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Bicycle Crank Design for Improved Safety

Click here for a detailed design report:

Project Objective: design, produce, and test a bicycle crank with a failure load of 8-10lbf to prevent user injuries.

Won first place in course competition by achieving the lowest device mass within the target load range.

Click on each photo for a short description pertaining to it.

Load Calculations

Load Calculations

Initial Design One

Initial Design One

Initial Design Two

Initial Design Two

Initial Design Three

Initial Design Three

Design One Hand Calculations

Design One Hand Calculations

Design Two Hand Calculations

Design Two Hand Calculations

Design Three Hand Calculations

Design Three Hand Calculations

Design One FEA Stress Plot

Design One FEA Stress Plot

Design One FEA FOS Plot

Design One FEA FOS Plot

Design Two FEA Stress Plot

Design Two FEA Stress Plot

Design One FEA FOS Plot

Design One FEA FOS Plot

Design Three FEA Stress Plot

Design Three FEA Stress Plot

First Prototype

First Prototype

First 3D Printed Prototype

First 3D Printed Prototype

Thickness Iteration

Thickness Iteration

Additional Feature

Additional Feature

Competition-Ready Specimen

Competition-Ready Specimen

Post-Test Plastic Deformation

Post-Test Plastic Deformation

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