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Compliance Engineering Journal ISSN NO: 0898-3577

Design and Fabrication of Driven by Shaft and System

1R. Panchamoorthy,2 P. Balashanmugam,3 S. Muthukumar ,4 N. Sivakumar 1,3,4 Assistant Professors, 2Associate Professor(1234 Deputed) , Annamalai University, Chidambaram, Tamilnadu, India.

Abstract: A chainless bicycle is a bicycle that uses a instead of a chain to transmit power from the pedals to the . Shaft drives were introduced over a century ago, but were mostly supplanted by chain-driven due to the gear ranges possible with and . Recently, due to advancements in internal gear technology, a small number of modern shaft-driven bicycles have been introduced. Shaft-driven bikes have a be where a conventional bike would have its chain ring. This meshes with another mounted on the drive shaft. The Bevel are the most efficient way of turning drives 90 degrees as compared to worm gears or crossed helical gear. The shaft drive only needs periodic lubrication using a grease gun to keep the gears running quiet and smooth. This “chainless” drive system provides smooth, quite and efficient transfer of energy from the pedals to the rear wheel. It is attractive in compare with chain driven bicycle. It replaces the traditional method. Keywords: , drive torque, bicycle, forming process, internal gear technology

1. Introduction Elimination of Chain Drive in bi-cycle uses two sets of spiral bevel gears and a shaft rod to smoothly transfer power from the cranks to rear wheel. The bevel gears are made of heat treated comely and paired with high quality sealed cartridge bearings coupled to a steel shaft rod – all sealed inside lightweight, durable aluminum alloy. Our shaft drive, now in its third generation, has been in production since 1991, and is already on tens of thousands of bikes all over the world. By integrating our shaft drive with 's internal hubs, our bikes not only have a sleek, modern look, but they deliver an incredibly smooth ride, great performance and eliminate the number one complaint people have always had about their bikes the chains and derailleur. With our shaft drive bikes; there is no more grease; no more mess; no more cuts on fingers or tears in clothes; and no more chain and derailleur maintenance. Just pure, worry-free riding fun. An elimination of chain drive in bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power from the pedals to the wheel. Chain drive in by-cycle has a large bevel gear where a conventional bike would have its chain ring. This meshes with another bevel gear mounted on the drive shaft. The use of bevel gears allows the axis of the drive torque from the pedals to be turned through 90 degrees. The drive shaft then has another bevel gear near the rear wheel hub which meshes with a bevel gear on the hub where the rear would be on a conventional bike, and canceling out the first drive torque change of axis. The 90-degree change of the drive plane that occurs at the and again at the rear hub requires the use of bevel gears. Bevel gears are the most efficient way of turning drives 90 degrees as compared to worm gears or crossed helical gears. The drive shaft is often mated to a which is an internal gear system housed inside the rear hub.

2.Literature Review The first shaft drives for cycles appear to have been invented independently in 1890 in the United States and England. The Drive shafts are carriers of torque; they are subject to torsion and shear stress, which represents the difference between the input force and the load. They thus need to be strong enough to bear the stress, without imposing too great an additional inertia by virtue of the weight of the shaft. Most automobiles today use rigid driveshaft to deliver power from a to the . A pair of short driveshaft is commonly used to send power from a central differential, transmission, or transaxie to the wheels. Shaft drives were introduced over a century ago. The first shaft drives for cycles appear to have been invented independently in 1890 in the United States and England. A. Fearnhead, of London

