Bicycle Exerciser Machine

Project Report
Machine Design and Cad 1

Submitted By
Usman Umer Bme143021
Saad bin Sarfraz Bme143004
Muhammad Faizan Zafar Bme143036

Submitted to

Shahwar Yasin

Department of Mechanical Engineering

Faculty of Engineering
Capital University of Science and Technology
Islamabad.

30th, January, 2017

 Abstract

The goal of the project is to design bicycle exerciser machine. As there are different parts of
bicycle machine i.e. Shaft, gear, Flywheel, bearings etc. We are required to design only the main
parts of the machine i.e. Shaft, Flywheel, gear. The procedure to design three different parts is
that first of all we have to design shaft, and then by using the calculations obtained through
solution of static and with the help of singularity function we have to design other two parts that
are Flywheel and gear. There are steps in shaft and these steps are causing stress concentration
hence we have to find dia of shaft at these points. For all the parts we have to find factor of
safety whose permissible value is 2.5.
Contents
1.0Problem Statement......................................................................................................................4
2.0Problem Constraints....................................................................................................................4
3.0Procedure....................................................................................................................................4
3.1Shaft Design........................................................................................................................4
3.2Flywheel Design.................................................................................................................4
3.3Gear Design........................................................................................................................4
4.0Introduction.................................................................................................................................5
5.0Parts............................................................................................................................................5
5.1Shaft........................................................................................................................................5
5.2Gear.........................................................................................................................................6
5.3Flywheel.................................................................................................................................7
6.0Discussion and Conclusion.........................................................................................................7
1.0Problem Statement
Design an indoor bicycle exerciser. The concept is to provide twin rollers to support the rear
wheel and a single roller for the front wheel. The rear rollers will be attached in some kinematic
fashion (to be designed) to a DC generator whose output is shunted through an electrical load
that can be varied by the rider to provide a dynamometric resistance. Design the parts for infinite
life.

2.0Problem Constraints
The constraints of our project is to design only the main parts i.e. shaft, Flywheel and Gear.

3.0Procedure
3.1Shaft Design
1.First of all, we assume the dimensions of the shaft.
2.Then we calculate the power and torque.
3.Using statics, we have calculated forces Fs, Fn, Fg-tangential and Fg-radial
4.Then we have calculated reaction forces.
5.Then with the help of singularity functions we have calculated maximum shear
force and maximum bending moment.
6.After that we have calculated Se using different factors like Csurface, Cload, Csize,
Ctemp and Creliability.
7.We have calculated q, kfs, kf and then plug it into the dia equation and find the
permissible value of the dia of the shaft.

3.2Flywheel Design
1.First of all, we assume the inner radius of the flywheel.
2.After that we calculated the kinetic energy.
3.After that we calculated the mass moment of inertia of the flywheel.
4.Finally, we have calculated the outer radius of the flywheel and the stresses in the
flywheel.

3.3Gear Design
1.First of all, we calculated the tangential and the radial force on the gear.
2.Then we assume the no of teeth on gear and pinion and the finally calculate the
gearing ratio.
3.Now we have calculated dia of pinion and gear.
4.Using AGMA equation we have calculated stresses.
5. At last we have calculated factor of safety which is in required range.
4.0Introduction
A stationary bicycle (also known as exercise bicycle, exercise bike) is a device with
saddle, pedals, and some form of handlebars arranged as on a bicycle, but used as
exercise equipment rather than transportation. An exercise bicycle is usually a special-
purpose exercise machine resembling a bicycle without true wheels, but it is also
possible to adapt an ordinary bicycle for stationary exercise by placing it on bicycle
rollers or a trainer. Rollers and trainers are often used by racing cyclists to warm up
before racing, or to train on their own machines indoors. Exercise bikes are used for
exercise, to increase general fitness, and for training for cycle events. The exercise bike
has long been used for physical therapy because of the low-impact, safe, and effective
cardiovascular exercise it provides. The low-impact movement involved in operating an
exercise bike does not put much stress on joints and does not involve sporadic motions
that some other fitness equipment may require. We have designed three main parts of the
bicycle exerciser machine i.e. shaft, flywheel and gear.

5.0Parts
Following are the main parts of bicycle exerciser machine

1.Shaft
2.Gear
3.Flywheel

5.1Shaft
A shaft is a rotating machine element, usually circular in cross section, which is
used to transmit power from one part to another, or from a machine which produces power
to a machine which absorbs power. The various members such as pulleys and gears are
mounted on it.
5.2Gear
A gear is a rotating machine part having cut teeth, or cogs, which mesh with another
toothed part to transmit torque. Geared devices can change the speed, torque, and
direction of a power source. Gears almost always produce a change in torque, creating a
mechanical advantage, through their gear ratio, and thus may be considered a simple
machine. The teeth on the two meshing gears all have the same shape. Two or more
meshing gears, working in a sequence, are called a gear train or a transmission. A gear can
mesh with a linear toothed part, called a rack, thereby producing translation instead of
rotation.
 5.3Flywheel
A flywheel is a rotating mechanical device that is used to store rotational energy.
Flywheels have an inertia called the moment of inertia and thus resist changes in
rotational speed. The amount of energy stored in a flywheel is proportional to the square
of its rotational speed. Energy is transferred to a flywheel by the application of a torque to
it, thereby increasing its rotational speed, and hence its stored energy. Conversely, a
flywheel releases stored energy by applying torque to a mechanical load, thereby
decreasing the flywheel's rotational speed.

6.0Discussion and Conclusion

The constraint to design main parts of machine i.e. shaft, gear, flywheel is factor of safety.
The permissible value of factor of safety was 2.5 for our project. All the design is under the
criteria of factor of safety. For iteration, if we choose different values of angular velocity, then
the value of torque changes which ultimately result in changes in power, Fs and Fn. First of all,
we have designed shaft, and then with the help of values obtained through statics solution and
with the help of singularity function we have obtained values of moments at different points we
have designed gear. There are steps in shaft and these steps are causing stress concentration
hence we have to find dia of shaft at these points. Through graphs on xz plane and yz plane we
have chosen values of moments and using Pythagoras theorem we have find magnitude.one of
the value of F.O.S was not in our range so we iterate once and set the value again to obtained
desired result. We have to designed Shaft, Flywheel, gear for our machine i.e. bicycle exerciser
the results obtained are according to the criteria to design i.e. factor of safety. The permissible
value for factor of safety was 2.5.