Table 1: Application requirements

Application Function Wear Strength Cost

multi-part mechanical
Wheel tensile loading tensile strength 21%
performance

stress/strain tension/compression
Frame core structure 49%
loading strength

moving high
Components need varies 28%
mechanical parts mechanical wear

Comfort and
Seat Weight of rider weight 2%
support

3.3 MATERIAL ANALYSIS OF COMPONENTS

By using the information from the literature review above, the analysis of the material
for each component can be carried out by the aid of suitable material property chart and design
requirements table (function, objective, constraints, free variable). The top ranked candidates
of material for each component will be obtained in the analysis below.

3.3.1 FRAME

The design requirement shown in Table 2 is the summary of the literature review above.

Function As core structure

Objective Withstand tension or compression strength
Constraint (i) Contributes to 68% of the total weight of the bicycle
(ii) Contributes to 49% of the total price
(iii) Density is to be limited at 5000 KG/M^3.
(iv) Stiffness more than 30GPa and less than 400GPa

Free variable The choice of the material

Table 2
 Based on table 2, there is only 1 specific function for the frame. The main objective of
the frame is to withstand compression strength.

Based on the Ashby’s graph, we can determine the material that satisfies the
requirement of the constraints of the material. Based on the graph, we can determine the
candidates of material:

Candidates of material Density Young’s Modulus Cost/Kg

Steel 7.8 200 0.39USD
Aluminium Alloy 2.8 73.1 1.61USD
Titanium Alloy 4.5 100 25.81USD
CFRP 1.5 50 16.71USD
Price is based on [2]

Each of the material has different characteristics.

Materials Advamtages Disadvantages

Steel - Cheap - Heavy
- Maleable - Not rust resistant
- Durable
- Widely avalible
Aluminium alloy - Light weight - Lower shock
- Rust resistant absorbance
 - High Stiffness
Titanium alloy - high durablity - Expensive
- Adds “springiness” to frame - Dofficult to
manufacture
CFRP - Light weight - Expensive
- High Stiffness - Not suitable for
- Durable rough users
- Ability to absorb shock

Based on the characteristics, we are able to determine the best option of material for a.
bicycle. The other components of a bicycle are taken into consideration as well.

Steel has been used by framebuilders for over a century. Many types of steel tubing are
available and the material is easy to bend and shape. Plus, there are myriad methods of
assembly making steel very adaptable to cyclists' needs. It also offers excellent ride quality,
durability, is easily repaired and affordable. If there's a knock on steel, it's that it tends to be
heavy when low-quality tubing is used. Steell can rust if treated carelessly [1]

Aluminium is the lightest frame material, lighter than carbon and titanium. It makes
aluminum frames great choices for racing and time trialing. And, unlike steel, aluminum won't
rust; another advantage. [1]Titanium alloy is the combination of the best characteristecs of
others. It is highly durable and lightweight. However, the manufacturing and the material of
titanium is very expensive. Hence makes it the most expensive material for a bicycle. Besides,
Carbon Fibre, a composite, is also a good material. Similar to titanium alloy, it is costly due to
the carbon fibre material and the complicated manufacturing.

3.3.2 WHEELS

The design requirement shown in Table 2.2 is the summary of literature review above.

Function A round device capable of rotating on its

axis (axle) and thus facilitates movement or
transport by rolling.
Objective Minimize the mass of the wheel
 Constraints 1) High tensile strength
2) High Young’s Modulus
3) Low density
Free Variables The choices of materials
Table 2.2: Design requirement of wheel

Based on the table 2.2 functional requirements are directly related to the required
characteristics of the component, subassembly, or product. The wheel is a circular tool that
serves to rotate on the axis (axle) and thus facilitates movement or transport by rolling. An
important requirement for materials used in bicycle wheel is its strength. Compressive strength
is the basic measurement of strength of a material. It is specifically a measurement of the force
required to push apart a material. In frame design, the higher the strength betters the
performance of the wheel. Yield strength (YS) measures how much force it takes to
permanently bend a material. As with compressive and fatigue strength, higher YS is expected
from the candidate materials for the use of wheel.

Figure 3.3.1 Modulus-density chart for the wheel

Based on the figure 3.3.1 shows the ashby chart density vs youngs modulus. Assume
that the minimum density of bicycle wheel is 5000 kg/m^3 and the young modulus in the range
of 40 GPa to 200 GPa. Thus, the range materials are carbon fibre, aluminum, titanium, steel,
solid wood, glass fibre, ceramics and alloy. The mechanical properties of materials to make
wheel must be high tensile strength, high Young’s Modulus and low density. This is due to
cope with the weight of the rider, to ensure the materials used for long lasting and corrosion
resistance. Hence, the suitable materials for the bicycle wheel are carbon fibre, aluminium,
titanium and steel. While, ceramics, solid wood and glass fibre are not suitable because they
are brittle and easy to break.