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developed one in 1890 and received a patent in October 1891. His prototype shaft was enclosed within a tube running along the top of the chain stay. Later models were enclosed within the actual chain stay. The first shaft drives for cycles appear to have been invented independently in 1890 in the United States and Britain. A. Fearnhead, of North London developed one in 1890 and received a patent in October 1891. His prototype shaft was enclosed within a tube running along the top of the chain stay; later models were enclosed within the actual chain stay. The shaft drive was not well accepted in Britain, so in 1894 Fearnhead took it to the USA where Colonel Pope of the Columbia firm bought the exclusive American rights. Belatedly, the British makers took it up, with in particular plunging heavily on the deal. Curiously enough, the greatest of all the Victorian cycle engineers, Professor Archibald Sharp, was against shaft drive; in his classic 1896 book "Bicycles and ", he writes "The Fearnhead Gear.... if bevel-wheels could be accurately and cheaply cut by machinery, it is possible that gears of this description might supplant, to a great extent, the chain-drive gear; but the fact that the teeth of the bevel-wheels cannot be accurately milled is a serious obstacle to their practical success". In the USA, they had been made by the League Cycle Company as early as 1893. Soon after, the French company Metropole marketed their Acatane. By 1897 Columbia began aggressively to market the chainless bicycle it had acquired from the League Cycle Company. Chainless bicycles were moderately popular in 1898 and 1899, although sales were still much smaller than regular bicycles, primarily due to the high cost. The bikes were also somewhat less efficient than regular bicycles: there was roughly an 8 percent loss in the gearing, in part due to limited manufacturing technology at the time. The rear wheel was also more difficult to remove to change flats. Many of these deficiencies have been overcome in the past century. In 1902, The Hill-Climber Bicycle Mfg. Company sold a three-speed shaft-driven bicycle in which the shifting was implemented with three sets of bevel gears. While a small number of chainless bicycles were available, for the most part, shaft-driven bicycles disappeared from view for most of the 20th century. There is, however, still a niche market for chainless bikes, especially for commuters, and there is a number of manufacturers who offer them either as part of a larger range or as a primary specialization. A notable example is Biomega in Denmark. Shaft drives operate at a very consistent rate of efficiency and performance, without adjustments or maintenance, though lower than that of a properly adjusted and lubricated chain. Shaft drives are typically more complex to disassemble when repairing flat rear tyres, and the manufacturing cost is typically higher. A fundamental issue with bicycle shaft-drive systems is the requirement to transmit the torque of the rider through bevel gears with much smaller radii than typical bicycle sprockets. This requires both high quality gears and heavier frame construction. Since shaft-drives require gear hubs for shifting, they gain the benefit that gears can be shifted while the bicycle is at a complete stop or moving in reverse, but internal hub geared bicycles typically have a more restricted gear range than comparable derailleur-equipped bicycles. The Drive shafts are carriers of torque, they are subject to torsion and shear stress, which represents the difference between the input force and the load. They thus need to be strong enough to bear the stress, without imposing too great an additional inertia by virtue of the weight of the shaft. Most automobiles today use rigid driveshaft to deliver power from a transmission to the wheels. A pair of short driveshaft is commonly used to send power from a central differential, transmission, or transaxiel to the wheels.

3. Components and Description The Fabrication of Bicycle Driven by Shaft and Gear System consists of the following components (shown in figure 1). Pedal Frame Hub Driven Shaft Bearing

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Bevel gear

Fig 1. Components of bicycle

3.1. Pedal A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the bicycle. It provides the connection between the cyclist's foot or shoe and the crank allowing the leg to turn the bottom bracket spindle and propel the bicycle's wheels. on which the foot rests or is attached, that is free to rotate on bearings with respect to the spindle. Part attached to crank that cyclist rotate to provide the bicycle power as shown in figure 2.

Fig 2. Pedal

3.2. Fender Piece of curved metal covering a part of wheel (shown in figure 3) to protect the cyclist from being splashed.

Fig 3. Fender

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3.3. Front Brake activated by brake cable compressing a calliper of return springs. It forces a pair of brake pads against the sidewalls to stop the bicycle. 3.4. Hub Centre part of the wheel from which radiate, inside the hub are ball bearings enabling to rotate around in as shown in figure 4 .

Fig 4. H u b 3.5. Driven Shaft A shaft-driven bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power from the pedals to the wheel is shown in figure 5. Shaft drives were introduced over a century ago, but were mostly supplanted by chain-driven bicycles due to the gear ranges possible with sprockets and derailleur. Recently, due to advancements in internal gear technology, a small number of modern shaft-driven bicycles have been introduced.

Fig 5. Driven Shaft

3.6. Bearing For the smooth operation of Shaft, bearing mechanism is used as shown in figure 6. To have very less friction loss the two ends of shaft are pivoted into the same dimension bearing.

