CHAPTER-01

ABOUT THE PROJECT

1.1 INTRODUCTION

In the present day lifestyle man is not able to dedicate specific time for his health,
importance is least given to exercise and body fitness due to time shortage and stressful
life. Obesity is one of the common issues seen in the society, which leads to many health
hazards. Exercises are advised for health promotion, and treatment for many diseases.
Among the exercises aerobic exercises are appropriate for these purposes. To do aerobic
exercise many methods are available for example: running, jogging, walking, cycling
and others.

Transport has been one of the major issues in developing cities such as Bangalore since
commuting from one place to another has become tedious and expensive. With the petrol
and diesel prices increasing day by day, almost all the modes of transport are becoming
expensive. It is difficult to reach the nearest public transport facility and in many cases
the destination will be far from the main roads where the public transport might not be
able to reach due to the small roads, to avoid which most people use vehicles of their
own, which in turn leads to issues with parking, traffic, etc. But not all can opt for having
own vehicles as it is expensive. With such issues in health, transport, space for parking,
etc. one solution that comes to mind is bicycle. Bicycles are being promoted in the
corporate and educational sectors. But how convenient is it to use a conventional bicycle?
In many cases there is no special facility provided for locking the bicycles and even if
one is present, it is probable to theft, which is one of the fears that obstruct use of bicycle.
Conventional bicycles occupy sufficient space and hence providing one at work place or
at home are quite difficult. They are probable to be exposed to the weather outside and
do require frequent maintenance. With all such issues in the conventional bicycles, the
next possible solution is the usage of foldable bicycle. With foldable bicycles, there is no
issue since the bicycle can be folded and carried around to the work place or even it can
be used to reach the nearest public transport facility and then folded and carried along.
Since the bicycle is being folded, it occupies very less space and doesn’t require any
special parking space. They are not exposed to the weather since they can be carried
inside buildings with ease and hence prone to less maintenance. We can also carry it with

1
us due to have carrying facilities with the folding system. The usage of foldable bicycle
helps combine the different modes of transport as mentioned above, which helps in
cutting down some cost involved in travelling.

Global warming is one of the most highlighted sectors over which the concentration and
dilemma of human beings have shifted in past recent years. It is only due to the harmful
effects of this global warming phenomenon which has caused disaster to our mother
nature and to us. Effects like global warming, depletion of ozone layer etc are very
prominent in now a day.

The main cause of these harmful effects is green house effect which is mainly caused due
to the production of carbon dioxide, sulphur di oxide, nitrous oxide etc. From the studies
of year 1896 to the present age ,one thing is clear that major production of these gases
takes place from our mode of transportation. They create a large amount of these types of
harmful pollutants and release them into the atmosphere which in turn causes green
house effect and leads to such harmful conditions. So in order to reduce and restrict this ,
the main focus is to reduce the production of those harmful pollutants from vehicles, and
in order to meet this ,research ,innovations and studies are conducted on the modes of
transportation such as cycles which produces nearly 0% pollutants.

From the very ancient time, cycle is always an important mode of transportation in our
world. It is not only the transportation mean but also very effective equipment for
achieving and maintaining a good physical and mental health. Apart from this ,it is the
cheapest mode of transportation as it requires no fuel or source of energy and it requires
no maintenance .It is also the most eco-friendly mode of transportation ever invented in
this world as it produces 0% pollution. Besides this it is very economical and easily
available mode of transportation. Folding bicycle is the modified and evaluated version
of the cycles .It is the type of the cycles which is taking the legacies of the cycles to the
new heights. It’s characteristics and properties like light weight, easy to carry ,portable,
less space requiring ,low maintenance needed, are making them more popular and first
choice of cycle riders, mountaineers etc.

Moreover, to reduce the force requires for paddling to pull the chain and the effort for
this, we are going to add chainless system. It will also reduce the material requirement
and weight of the cycle.