Material Carbon Fibre Aluminium Titanium Steel

Density 1.5 2.8 4.5 7.8
(Mg/m3)
Youngs Modulus 50 73.1 100 200
(GPa)
Cost/Ib 16.71 1.61 25.81 0.39
(usd, $)
Table 3.3.2 Comparison of materials

3.3.3 MECHANICAL PARTS

Function To support the movements of the bike

Objective Long lasting life spent

Constrains a) High resistance to corrosion

b) High durability and strong

c) High thermal conductivity

Free Variables The choices of materials.

Table 3.3.3: Design requirement for bicycle components

Table 3.3.3 shows the design requirement for bicycle components. Based on the

function and the possible disc damage modes above, certain material requirement for

disc brake is needed to be taking into consideration. The material requirements for disc

brake are as below:

a) High strength even at elevated temperatures

b) High stiffness (modulus of elasticity)

 c) Low density

d) High thermal conductivity

e) Excellent abrasion resistance

f) Good creep resistance

Figure 3.3.3

Figure 3.3.3 shows the ashby chart density vs youngs modulus. Assume that the density

of mechanical parts of bicycle is below 5 and the young’s modulus is above 20. So, the

range materials are solid wood, carbon fibre, glass fibre, ceramics, alloy, steels,

titanium, cement/concrete and aluminium. The mechanical properties of materials must

be strong, ductile, corrosion resistance, and high stiffness. This is to overcome the

weight of the rider, to ensure the materials used are long lasting and corrosion

resistance. So, the suitable materials for the mechanical compartments of bicycle are
 carbon fibre, alloys, steels, titanium and aluminium. Ceramics, wood, glass fibre and

cement are not suitable because they are brittle and easy to break.

Aluminium Steels Carbon Fibre Titanium

Density (Mg/m3) 2.7 7.8 1.5 4.5

Youngs Modulus (Gpa) 73.1 200 50 100

Costs/Ib (USD) 1.61 0.39 16.71 25.81

Table 3.3.3.1 : Comparison of material selection

Table 3.3.3.1 shows the comparison of materials selection of the mechanical

components of bicycle. The good materials are low density, higher young modulus and lower

costs. Based on the table above, we can select the best material for a bicycle’s mechanical part.

3.3.4 HANDLEBAR

Function To steer the front wheel

Objective To control the bicycle

Constraints 1)High durability

2)Light and flexible

3)Shock absorbent

4)High resistant to corrosion

Free Variable The choice of material

Table 2.3.1

A bicycle handlebar is the steering control for bicycles; it is the equivalent of a steering wheel

for vehicles and vessels. Besides steering, handlebars also often support a portion of the rider's

weight, depending on their riding position, and provide a convenient mounting place for brake

levers, shift levers, bells. Handlebars are attached to a bike's stem which in turn attaches to the

fork.
The material requirements for the bicycle handle bar is as below:

1)High durability and strong

2)Light and flexible

3)Shock absorbance

4)High resistant to corrosion

From the Ashby chart above, assume that the density of bicycle handlebar is less than

5 and the young’s modulus is more that 30. So the available materials that can be chose is steel,

aluminium and titanium. The mechanical properties of the handlebar must be strong, ductile,

high stiffness, high resistant to corrosion and shock absorbent. This is because we must make

sure that the handlebar is shock absorbance in order to easily control the bicycle at bumpy road.

Not only that, the materials selected must be high resistant to corrosion, so that it will last

longer. Lastly, the handlebar need to be high durability and strong to withstand any impact if

we might get into accident.

 Aluminium alloy Steel Titanium

Density (Mg/m3) 2.7 7.8 4.5

Young’ modulus 73.1 200 105

(Gpa)

Cost (USD) 1.61/lb 0.39/Ib 25.81/lb

Table 3.3.4
The table 3.3.4 shows the comparison of suitable materials to make a handlebar. The needed

material must be low density, high young’s modulus and the price is affordable. So, the best

material is aluminium.