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Fig 6. B e a r i ng 3.7. Bevel gear A kind of gear in which the two wheels working together lie in different planes and have their teeth cut at right angles to the surfaces of two cones whose apices coincide with the point where the axes of the wheels would meet is shown in figure 7.

Fig 7. Bevel Gear

4. Manufacturing Process 4.1. Introduction Manufacturing involves turning raw material to finished products, to be used for various purposes. There are a large number of processes available. These processes can be broadly classified into four categories . Casting process Forming process Fabrication process

4.2. CASTING PROCESS These processes only processes where the liquid metal is used. Casting is also the oldest known manufacturing process. Basically, it consists of inducing the molten metal into a cavity of mould of

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the required form and allowing the metal to solidify. Casting is the most flexible and cheapest method and given high strength of rigidity to the parts which are difficult to produce by other manufacturing processes. The principle process among these sand casting where sand is used as the raw material. The process is equally suitable for the production of a small batch as well as on a large scale. Some of the other classified casting processes for specialized need are • Shell mould casting • Precision mould casting • Plaster mould casing The various types of casting processes are given in the table1. Table 1 Types of casting process

Process Advantages Disadvantages Examples

Many Engine blocks, Sand metals, sizes, Poor finish & tolerance cylinder heads shapes, cheap Connecting heads, Shell Mold Better accuracy, finish, Limited part size brake components higher production rate

Expendable Wide shapes of Patterns have Cylinder heads, Pattern metals, sizes, shapes low strength brakes components

Plaster Complex shapes, Non-ferrous metal, Prototype of good surface finish low production rate mechanical Mold parts

Ceramic Complex shapes, Small sizes Impellers, Mold high accuracy, good injection mold finish tooling Complex Investment shapes, Small parts, expensive jewellery excellent finish Good finish, Permanent low porosity, Costly mold, Gears, gear Mold high simpler shapes housings production rate only Excellent Die dimensional Costly dies, small Gears, camera accuracy, high parts, non-ferrous bodies, wheels production rate metals Large cylindrical parts, Pipes, Centrifugal good quality Expensive, few shapes boilers, 4.3. Forming process These are solid state manufacturing processes involve minimum amount of material wastage. In forming process metal may be heated to temperature which is slightly below. These solidify temperature and large force is applied such the material flows and act in desired shape. The desire shape is controlled by means of a set of tool ties and dies, which may be closed during manufacturing.

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These processes are normally used for large scale production rates. These are generally economical and, in many cases, improve the mechanical properties. These are some of the metal forming processes. Rolling forging Drop forging Press forging Upset forging

4.4. Fabrication Process These are secondary manufacturing processes where the starting raw materials are produced by any one of the previous manufacturing processes desired. Its assembly involves joining pieces either temporary or permanent. So that they would be perform the necessary function. The joining can be achieved by either or both of heat and pressure joining materials. Many of the steel structure construction, we see are first rolled and then joined together by a fabrication process are Gas welding Electric arc welding Electrical resistance welding Thermo welding

4.5. Material Removal Process These are also a secondary removal manufacturing process, where the additional unwanted material is removed in the form of chips from the blank material by a hard tool so as to obtain the final desired shape. Material removal is normally a most expensive manufacturing process. Because more energy is consumed and also a lot of waste material is generated in this process. Still this process is widely used because it delivers very good dimensional accuracy and good surface finished. Material removal process are also called machining processes as shown in figure 8,9,10 and figure11. Various processes in this category are Turning  Drilling  Shaping and planning  Milling  Grinding 

Fig 8. Drilling Operations

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Fig 9. Turning Operations

Fig 10. Grinding Operation

Fig 11. Milling Operation

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4.6. Welding Welding is a process of joining two metal pieces by the application of heat. Welding is the least expensive process and widely used now a days in fabrication. Welding joints different metals with the help of a number of processes in which heat is supplied either electrically or by mean of a gas torch. Different welding processes are used in the manufacturing of Auto mobiles bodies, structural work, tanks, and general repair work. In the industries, welding is used in refineries and pipe line fabrication. It may be called a secondary manufacturing process as shown in figure 12 and 13. 4.6.1. Types of Welding Process GAS WELDING Oxy-Acetylene Air-Acetylene Oxy-Hydrogen 4.6.2. Resistance Welding Butt Welding Spot Welding Seam Welding Projection Welding 4.6.3. Arc Welding Carbon Arc Welding Metal Arc Welding Plasma Arc Welding Gas Metal Arc Welding Gas Tungsten Arc Welding 3.6.4. Newer Welding Electron Beam Welding Laser Beam Welding

