Finite element simulation of A356 and A6061 aluminum combination bicycle elements to optimize weight of frame

Abstract

Alternative frame production technology is needed to reduce dependence on raw material for frame pipes and bicycle frame production processes so that they can be produced by small and medium industries. Design and simulation are the first step to get a bicycle frame that has an attractive design, has a light weight, has adequate strength and is able to improve the overall performance of the bicycle. The purpose of this research is to develop the design and analysis of the finite element on the bicycle frame so that it can reduce the weight of the bicycle frame and meet the standardized strength. The design is done by modifying the material and size of the bicycle frame on the market by combining 2 types of aluminum material and conducting a study of the thickness of the bicycle frame. The thickness of the tube material is varied with 3 sizes, namely 1 mm, 1.5 mm and 2 mm. The loading is carried out above the seat tube of 1500 N. By taking the characteristics and material properties of the two types of aluminum, it can be determined the stress and deformation formed due to loading at the end of the seat tube. The agreed design is then analyzed with finite elements using ANSYS software. The results show that the frame design uses a modern frame shape with A356 Aluminum material on the head tube, seat tube, stay and A6061 material on the top tube and button tube. The simulation of a bicycle frame with a load of 1500 N with variations in tube thickness of 1 mm, 1.5 mm and 2 mm from A6061 material shows that the deformation that occurs when loading is 0.275 mm, 0.168 mm and 0.156 mm, respectively. Based on the magnitude of the von Mises stress that occurs in each frame, it is found that each is 132 MPa, 107 MPa and 99 MPa and is located at the arm of the seat tube joining with the upper stay. The stress is still below the yield stress of the A356 material, which is 165 MPa, so it is declared safe from static loading that applied in the frame.