Stress analysis and fabrication of composite monocoque bicycle frames

An analytical and experimental investigation was conducted to study the design and fabrication of carbon fiber track bicycle frames. A finite element software was used for the geometry development, laminate configuration, and for predicting failure using the maximum stress criteria. A load case and boundary conditions simulating actual riding conditions were developed. The stresses in each of the composite layers were found to be lower than the allowable stresses because of a properly designed geometry and laminate. Two composite frames were fabricated using the hand lay-up technique, using unidirectional and woven carbon fiber pre-preg material over an internal foam core. Using static testing techniques and comparisons with traditional tubular frames, the carbon fiber prototypes were shown to be better in all rigidity aspects. Combining the experimental and theoretical results, a good understanding of the critical problems related to composite monocoque bicycle frame design was obtained