3.3.5 SADDLE

The design requirement shown in Table 3.3.5

Function As comfort and support

Objective Withstand weight
Constraint (i) Contributes to 2% of the total weight of the bicycle
(ii) Contributes to 2% of the total price
(iii) Density is to be limited at 102.5 KG/M^3.
Free variable The choice of the material
Table 3.3.5

Based on the graph, we can determine the material that satisfies the requirement of the material
Saddle material Advantages Disvantages Cost

Synthetic saddles 1. Water resistance 1. Light weight 45-50usd

with foam (spunge) – the saddle won’t 2. It’s ability to spring
padding get soaked in back in shape after being
pouring rain or compressed – they take a really
accumulate sweat long time to become compacted
on long rides. from use and loose springyness.
Synthetic saddles 1. Comform to 1. It relatively quickly becomes 10-20usd
with gel padding body shape a bit compacted.
better than other 2. Loosing springyness.
materials – 3. A bit heavier than
instantly, without foam.
the need for a
“break in” period.
2. Comfortable for
beginners
Leather saddles 1. Look very 1. Require maintenance. 100-
elegant, especially 2. Not being water 500usd
on vintage, or retro resistant - leather saddle will get
bicycles. soaked in the rain.
2. the ability of 3. The wet leather will stretch more
leather to take the quickly if ridden before it is dried.
shape of the rider’s 4. Leather will dry and crack if it is
back – just like not regularly waxed with leather
leather shoes, they care products.
will break in after 5. Leather feels very cold in the
some use and “fit winter - most riders will need some
like a glove” padding, or thicker shorts/pants at
3. Feel more the part where the back contacts
comfortable in the the saddle.
summer, especially
 if no padded 6. Heavy and requires a sturdy
cycling shorts is steel frame to keep it stretched –
used when riding. leather saddles are by far the
4. Leather saddles heaviest.
(if mantained
properly) are
among the longest
lasting – having the
most durable
material, resisting
cuts and chafing.
Table 3.3.5.1 shows the candidate of materials selection of saddle. [8]

Bike seats are a lot like running shoes. There are numerous varieties and styles designed to
suit a type of body and style of riding. This section outlines the features of the different kinds
of bike saddles and why the differences are important. [9] Based on imformation above we
can chose the most suitable.

4.0 DISCUSSION

Metal is the most common material as bicycle frame. Metal is us due to its durability,
high tensile strength, high modulus and malleability. The best material as bicycle frame is
Aluminium alloy. This is lightest among the the candidates , high stiffness, high resistance to
corrosion and cost effective. Besides, it can resist both tensile and compressive strength.
Furthermore, the best material for wheels is steel. This is because steel is highly
durable and cost efficient. It can withstand high tensile strength and has high modulus.
Although the metal is heavy, it's is acceptable because the weight of other parts has
compensate the weight of steel and it is best to use steel because the spokes are to be change
more frequently. Steel can be recycled hence reduce pollution and wastage.
Moreover, steel is the best material for mechanical parts of bicycle. Same as wheels,
the mechanical parts are to be changed frequently as to maintain the bicycle. The reason why
steel is the best is because the unwanted steel can be recycled and it is very cost efficient.
Besides, the best material for the handlebar is aluminum alloy. Aluminum alloy fits
the criteria of a handle which is high durability, lightweight, and high resistance to rust.
Aluminum alloy is also cost efficient.
Furthermore, nowadays, market demands for cruelty-free product. Hence, the best
material for bicycle saddle is synthetic saddles with gel padding. This is because synthetic
saddle with gel padding is comfortable and cost efficient. It requires minimal maintenance
and it is cruelty-free.

5.0 CONCLUSION

Based on the analysis above, the top-ranked materials to design the frame, wheels,
mechanical parts, handlebar and saddle are aluminum alloy for frame and handlebar steel for
wheels and mechanical parts and synthetic saddle with gel padding for saddle. However,
bicycles comes in different designs and specifications. On the other words, the material stated
above is only suitable for road bicycles.
6.0 REFERENCES

[5] Essays, UK. (November 2018). Bicycle Frame Materials. Retrieved from
https://www.ukessays.com/essays/engineering/materials-on-bicycle-frames-engineering-
essay.php?vref=1
[2] Metal Prices Archives - Steel, Aluminum, Copper, Stainless, Rare Earth, Metal Prices,
Forecasting. (n.d.). Retrieved from https://agmetalminer.com/category/metal-prices/
[1] SmartEtailing Inc. (n.d.). Road Bike Materials. Retrieved from
https://www.citybikes.com/articles/road-bike-materials-pg57.htm
[7] Anon, (2019). [online] Available at: https://www.researchgate.net/publication
330563989_Advanced_Manufacturing_with_Natural_Materials [Accessed 20 Apr. 2019].
[8] Saddle fit [01] Saddle materials explained - BikeGremlin. (n.d.). Retrieved from
https://www.google.com.my/amp/s/bike.bikegremlin.com/2954/bicycle-saddle-materials-
explained/?amp
[9] Guides, B., Manufacturers, B., Us, A., Us, C. and Guides, B. (2019). Guide to Bicycle
Saddles. [online] Ebicycles.com. Available at: https://www.ebicycles.com/article/guide-to-
bicycle- saddles.html#why-bicycle-saddle-is-important [Accessed 20 Apr. 2019].