McEwen, Iain, Cooper, David E., Warnett, Jason M., Kourra, Nadia, Williams, M. A. and Gibbons, Gregory John (2018) Design & manufacture of a high-performance bicycle crank by additive manufacturing. Applied Sciences, 8 (8). 1360. doi:https://doi.org/10.3390/app8081360

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Abstract

A new practical workflow for the laser Powder Bed Fusion (PBF) process, incorporating topological design, mechanical simulation, manufacture, and validation by computed tomography is presented, uniquely applied to a consumer product (crank for a high-performance racing bicycle), an approach that is tangible and adoptable by industry. The lightweight crank design was realised using topology optimisation software, developing an optimal design iteratively from a simple primitive within a design space and with the addition of load boundary conditions (obtained from prior biomechanical crank force–angle models) and constraints. Parametric design modification was necessary to meet the Design for Additive Manufacturing (DfAM)considerations for PBF to reduce build time, material usage, and post-processing labour. Static testing proved performance close to current market leaders with the PBF manufactured crank found to be stiffer than the benchmark design (static load deflection of 7.0±0.5 mm c.f. 7.67mm for a Shimano crank at a competitive mass (155g vs. 175g). Dynamic mechanical performance proved inadequate, with failure at 2495±125cycles; the failure mechanism was consistent in both its form and location. This research is valuable and novel as it demonstrates a complete work flow from design, manufacture, post-treatment, and validation of a highly loaded PBF manufactured consumer component, offering practitioners a validated approach to the application of PBF for components with application outside of the accepted sectors (aerospace, biomedical, autosports, space, and power generation).

Item Type:	Journal Article
Subjects:	T Technology > TJ Mechanical engineering and machinery
Divisions:	Faculty of Science > WMG (Formerly the Warwick Manufacturing Group)
Library of Congress Subject Headings (LCSH):	Three-dimensional printing, Cranks and crankshafts, Tomography, Bicycles, Mathematical optimization, Topology, Structural optimization
Journal or Publication Title:	Applied Sciences
Publisher:	MDPI
ISSN:	2076-3417
Official Date:	13 August 2018
Dates:	Date Event 13 August 2018 Published 7 August 2018 Accepted 7 August 2018 Modified 17 July 2018 Submitted
Volume:	8
Number:	8
Article Number:	1360
DOI:	https://doi.org/10.3390/app8081360
Status:	Peer Reviewed
Publication Status:	Published
Access rights to Published version:	Open Access
Copyright Holders:	MDPI
Open Access Version:	Publisher

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