2
This is the new technology developed in recent years in which the bicycles are not
installed with chains but instead of this the transfer of motion from paddling system to
the rear wheel takes place with the help of the strings .This reduces the loss of energy
and makes the bicycle very efficient in nature .Now the same concept of technology can
be implemented in the case of the 4 fold foldable bicycle which will increase its
efficiency.
The most important things in folding bicycle are the joints, material used and the type of
joining techniques such as welding, brazing etc. done for the fabrication of the folding
bicycle.

Foldable bicycles are available in the market, but are expensive since they are being
imported. There are very few recognized foldable bicycle manufactures in India. Hence
we ceased the opportunity to provide a low cost, locally manufactured foldable bicycle.

1.2 OBJECTIVE
To cope with the deficit, we can utilize the time spent on commuting efficiently to
exercise by using bicycles, thereby also contributing to pollution control. The main
objective is to design and develop a chainless foldable bicycle, which is comfortable to
ride and economical.

General the cycle presently available in market is heavy in weight and there is carry and
parking problem. To solve this problem, foldable cycles come in market. But the cost of
that foldable bicycle available in the market is so high that is no affordable for every
common person. For that reason we thought to make it under a cheapest and also add on
some new things that will beneficial for people.

For parking and carrying purpose that we can easily carry anywhere from one place to
another. We thought to design foldable bicycle and to reduce paddling force, material
requirement, weight and cost we add chainless system.

1.3 LITERATURE SURVEY OF RESEARCH PAPERS

ME450 Fall 2009 Chainless Challenge Project 14 Andrew Berwald1, Philip Bankaski2,
Henry Kohring3, Chris Levay4. Section Instruction: Steven J.S Karlos, December 15,
2009.

International Research Journal of Engineering and Technology (IRJET). Volume : -05

3
Issue March 03, 2018. Design and Febrication of Chainless Bicycle, Khan Hassan
Zakariya1, Kokar Abhimaneu Dashrath2, Quazi Azhar Hussain Farru Khzama3, Assist.
Prof. Shivraj Kavhale4. Department of Mechanical Engineering, Dikap Research
Engineering and Management studies, Keral, Maharashtra, India (IJESC).

Research article Volume 7,Issue No. 6, Purpose and Manufacturer of Chainless Bicycle.
Amit Kumar Singh1, Vinay Kumar chaurasia2, Ankit yadav3, Arvind Yadav4, Nitish
Kumar Mishra5. Assistant professor1, B.Tech Student2,3,4,5 of Mechanical Engineering,
United college of Engineering and Management, Allahabad, UP, India.

SSRG Interational Journal of Mechanical Engineering (SSRG-IJME) – Volume 2

Issue ;06 June 2015. Design and Fabrication of Foldable Bicycle, Shishir S1, Manjunath
P2, Pavanasudan R3, Ravi Styajith4, 1,2,3,4
Department of Mechanical Engineering, S.J.B
Institute of Technology, Bangaloru, Karnatka, India.

IJESC Research Article Volume 6 Issue No. 6. Designing and Fabrication of 4-Fold
Foldable Bicycle, Dr. A.K. Jauhri1, Kushal Sharma2, Viblum Dixit3, Bassi Abbas4,
Vanshaj Shukla5, Professor1, UG Scholar2,3,4,5, Department of Mechanical and
Automation Engineering, Amity University, Luckhnow, India.

ARPN Journal of Engineering and Applied Science Vol. 9 No. 5 May 2014, Foldable
Bicycle: Evaluation of Existing Design and Novel design Ptoposal, Arunachalam M,
Arun Prakash R, and Rajesh R, PSG College of Technology, Coimbatore, India.

International journal of Computer Applications (0975-8887), Vol. 57-19,Feb-2014, A

Typical Approach in Conceptual and Embodiment Design of Foldable Bicycle.
Arunachalam M, Arun Prakash R, and Rajesh R, Department of Production Engineering,
PSG College of Technology, Coimbatore, India.

Fabrication of Smart Bicycle Project Reference No. 37S1127. Pradeep S, Ramesh N,

Peddy Reddy, Raghu S.N.,Guide- RG Deshpandey, Mechanical Engineering, BMS
Institute of Technology, Bangaloru, India.