Fig 12. Arc Welding

Fig 13. Gas Welding

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5. Working Principle A chainless bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power from the pedals to the wheel. Shaft drives were introduced over a century ago, but were mostly supplanted by chain-driven bicycles due to the gear ranges possible with sprockets and derailleur. Recently, due to advancements in internal gear technology, a small number of modern shaft-driven bicycles have been introduced. Shaft-driven bikes have been where a conventional bike would have its chain ring. This meshes with another bevel gear mounted on the drive shaft. The 2D view of Shaft driven bicycle is shown in figure 14. The Bevel gears are the most efficient way of turning drives 90 degrees as compared to worm gears or crossed helical gear as shown in figure 15. In this shaft driven bicycle, the is mounted with the bicycle. It is mainly used to the gear transmission for increasing the speed of the bicycle. The shaft drive only needs periodic lubrication using a grease gun to keep the gears running quiet and smooth. This “chainless” drive system provides smooth, quiet and efficient transfer of energy from the pedals to the rear wheel. It is attractive in look compare with chain driven bicycle. It replaces the traditional method.

Fig 14. Bicycle in 2D view

Fig 15. Gear Arrangement

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6.Comparison of Shaft V s Chain Chain Drive in by-cycle operates at a very consistent rate of efficiency and performance, without adjustments or maintenance, though lower than that of a properly adjusted and lubricated chain. Shaft drives are typically more complex to disassemble when repairing flat rear and the manufacturing cost is typically higher. A fundamental issue with bicycle shaft- drive systems is the requirement to transmit the torque of the rider through bevel gears with much smaller radii than typical bicycle sprockets. This requires both high quality gears and heavier frame construction. Since shaft-drives require gear hubs for shifting, they gain the benefit that gears can be shifted while the bicycle is at a complete stop or moving in reverse, but internal hub geared bikes typically have a more restricted gear range than comparable derailleur-equipped bikes. Most of the advantages claimed for a shaft drive can be realized by using a fully enclosed chain case. Some of the other issues addressed by the shaft drive, such as protection for thing and from ingress of dirt, can be met through the use of chain guards. The comparison of shaft and chain is shown in figure 16.The reduced need for adjustment in shaft-drive bikes also applies to a similar extent to chain or -driven hub-geared bikes. Not all hub gear systems are shaft compatible.

Fig 16. Comparison of shaft Vs chain 7.Merits of Drive Shaft • They have high specific modulus and strength. • Reduced weight. • Due to the weight reduction, energy consumption will be reduced. • They have high damping capacity hence they produce less vibration and noise. • They have good corrosion resistance. • Greater torque capacity than steel or aluminium shaft. • Longer fatigue life than steel or aluminium shaft. • Lower rotating weight transmits more of available power. 8.Design Assumptions • The shaft rotates at a constant speed about its longitudinal axis. • The shaft has a uniform, circular cross section. • The shaft is perfectly balanced, i.e., at every cross section, the mass • center coincides with the Geometric center. • All damping and nonlinear effects are excluded. • The stress-strain relationship for composite material is • linear & elastic; hence, Hooke’s law is Applicable for composite materials. • Acoustical fluid interactions are neglected, i.e., the shaft is assumed to be acting in a vacuum.

