CYCLONE BIKE PEDALFinal Report

Abby Dutke, Alex Patow, and David Villari

B o s t o n U n i v e r s i t y E N G E K 1 5 6 : D e s i g n a n d M a n u f a c t u r e

CYCLONE BIKE PEDALFinal Report

Abby Dutke, Alex Patow, and David Villari

B o s t o n U n i v e r s i t y E N G E K 1 5 6 : D e s i g n a n d M a n u f a c t u r e

Abstract! The Cyclone bike pedals are specifically designed with the typical everyday rider in mind. Cast out of 6061 T-6 Anodized Aluminum, The Cyclone flawlessly combines this lightweight material with strength and durability. The precision behind the Cyclone’s ergonomic design sets a new precedence for strapless bike pedals. Its structure considers the foot’s natural shape and form during peddling. By fitting to the rider’s foot, no power is lost from shifting on the surface of the pedal, thus maximizing the rider’s overall efficiency.

B o s t o n U n i v e r s i t y E N G E K 1 5 6 : D e s i g n a n d M a n u f a c t u r e

Table of Contents

Work Statement 1

Initial Design Description 2

Manufacturing Description and Design Changes 3

Manufacturing Processes Used for Prototype 4

Schedule 5

Cost for One Prototype Pedal 6

Material Selection for Manufactured Pedal 7

Pedal: 7

Center Sha!: 7

Material Selection for Prototype Pedal 7

Pedal: 7

Center Sha!: 7

Appendices 8

Physical Properties of 6061"T6 Aluminum: 8

Physical Properties of 4130 Steel: 10

Physical Properties of Acrylic: 10

Physics Properties of Leaded Steel: 11

Description of Parts for Manufactured Pedal: 12

Pedal: 12

Center Sha!: 12B o s t o n U n i v e r s i t y! C y c l o n e B i k e P e d a l

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Bearings: 12

Additional Components: 12

Description of Parts for Prototype Pedal: 12

Pedal: 12

Center Sha!: 12

Bearings: 12

Stand: 12

Additional Components: 12

Pictures of Manufacturing: 13

CNC Milling of Mold: 13

Belt Sanding of Mold: 13

Heating and Bending of Curves: 14

Turning of Center Sha!: 14

Design Verification: 15

Completed Project: 15

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

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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 fixed 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 specifically for that reason. The pegs on the pedal are to increase gripping ability and allow for further efficiency 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.

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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 simplified 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.

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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

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Schedule

Date Goal Location

Friday, October 19 Project Presentation Photonics Building

Monday, October 22 Finalize Manufacturing Methods and Design

Machine Shop/ESL Lab

Wednesday, October 24 Meet with Joe Estano Joe Estano’s Office

Friday, October 26 Purchase Materials

Friday, November 2 Test Bending of Metal

Monday, November 19 Begin and Finish Manufacturing of Mold, Curves and Center Tube

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

Friday, December 7 Finish Project Report and Presentation

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Cost for One Prototype Pedal

Part Cost Per Item

Number of Items

Vendor Total

Bearings $13.03 2 McMaster-Carr $26.06

1” Leaded Steel 1’ $7.79 1 Onlinemetals.com $7.79

1” Acrylic Tube 1’ $7.84 1 McMaster-Carr $7.84

1/4”-20UNC Nut (Box of 100)

$10.10 N/A McMaster-Carr $10.10

3/8” Sheet Acrylic (18”x24”) $23.49 1 Estreetplastics.com $23.49

Shipping $7.50 N/A Various $7.50

Total $82.78

We received all of our materials for free through BU.

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Material Selection for Manufactured PedalPedal:

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 PedalPedal:

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, specifically smaller chips.

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AppendicesPhysical Properties of 6061"T6 Aluminum:

(http://asm.matweb.com)

(http://www.metalreference.com)

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(http://californiametal.com/)

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Physical Properties of 4130 Steel:

(http://asm.matweb.com)

Physical Properties of Acrylic:

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

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Physics Properties of Leaded Steel:

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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 specified as necessary in the final 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 specified as necessary in the final design.

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Pictures of Manufacturing:

CNC Milling of Mold:

Belt Sanding of Mold:

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Heating and Bending of Curves:

Turning of Center Sha!:

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Design Verification:

Completed Project:

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