Folding Bike Implementation Plan, M Metro, Los Angeles Country, Metropolitan

Transportation Authority, One Gateway Plaza, April 2011; prepared by; CALSTART, 48
S Chester Ave Pasadena.

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 CHAPTER-02

DESIGN AND FEBRICATION

2.1 SELECTION OF MATERIAL

Next was the selection of suitable material for the frame. It was important to make the
frame sturdy, yet light. After long sessions of discussion it was finalized to use the
standard material used in conventional bicycles i.e. Mild steel. Mild steel is easily
available in the required diameter and length and is also not expensive. One main
advantage of using mild steel is that it is easy to fabricate with it as welding of mild steel
is by arc welding process which is cheap compared to other welding methods. Use of
other materials like alloys of aluminum was not selected as the availability is less and
also the fabrication cost is high. Mild steel tubes of 1”, 1.5”, 0.5” are easily available in
the market and are the ones used for conventional bicycle manufacturing. The hinge
found in the market is also made of mild steel which eases the process of joining the
frame to the hinges.

The following are the chemical composition and mechanical properties of mild steel.

(a) Mechanical properties

Maximum Stress = 400-560 N/mm^2

Yield Stress = 300-440 N/mm^2

Minimum 0.2% Proof Stress 280-420 N/mm^2 Minimum Elongation 10-14% Minimum
Young’s Modulus = 210 Gap s

(b) Chemical composition

Carbon = 0.16-0.18%

Silicon = 0.40%

Maximum Manganese = 0.70-0.90%

Sulpher = 0.040%

Maximum Phosphorus = 0.040%

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2.2 WORKING

The fabrication of the bicycle will do with the help of the CAD drawings. First the
hinges will be fabricated, followed by the frame. A M6 25mm long nut will be welded
on the inside of the hinge first. The two half cups will be welded on the outer faces of the
hinges. Once that will complete the machine clamp and will be assembled with the hinge
with the help of quick release levers.
Once the hinge will successfully done, the fabrication of the frame will start. First the
bottom shell will be taken and the seat tube will be welded to it. Once the seat tube will
fix, come the tricky part where the frame tube, the rear part of the frame etc. will be
welded at different angles. With reference to the CAD drawing, the angles will be
measured and the welding will be done carefully and rechecked for errors in angle and
straightness of the members. Once the tubes will be welded to the right angle and cut to
the required dimension, the hinges will be welded to the ends of the tubes, making sure
that all the hinge axes are perpendicular to the ground. After the hinges will be welded,
the hinges will be clamped tight and then the rest of the welding begin. After the
members welded, they will be folded and checked for errors. After the welding will be
done the whole frame will be checked for alignment errors and once the errors will
rectified the weld will be finalized and the process of grinding the joints will be carried
out. Once the whole frame will ready, the wheels will be assembled to the frame and the
alignment will be checked. Then the frame will be folded and checked for errors. After
the folding errors will be checked, the frame will be tested for load carrying capacity.

1st Fold: - Handle Sliding fold, which is use to adjust the height of the handle according
to our need, provided with a interlocking clamping system, to tighten the handle at
desired height.

2nd Fold: - It is also provided in the handle of the foldable bicycle. It is used to partially
dissemble the handle from the main frame of the bicycle .It is provided with a spring
loaded clamping system.

3rd Fold: - It is the fold provided in the seat bar of the bicycle, it is used to raise or lower
down the height of the seat according our need. It is provided with a clamp interlocking
system.

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4th fold: -It is the most important type of fold of the bicycle. It uses to fold a bicycle
from 180 degree to 360 degree. It is provided with a bolt clamping system in which a
bolt and the holes of the same diameter form the interlocking system. It is the most
important type of folding system.
After completing folding part we will go for chainless system. For that we will remove
chain parts and will design and implement the different type of paddle bar. We will make
it by different type of machining processes. Cutting, milling, facing, drilling, welding
and grinding these are the main machining processes we are going to use to make that
part.