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9.Advantages

• Drive system is less likely to become jammed. • The use of a gear system creates a smoother and more consistent pedaling motion. • Lower maintenance. • Efficiency is more as compared to conventional bicycle design. • High durability. • Low cost of ownership when manufactured in large scale. 10.Applications

• It is used for racing purpose. • Also used for Off-road riding. • For . • For public and bicycle rental purpose. Conclusion This research work is cleanly explained about how the bicycle runs by the shaft and gear system. We used bevel gear mechanism. It is used to transmits the power through the bevel gear to run the bicycle. Existing material used in bicycle crown wheel and crown shaft, is used to transmit the power to the bicycle. We are replacing the crown wheel and crown soft into bevel gear. Use of bevel gear the starting torque is high when compared to the already existing bicycle which is present in the market. It is made up of mild steel .so load carrying capacity of our bicycle of shaft driven bicycle is high when compared to the other product. The shaft driven bicycle is designed successfully. The bicycle works efficiently and transmits the power from pedal to rear wheel smoothly, but it is requiring slightly more initial torque compare to drive torque. The noise and the vibration of the gear pair are considerably reduced. This bicycle can be used for racing purpose and off-road riding. As the speed of the shaft driven bicycle is more enough, it can be utilized for generating pedal work. The presented work was aimed to reduce the wastage of (energy) on bicycle riding or any machine, which employs drive shafts; in general, it is achieved by using light weight drive shaft with bevel gears on both sides designed on replacing chain transmission. The design of drive shaft is critical as it is subjected to combined loads. The designer has two options for designing the drive shaft whether to select solid or hollow shaft. The solid shaft gives a maximum value of torque transmission but at same time due to increase in weight of shaft, For a given weight, the hollow shaft is stronger because it has a bigger diameter due to less weight & less bending moment. References

[1] Prasad G. H., Marurthi S., Ganapathi R., Janardhan M., Madhusudan M.P., 2014, “Design & fabrication of shaft drive for bicycle”, International Journal of Emerging Engineering Research and Technology, Volume 2, Issue 2, pp.43-49

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[2] BhajantriV. S., Bajantri S. C., Shindolkar A. M., Amarapure S. S,2014,"Design and analysis of composite drive shaft"., International Journal of Research in Engineering and Technology, Volume 03 Special Issue 03, pp.738-745 [3] Parashar A., Purohit S., Malviya S., Pande, 2016, “Design and fabrication of shaft driven bicycle”, International Journal of Science Technology and Engineering, Volume 2, Issue 11, pp.23- 31. [4] Gawande A. S., Gedam A. E., Pipre A. G., Bajait N. C.,2015, “Design and fabrication of shaft driven bicycle”, International Journal for Scientific Research &Development, Volume 3, Issue 02, pp.2526-2529. [5] R. P. Kumar Rompicharla1, Dr. K. Rambabu2 Sep-Oct. 2012 Design and Optimization of Drive Shaft with Composite Materials International Journal of Modern Engineering Research (IJMER) www.ijmer.com Vol.2, Issue.5, pp-3422- 3428 ISSN: 2249-6645. [6]. Design and Fabrication of Shaft Driven Bicycle, (IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 02, 2015 | ISSN (online): 2321-0613) [7]. Design of Dual Mode Bicycle by Using Gear Box, ISSN: 2277-3754 ISO 9001:2008 Certified International Journal of Engineering and Innovative Technology (IJEIT) Volume 4, Issue 12, June 2015 [8]. Design & Fabrication of Shaft Drive for Bicycle, International Journal of Emerging Engineering Research and Technology Volume 2, Issue 2, May 2014, PP [9]. Design & Fabrication of Shaft Driven Bicycle, (IJSTE - International Journal of Science Technology & Engineering | Volume 2 | Issue 11) [10] Rastogi, N. (2004). Design of composite drive shafts for automotive applications. Visteon Corporation, SAE technical paper series. [11] 73332270 Design and Analysis of a Propeller Shaft of a Toyota Qualis by “Syed Hasan”. [12] A.M.Ummuhaani and Dr.P. Sadagopan “Design, Fabrication and Stress Analysis of a Composite Propeller Shaft, 2011-28-0013. [13] Anup A. Bijagare, P.G. Mehar and V.N. Mujbaile “Design Optimization & Analysis of Drive Shaft”, Vol. 2 (6), 2012, 210-215. [14] Rangaswamy, T.; Vijayrangan, S. (2005). Optimal sizing and stacking sequence of composite drive shafts. Materials science, Vol. 11 No 2., India. [15] Rastogi, N. (2004). Design of composite drive shafts for automotive applications. Visteon Corporation, SAE technical paper series.

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