Posted: February 5th, 2015

Bicycle Brake Calliper

Paper, Order, or Assignment Requirements

A bicycle manufacturing company has identified a market opportunity for a high quality, low weight bicycle suitable for use by children aged between 6 and 8 years old. The target market is considered to be in the region of 25,000 parts per year and the companies usual product life cycle is 8 to 10 years. The Engineering Design department has been tasked with investigating the redesign of four, key components using alternative, polymer based, materials.

You are required to investigate the functional requirements, existing materials and manufacturing processes used in the production of your allocated component. A new, alternative, design should be developed so that a polymer-based material can be used in its manufacture. Detailed design documentation together with a manufacturing rationale should be generated.

Bicycle Brake Calliper

1. The existing component should be considered/investigated before the redesign is attempted. Suitable tools and techniques (including the Coordinate Measurement Machine and related software) should be used to appraise the component’s features and functional requirements.

2. A Product Design Specification should be compiled in order to capture the design targets for the new, replacement component or assembly.

3. Suitable design techniques should be used to develop a detailed design solution.

4. Using SolidWorks Computer Aided Engineering software, the final design should be modelled using appropriate modelling techniques and assembly constraints/mates. The final assembly should be modelled and constrained in such as way as to allow the functional, inter-part relationships to be appraised.

5. Finite Element Analysis (FEA) should be completed on your final design. A minimum requirement is to analyse a single component of the assembly (not the assembly as a whole). Appropriate loads will be given for a standard analysis. However, motion simulation may be used to generate appropriate loadings for the component being analysed. Interpretation of the results obtained from your analysis (and how they have influenced your design decisions) should be discussed in your report.

6. A detailed 3rd angle projection technical drawing of the final design should be produced. Appropriate specifications should be included such as limit/geometric tolerances and surface finish requirements.

7. Your work should initially identify the materials and manufacturing processes used in the current design.
8. Using suitable material selection tools, consideration should be given to different material solutions, manufacturing processes and assembly processes, which could meet the product requirements.
9. The technical proposal for the newly designed component should include final material specifications and manufacturing process selection. The report should also consider environmental issues and any health and safety implications with these solutions.
10. Marks will be awarded for the structure, presentation and referencing.

Brake Calliper – 8kg

11.Give a 5 minute presentation