After completing all construction process we will go for testing. We will test the parts we
designed and implemented. Then we will test the overall maintenance and efficiency of
the cycle.

2.3 METHODOLOGY

Methodology the methodology used for research work is summarized in figure given
below:- Study Of the literature

Identification of problem

Literature Review

Gaps in literature

Objectives Of work

Design of model

Fabrication of model

Testing of models Modification of model

Validation of model

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2.4 DESIGN OF PARTS

First the existing designs of the foldable bicycles were studied. It was found that almost
all the bicycles have a very similar frame design and folding mechanism. That gave us
way to change the design of the frame and also improve the folding mechanism by
making it simple. Once all the survey on the existing designs will be done, few hand
sketches will be done. The feasible ones i.e. the ones that will having proper ergonomics
and will easy to manufacture will be selected for compariso
comparison.
n. The bicycle frame
concepts developed will based on the ergonomics of the convention bicycle frame.

(a) Hinge Design

A Hinge is a mechanical bearing that connects two solid objects, typically allowing only
a limited angle of rotation them. Two objects cconnected
onnected by an ideal hinge rotate relative
to each other about a fixed axis of rotation. Hinges may be made of flexible material or
of moving components.

The hinge has 2 “caps’, 2 “leaves” and 5 “knuckles”. The 5 knuckles made up the hinge
“barrel’. Insidee the hinge barrel and the hinge “pin”. A hinge does its job by pivoting
around the hinge pin. The hinge barrel and the hinge pin comprise the hinge “joint”. The
hinge joint is the pivoting mechanism of a hinge, just like your elbow joint is a pivoting
mechanism for your arm.

Fig 2.4.1 Hinge joint

The hinge being a very important member of the frame required utmost attention. The
Hinge is the load bearing member. After a long survey of the existing hinge mechanisms
used in the foldable bicycles, it was found that most of the bicycles used similar kind of
hinge and locking mechanism. The mechanism used was simple, but manufacturing

8
something
hing similar with available resources turned out to be expensive. But the hinge
mechanism or the simplest hinge mechanism used in Brompton bicycle caught our
interest. This mechanism was very simple and used a screw and spring loaded
mechanism to lock the hinge. The design was simple yet strong and chances of failure
are minimal. The following figure shows the hinge mechanism used in the Brompton
bicycle.

Figure 2.
2.4.2 Brompton Hinge Clamp Mechanism

This design inspired us to come up with something similar with locally available
resources. First a hunt for the right type of hinge to be used was done. The Specification
report on Steel butt hinges by Bureau of Indian Standards gave us the following
information regarding the heavy duty square hinges.

Table 2.4.3 Dimension of Heavy weight Mild Steel Butt Hinges

9
We identified the proper hinge for our bicycle, we selected the 50mm X 50mm hinge, it
was up to us to modify it for the purpose. A normal mild steel hinge will be converted
into a member that can lock after the bicycle will unfolded. This is a challenging task.
Once the required data will gathered regarding the dimensions of the hinge and frame,
the hinge will be modeled using 3D tools. The clamping mechanism will be also
designed with the hinge. The following figures show the hinge clamp mechanism.

Figure 2.4.4 3D Model of Hinge Mechanism

The Hinge will be so designed that welding the mild steel tubes to it any angle will be an
easy task, which will be achieved by using the half cups on each face of the hinge. An
M6 25mm long nut will be welded on the inner face of the hinge to facilitate clamping.
The clamp will be designed based on the dimensions of the hinge. The clamp will be so
designed that the hinge can be locked with minimum effort yet there is no compromise
with the strength of the clamp.

(b) Frame design

The 3D model of the bicycle frame will develop based on the concept design. First a 2d
draft of the design will do in AutoCAD with the required dimension and angles, then a
selection of the bicycle from will develop with the position of the hinges.

(c) Crank design

To make the bicycle, we are going to make a new type of crank for paddling. The new
mechanism of the crank is near about the mechanism of the crank shaft of IC Engine. In
that mechanism the paddler need not to rotate the paddling 360 degree. He/ She have to
force downward on one side and at the same time another side more upward
automatically. With that up and down force the wheel will rotate.

