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MECH 0011 Manufacturing Technology and Materials - Middle East College

Learning Outcome 1: Be able to formulate manufacturing procedures from raw material specification to end products, including design modification procedure.

Learning Outcome 2: Be able to demonstrate an understanding of correlation between material properties and manufacture process with aid of material microstructure concept.

Learning Outcome 3: have developed information gathering skills

Learning Outcome 4: have improved their written communication skills

Question:

Why have these particular materials been chosen? Discuss what alternatives could be employed - why? What properties do they possess/need?

How have the component parts been manufactured? Why has that process been used? What alternative processes could be used?

What are the effects of the process used and the materials on the environment? Is the product recyclable?

Solution:

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1. Introduction:

Product analysis:

In our day to day life, we come across a variety of product starting from toothbrush to mobile phones and bikes to dishwashers. Each and every product is made up of different methods and materials, the Product Analysis helps to study and take decisions on the materials, processing methods, aesthetics, and ergonomics of a product that is about to be manufactured. The product analysis process helps the design process. To be concise the product analysis provides answer to the questions what does it do? How does it look like? How does it do? What will be the cost? What is the material to be used? Is there any alternative? As such many questions can be answered using the product analysis process.

Fig1. Product analysis and Design cycle.

History of the process:
The product that has been selected for the analysis process is Bicycle. A bicycle is a day to day usage product which is used for the purpose of transportation. In general, a bicycle consists of two wheels which are mostly powered by humans pedalling force. There are also advanced electric bikes that emerged in the market nowadays. The first arch type bicycle was invented and used by Karl Von Drais at 1817 in Germany and it is redesigned by Denis Johnson.

Fig2. Two men riding Hobby horse and Boneshaker

The early bicycle is named as Hobby horse and Boneshaker. These bicycles are generally made out of wood. In modern bicycle variety of materials are being utilized, the Hobby horse bicycle and any other initially used bicycles were pedal less the first pedalled bicycle was designed by Pierre Michaux. At the end of the 18th century a full pedal powered chain drive enabled bicycles.
Nowadays the bicycles are the most essential part of transportation they are generally used for short trips by households, or long rides by riders, bike racing competitions, etc. The advancement in today's bicycles marks a remarkable history of human life. Design engineers were pushed to design and develop the most affordable, lightweight, high performance, and reliable bicycles each and every day. The usage of bicycles does not adds any harm to the environment thus Go green moment motivates everyone to utilize bicycles to save the planet instead of riding motorcycles.

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2. Existing Material used for the bicycle:

To find the various materials that are being utilized for the different bike parts let us first find the various parts that are associated with the bicycle. The various parts such as the frame, pedal, tyres, tubes, handlebars, etc. and the material associated with that part are tabulated in the table1.

Fig3. Illustrates various parts of a modern bicycle

Table 1. Bicycle Parts and materials

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The Existing materials are used for the following reasons:

Part1: The Frame
A frame is the most important and building block of a bicycle the frame is the part which withstands all the major loads that are imparted on the bicycle it makes up the basic unit of the total system. A bicycle frame should be made up of really strong as well as light materials. In general, if we choose iron for a bicycle frame there are many problems related to iron such as heavy in weight, corrosion properties, etc. So in order to overcome these problems, a material with less weight and more strength must be introduced which is Carbon steel.
Carbon steel possesses the following properties:
• High tensile and compressive strength
• Resistance to Hardness and wear
• Resistance to corrosion
• Low ductility
• Good formability
• Good machinability
• Lighter in weight
• Durability
• Hardenability

Part 2: Handlebars

Handlebars are the part which acts against the torque loads that are imparted on the vehicle due to turning, and gliding. The different type of loads acting on the wheels reaches the frame through the handlebar system. In general, the handlebars are also made up of the Carbon steel but of comparatively lower grade than that of the frame.

Properties of Material required for the Handlebar:
• High Torque loading capacity
• Durability
• Reliability
• Light in weight
• Resistance

Part 3: Rims

Rims are the most important and the most crucial part of any bicycle which provides the rotational motion to the bicycle for transportation. The wheel is an assembly of Rim, tubes and Tyre. The Rim is the basic part of any wheel the rims should be made of very strong and light material such as aluminium alloy. Aluminium possesses very good strength, light in weight, formability, etc. The major properties of the aluminium alloy used for this purpose are listed below:

• Lighter in weight
• High tensile and compressive strength
• Good formability
• Reliability
• Durability
• Resistance to corrosion

Part 4: Tyres and tubes

These are generally made up of Rubber the tyre is the most important part which creates road contact with the wheels the riding capacity, riding surface, etc. are based only on the type of tyre that is being utilized different types of tyres are in products such as Off-road tyres, soft tyres, hard tyres, etc.

