This article is a successful case for the optimization design of folding bicycles for the selection of SolidWorks design and simulation integrated solutions for Daxing Technology (Shenzhen) Co., Ltd.
Introduction of Daxing Technology (Shenzhen) Co., Ltd.
Since its establishment in California in 1982, the DAHONCALIFORNIA (INC.) Group has been the first to promote environmentally friendly transportation tools---folding bicycles. And with their own brands DAHON and YEAH! Folding bicycles are sold well all over the world and have won many international awards. They have set up branches or factories in mainland China, Taiwan, the Netherlands and Macao, and have been praised as “the world's largest manufacturer of folding bicycles†by Guinness.
Big line folding bikes are divided into four categories: city cars, electric cars, mountain bikes and sports cars. They also offer 12", 14", 16", 18", 20", 24", 26" and other sizes. It is popular in the market and is highly favored by the market. The design of the vehicle follows the principle of human body mechanics, riding comfort, speed and effort. Dahang Company adheres to the principle of quality first and establishes a complete quality control system, strictly in accordance with EN, JIS, CPSC, DIN, BS, AS and other safety standards are produced, and the quality is trusted by consumers.
Challenges in product development
1. When the bicycle is exported, it needs to pass the test of the relevant standards in the area it sells to ensure the safety of the consumers.
2. Due to the complicated shape of the frame, it is difficult to check the strength by manual calculation.
3. It can only be tested repeatedly by making a prototype.
4. It is often necessary to modify the structure several times in order to meet the test requirements, which leads to a long time-to-market for new products and consumes a lot of manpower and material resources.
5. Rising material and labor costs have led to a decline in profits.
6. R&D engineers should balance product economics and safety.
7. The vibration of the bicycle when driving on different roads is unpredictable.
8. Will resonance occur, causing the frame to break.
Simulation-based solution
1.SimulationWorks solves structural strength, vibration, reliability, and optimal design.
2. According to the EN standard, the fatigue analysis of the pedal force of the frame should be carried out as follows.
3. Product SolidWorks model
4. The basis of fatigue analysis is static analysis
5. Constrain the model and load
6. Observe the stress, displacement, strain and safety factor distribution of static analysis
7. Fracture analysis in Simulaiton is simple
8. Considering that the frame is a plastic material, Gerber stress correction method is selected.
9. Watch the fatigue damage cloud map
10. Watch life is always a cycle picture
11. The distribution of safety factors tells us that the safety factor of 3 may be too conservative, and the optimized design of Simulation is used to optimize the frame to save materials;
12. The optimized quality is reduced from 3.35Kg to 2.48Kg, saving 26% of material.
13. Perform frequency analysis on the frame to avoid resonance of the frame
14. List resonance frequency and view vibration mode
By checking the results of the analysis, the following conclusions can be drawn:
1. The analytical method and analysis template are correct and can be used for analysis of similar products.
2. There is a very good mapping relationship between the test data and the simulation data, and the test data can be derived based on the simulation data.
3. The simulation analysis part can be used instead of the test to reduce the test workload and cost.
4. Simulation analysis can be used to verify product performance and optimize design.
5. Relying on simulation software to analyze products, shortening the research and development cycle of new products and reducing product costs.
6. Make the R&D capability of Daxing far ahead in the industry and enhance the image and competitiveness of the company.
7. The performance and appearance of our design new products will have a strong response in the European exhibitions, Japan exhibitions and Taiwan exhibitions over the years.
Extrusion Aluminium
Extrusion aluminium, also known as aluminum extrusion, is a manufacturing process used to create durable and versatile aluminum-based products. The process involves pushing molten aluminum through a die under high pressure or pulling it through the die using a ram. The resulting product is a smooth surface, uniform cross-section, and precise dimensions.
The extrusion process can create complex shapes and intricate designs, making it popular in various industries such as architecture, automotive, and aerospace. Common extruded aluminum products include window frames, door frames, curtain walls, and structural components.
One advantage of extrusion aluminum is its versatility. It can be modified and finished to suit different requirements, such as anodizing to provide extra corrosion resistance or powder coating to add a decorative finish. Additionally, extrusion aluminium offers excellent strength-to-weight ratios and is highly durable, making it an ideal material for products that require high strength and durability.
Another advantage of extrusion aluminium is its cost-effectiveness. The manufacturing process is highly efficient, allowing for the creation of large quantities of products at a reduced cost compared to other materials such as steel or copper.
Although extrusion aluminium has many benefits, it also has some limitations. The material is highly conductive and may require insulation in certain applications. Additionally, extruded aluminum products may have difficulty achieving tight tolerances and precision, making it unsuitable for some specialized applications.
Overall, extrusion aluminium has become an essential material in various industries, providing both strength and versatility at a reasonable cost. As technology continues to advance, even more advanced and innovative applications of extruded aluminum are expected to emerge.
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