kim allen, sam o’flaherty, and austin schantz. design note: all dimensions are in inches 3d...
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GLASS FIBER COMPOSITE BIG
WHEEL
Kim Allen, Sam O’Flaherty, and Austin Schantz
Design NOTE: All dimensions are in inches
3D Conceptual Design
Front View
Side View
Top View
Force Calculations
Force Calculations Continued Known values
Fp=250 lbs FS=3W=575 lbs FS=3
Calculated ValuesFw=127.63 lbs
FB=447.37 lbs
Force Calculations Continued Max Deflection=.1 inch
From this Max strain εmax-B=.025
εmax-w=.004545
If FB=447.37 lbs
Then σB=FB/A=1.553 psi
EB= σB/ εmax-B=61.32 psi=.000422787 GPa
If Fw=127.63 lbs
Then σw=Fw/A=7.977 psi
Ew= σw/ εmax=1755.12 psi=.0121GPa
Composite Design Theoretical Values
E1 (GPa) E2 (GPa) G (GPa) ν
In-Plane Load 3.66 1.65 0.56 0.29
Bending Load 9.09 3.37 1.08 0.28
Initial Values
Calculated Values
Note that the Emax =.0121 GPa. This composite lay-up should hold
E1 (GPa) E2 (GPa) G (GPa) ν
S-Glass Fiber/Epoxy 52.6 17.1 5.25 0.28
Closed Cell Foam Core
.689476 .689476 .27579 0.3
Test Section Small section with same material layup as
project
Planned Use: Find the maximum compressive and torsion load the layup could withstand
Actual Use: Identify the
difficulties in
manufacturing and
bagging a 3-D project
Manufacturing Foam Core Construction
Hot Wire Drilling the hole for the axle
Sanding
Foam Core
Laying Up the Foam with Glass Fiber Composite
Beginning the Lay-up
The Big Wheel Bagged and ready for vacuum curing
Attaching Front yoke and Preliminary Testing
Drilling Holes for Bolts Adjusting Yolk
Making sure it holds our weight
Making Sure it Moves Smoothly
Making Sure it moves and can hold extra weight
Final Product
Testing
Testing PlanRide around a parking lotBasic turnsRiding up a small rampTest completed 3 times
ResultsTests completed successfullyWithstood pull-up and torsion forces
Conclusion
SuccessesWeight rated for an adult riderWithstood forcesProject completed!!!!!
FailuresPedals slip within the hub limiting accelerationMetal components added significant weightTest section not suitable for analysis
QUESTIONS?