Part 5: Chain and Sprocket

The chain and sprocket convert the human pedal force into rotary motion of the wheels, they should be made up of strong and lightweight material as the main goal of any bicycle is making it lighter in weight. Thus they are generally made up of carbon steel. The properties of Caron steel are placed below:
• High tensile and compressive strength
• Resistance to Hardness and wear
• Resistance to corrosion
• Low ductility
• Good formability
• Good machinability
• Lighter in weight
• Durability
• Hardenability

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3. Manufacturing Process

The Manufacturing process that is being utilized to make the bicycles will be explained in this chapter the various raw material required, the processes needed, etc. will be discussed.

Raw materials required:
The various raw materials that are required to make a bicycle from simple nut and bolt to frame are listed below in the table2. The different parts of the bicycle are made up of different materials.

Table 2. Raw materials

Primary Process:
Frame:
Initially, the first and foremost important part of any bicycle is the frame as discussed previously the frame is made up of the Carbon steel tubes. The carbon steel tubes are the raw material for the frame the material is bought from the stores and then with the help of the Engineering Drawing the frame is made by Cutting and Welding process. Initially, the tubes are cut into correct proportions and then welded together to resemble the exact dimensions of the Engineering Drawing.

The handlebars:
The handles bars are also made up of the carbon steel tubes raw material the bars are heated and then bending operation takes place to bend and form the bars as per the required dimensions. Finally, Gripping material such as Foam or Rubber is placed.

The Rims:
Rims are made by pressing Operation the Steel plates or Aluminum alloy plates are the raw materials for the Rim, initially the plates are allowed to go through cutting operation then a forming machine is utilized for the process of forming the required cross-section, then finally the radial toroidal bending operation is carried out.

Tyres and tubes:
The tubes are made up of stitching the natural rubbers and the tyres are made with the help of moulding and pressing process. Initially, the raw material is fed into the moulding machine and pressed together.

Secondary Process:
The secondary process makes up the assembling process of the bicycle the different parts that are made using the primary technique are all assembled into a single body with various fasteners and thrust holding devices such as bearings, various types are bearing are utilized for the assembling of bicycle components into frame such as the wheels, the pedal, the handlebar, etc. These bearing can be outsourced for a quick and lean manufacturing process.

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4. Material Analysis:

The provided and discussed materials are the standard materials and process that are being utilized in the market the manufacturing and material science are the most fast growing domain in this world the world always searching for the most cost-effective, reliable, light in weight replacement for the existing component and manufacturing process. On the side of manufacturing process techniques such as the additive manufacturing helps in creating different contours and shapes of the parts for researching and developing the product.

Alternative materials with which the parts can be manufactured:

Table3. Alternatives Materials

Fig4. Carbon Fiber Frame for Bicycle

The proposed alternative materials are made in such a way that the materials are being replaced by the standard ones for various reasons such as:
• Weight reduction
• Cost Effectiveness
• Higher performance
• Productivity
• Formability
• Availability
• Transportation charges, etc.
The frames are being built by Composites for the cause of weight reduction which in turn increases the cost of the product at least 5 times the original cost also the performance of the vehicle is improved drastically due to the weight reduction. Carbon fibre is far stronger than steel and up to 10 times lower is weight than steel. The Alloy steels can be used for the replacement of carbon steels which provide similar to higher properties they can be used if the availability of the material goes low or the demand goes up. The tyres and other rubber parts can be replaced with synthetic rubber and the Guayule rubber as per the need and requirements.

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5. Cost analysis:

The various cost related to the manufacturing, design, assembly, marketing and sales of a bicycle is listed in the table4. Let us consider a company plans to produce 100 units of bicycle per week and plans to use the standard materials it is required to document all the cost related to the making of the bicycle from design to market per piece.

6. Environmental Impact:

Steel is the most used raw material for the bicycles the production of steel involves various heating processing, purification processes, chemical reactions, etc. These processes are highly harmful they emit greenhouse gases such as CO, Cox, PM2, NOx they cause a different type of pollution such as air, water, soil, etc. The Co is responsible for the greenhouse effect and the warming up of global temperature which impacts in melting of ice in Arctic and Antarctic zones which in turn increases the sea level. The NOx is responsible for different human health-related issues and Acid rain. Also, particulate matters create serious health hazards for human beings and pollute the atmospheric air.

The production and processing of Rubber and its related material are more harmful than that of the steel the quantity of water that is required for the processing of rubber is very high and the pollution level to the environment also wastes such as zinc, COD, Ammonia, sulphur, etc. Gets out as waste and they are dumped into waterways which kills all the life in the river or sea. Creatures suffocate due to different chemicals mixed with the water it also affects the humans and other creatures.

7. Conclusion:

Thus in this study a detailed analysis of the selected product which is bicycle is carried out by collecting various information related to the parts of the product, the manufacturing processes, the hazards and environmental effects related to the manufacturing processes, the alternative materials that can be used to replace the standard materials, the difficulties related to it, etc. were discussed appropriately.

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