10
For that result the force required will less. And this crank will directly connect with the
bearing of the wheel. For avoiding the chain mechanism the using this crank mechanism
the material required will also lesser.

Figure 2.4.5 Mechanism of the crank

First of all we will make the 2D draft of crank in AutoCAD with the required dimensions.
Then the 3D model of the crank will develop based on the concept design. And then a
skeleton of the crank will develop.

2.5 ASSEMBLY PARTS

The following parts we are going to take from market and assemble.

Pedal: - Part attached to a crank that the cyclist rotates to provide the bicycle’s power.

Reflector: - Device returning light toward its source so that other users of the road might
see the cyclist.

Rear Light: - Lamp signaling the bicycle’s presence in the dark.

Fender: - Piece of curved metal covering part of the wheel to protect the cyclist from
being splashed.

Carrier: - Device attached to the back of the bicycle for carrying bags on each side and
packages on top.

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Rear Brake: - Mechanism activated by a brake cable, comprising a caliper and return
springs; it forces a pair of brake pads against the sidewalls to stop the bicycle.

Seat Tube: - Part of the frame learning slightly to the rear, receiving the seat post and
joining the pedal mechanism.

Seat stay: - Tube connecting the top of the seat tube with the rear-wheel hub.

Seat Post: - Component supporting and attaching the seat, inserted to variable depth into
the seat tube to adjust seat tube to adjust the seat’s height.

Seat: - Small triangular seat attached to the bicycle’s frame.

Tire Pump: - Device that compresses air and is used to inflate a bicycle tire’s inner tube.

Crossbar: - Horizontal part of the frame, connecting the head tube with the seat tube and
stabilizing the frame.

Down Tube: - Part of the frame connecting the head tube to the pedal mechanism; it is
the longest and thickest tube in the frame and gives it its rigidity.

Tire Valve: - Small clack valve sealing the inflation opening of the inner tube; it allows
air to enter but prevents it from escaping.

Spoke: - Thin metal spindle connecting the hub to the rim.

Tire: - Structure made of cotton and steel fibers coated with rubber, mounted on the rim
to form the casing for the inner tube.

Hub: - Central part of the wheel from which spokes radiate. Inside the hub are ball
bearings enabling it to rotate around its axle.

Fork: - Two tubes connected to the head tube and attached to each end of the
front-wheel hub.

Front Brake: - Mechanism activated by a brake cable, comprising a caliper and return
springs; it forces a pair of brake pads against the sidewalls to slow down the front wheel.

Brake Lever: - Lever attached to the handlebars for activating the brake caliper via a
cable.

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Head Tube: -Tube using ball bearing to transmit the steering movement to the fork.

Stem: Part whose height is adjustable; it is inserted into the head tube and supports the
handlebars.

Brake Cable: - Sheathed steel cable transmitting the pressure exerted on the brake lever
to the brake.

Handlebars: - Device made up of two handles connected by a tube, for steering the
bicycle.

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 CHAPTER-03

PROJECT ANALYSIS

3.1 COST ESTIMATION

The following table shows cost of main parts of the project: -

S.NO. PARTS NAME NO. OF PARTS MARKET PRICE

1 Pedal 2 INR 375
2 Frame 1 INR 1000
3 Tire 2 INR 500
4 Tube 2 INR 300
5 Rear brake 1 INR 200
6 Seat 1 INR 240
7 Front brake 1 INR 200
8 Brake lever 2 INR 200
9 Handle bars 1 INR 375
10 Brake cable 2 INR 200
11 Crank 2 INR 350
12 Hinge 2 INR 100
13 Wheel 2 INR 500
14 Manufacturing cost - INR 500
15 Painting cost - INR 200
16 TOTAL 21 INR 5240
Table 3.1 Cost estimation

3.2 ADVANTAGES

Intermodality

The first advantage offered by folding bicycles is intermodality. Unlike conventional

bicycles, folding can be combined much more easily with other means of transport. This
quality is especially useful for people who have to travel long distances to reach their
destination. You can leave your home to the public transport station and as you approach

14
your destination you can assemble your bicycle and reach your final destination.
Currently, there are few cities that already have adequate infrastructure to transport the
bicycle on public transport.

