The perfect full suspension mountain bike
The goal of this project is to design and build the perfect full suspension mountain bike. This project is an independent research study advised by Dr. Rebecca Simmons and the Thomas Lord Department of Mechanical Engineering and Material Science at Duke University.
Design of suspension linkage with Particle Swarm Optimization, Advanced Mechanical synthesis, Constrained Optimization
Smart SolidWorks model linked to optimization results, FEA backed by hand calculations and experimentation
Design and build fixturing for fabrication, machine frame components
Design sensing harness complete with accelerometers, strain gauges, and biometric sensors to analyze the performance of the highly dynamic human-machine system
A common way to approach suspension kinematic design of a mountain bike is through software such as Linkage X3 in combination with a 2d mechanism design software such as Linkage. This workflow presents a challenge; any change to a pivot point may drastically change the leverage curve, vertical wheel travel, or other key suspension metrics.
All of the information needed can be condensed into a few digestible graphs: Rear Axle Path, Leverage Ratio, and Anti-Rise.
After the suspension design and the static geometry were nailed down, it was time to take the concept from 2D to 3D. With that came some tricky decisions about load cases and strength of joints and materials.
This stage involved designing and building an adjustable jig, machining components, and assembling the bike frame. The focus was on creating a precise and efficient fabrication process.
In the final stage, a testing harness will be designed complete with with accelerometers, strain gauges, and biometric sensors to analyze the performance of the human-machine system.