics.com N/A Various

$23.49 $7.50 $82.78

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Material Selection for Manufactured Pedal

Pedal:
We chose 6061-T6 Aluminum for the pedal because it is a lightweight, inexpensive material. It also has superior durability, especially after anodizing.

Center Sha :
We chose 4130 Chromoly Steel for the center shaft because it has a higher yield strength and tensile strength than carbon steel, yet has the same density. It is the industry standard. It is also corrosion resistant.

Material Selection for Prototype Pedal

Pedal:
The original plan was to make the parts out of metal, but the bending proved to be too inaccurate, also it did not allow us to use the CNC Vertical Mill. Bob Sjostrom suggested Acrylic Plastic because of its availability, bending and machining properties.

Center Sha :
Leaded Steel was used because of its availability and machining properties, specically smaller chips.

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Appendices
Physical Properties of 6061 T6 Aluminum:

(http://asm.matweb.com)

(http://www.metalreference.com)
B o s t o n U n i v e r s i t y! Cyclone Bike Pedal

(http://californiametal.com/)

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

Physical Properties of 4130 Steel:

(http://asm.matweb.com)

Physical Properties of Acrylic:

Can be found at: http://www.rmplastics.net/acrylic.htm

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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Physics Properties of Leaded Steel:

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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Description of Parts for Manufactured Pedal:

Pedal:
The Pedal is made out of cast 6061-T6 Aluminum.

Center Sha :
The Center Shaft is made out of 4130 Steel. It will be turned on an lathe.

Bearings:
The bearings are corrosion resistant type 440 stainless steel thrust bearings and can handle a radial load as well as minor angular misalignment.

Additional Components:
Additional components may be specied as necessary in the nal design.

Description of Parts for Prototype Pedal:

Pedal:
The Pedal is made out of 3 parts: 2 curves and a center tube. All parts of the pedal are acrylic.

Center Sha :
The Center Shaft is made out of Leaded Steel. It will be turned on a lathe.

Bearings:
The bearings are corrosion resistant type 440 stainless steel double sealed bearings.

Stand:
The stand is made from 2 pieces of laser cut acrylic. They are glued together.

Additional Components:
Additional components may be specied as necessary in the nal design.

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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Pictures of Manufacturing:
CNC Milling of Mold:

Belt Sanding of Mold:

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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Heating and Bending of Curves:

Turning of Center Sha :

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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Design Verication:

Completed Project:

B o s t o n U n i v e r s i t y!

Cyclone Bike Pedal

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