Retrench of space

A folded bike takes up half the space you would need to store a conventional bicycle.
You can easily store them in any corner. Their ability to fold makes them especially
useful for those who live in apartments or who do not have a proper place to park their
bicycles in their office. You fold it and put it on the side of your desk. If you wish to
store your bike at home and not leave it outside, you can easily fold it and store it indoors
without the hassle of handling a full-sized bike.

Easy to travel with

Whether you are using public transport or your personal car to travel, you can carry your
foldable bicycle without any restrictions. In public transportation, regular bikes are
usually not allowed, but folded bicycles can be carried like any other luggage.

Intermodal travel

If travelling to work requires you to use public transport to cover a certain distance and
the rest need to be travelled using a bike, then the foldable bicycle is exactly what you
need. When you reach your workplace, you can easily fold it and take it to the office - it
simply goes unnoticed under your desk at work. You can travel long distances without
the hassle of a motor vehicle through intermodal travel.

Fewer chances of getting stolen

Since you can fold up your bike and take it indoors, you do not have to lock your bike
outside and constantly worry about it getting stolen. Of course, while some bikes are
more compact than others, most of them are small enough for you to carry.

Less effort and force required for paddling

Due to the chainless system i.e. crank mechanism that we are going to implement the
force required for paddling will lesser. That means we can get more work efficiency
through a less effort. Without rotating the padel 360° as conventional bicycle we can get
the same efficiency and speed by lesser effort.

15
3.3 DISADVANTAGES

Increased sensitivity to road imperfections

This disadvantage concerns the folding of small wheels. Generally these bicycles use
wheels of 16 to 20 inches. The disadvantage of small wheels is that each imperfection of
the road feels more. This is because the smaller the diameter of the wheel, the more
difficult it will be for it to “roll” over obstacles and road imperfections. For the most part,
folding bicycles are designed for urban use. However, if you like to go out to the
mountain you can find mountain bikes of conventional size.

Difficulty to customize

Folding bicycles are much less popular than other types of bicycles. This makes it a bit
more difficult to customize, since it is more difficult to find the right accessories. The
good news is that these bicycles are slowly gaining market and every time we can find a
greater assortment and variety of specialized accessories for folding. Inclusive there are
distributors specialize in folding bikes. Also, thanks to the internet, you can find almost
any accessory and order it from the other side of the world.

Pricing

While traditional bicycles are available at various prices, foldable bikes are generally
more expensive than conventional bikes. Even though they have the same specifications,
you have the option of purchasing a regular bicycle of a better quality at the same price.

Attention from passersby

The small form of these bicycles may seem to make them less prone to unwanted
attention, but that is not the case. The unusual look of these bikes is sure to generate
stares from passersby. While this does not affect the way they are ridden, this could be a
deal-breaker for people looking to blend in.

These are some advantages and disadvantages that we have identified.

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3.4 BAR CHART

The following table shows that how will the work be done

Table 3.2 Bar Chart

3.5 FUTURE SCOPE

Kinetic Energy Reservoir System

Kinetic energy of the cycle can be stored and later it can be utilized whenever the user
feel tired, exhausted or when he wants to use it .The kinetic energy can be store in any
reservoir type device such as batteries. Besides this flywheel attached to the rear wheel is
also an important mechanical device which can be used to store the kinetic energy for the
future use.

Installation of Electronic Gadgets

Various types of electronic gadgets like mobile charger, music pods charger etc. can be
installed easily
ly on the foldable bicycle. They will draw energy for them through the
kinetic energy of the wheels of the bicycle and this will be conducted and initiated with
the help of the transducers. This Equipment will make the riding experience of the user
enjoyable and fun loving.

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