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    Tube To Tube Bicycle Frame Building

    Uploaded by

    Rusty_Iron_Works
    This document provides an agenda and overview of topics for a tube-to-tube carbon framebuilding technique seminar, including definitions of terms, introductions to composites and materials, laminate theory, design considerations, manufacturing processes like cutting/machining, bonding, joining, vacuum bagging, finishing, repairs, and a question and answer session. The key topics covered are tube-to-tube carbon frame construction using prefabricated frame tubes joined with additional carbon wrapping, introductions to epoxy matrix and carbon fiber materials, and laminate design and manufacturing techniques like bonding, vacuum bagging, and repairs.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Tube To Tube Bicycle Frame Building

    Uploaded by

    Rusty_Iron_Works
    186 views21 pages
    This document provides an agenda and overview of topics for a tube-to-tube carbon framebuilding technique seminar, including definitions of terms, introductions to composites and materials, laminate theory, design considerations, manufacturing processes like cutting/machining, bonding, joining, vacuum bagging, finishing, repairs, and a question and answer session. The key topics covered are tube-to-tube carbon frame construction using prefabricated frame tubes joined with additional carbon wrapping, introductions to epoxy matrix and carbon fiber materials, and laminate design and manufacturing techniques like bonding, vacuum bagging, and repairs.

    Original Description:

    Bicycle Frame building

    Original Title

    Tube to Tube Bicycle Frame building

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    This document provides an agenda and overview of topics for a tube-to-tube carbon framebuilding technique seminar, including definitions of terms, introductions to composites and materials, laminate theory, design considerations, manufacturing processes like cutting/machining, bonding, joining, vacuum bagging, finishing, repairs, and a question and answer session. The key topics covered are tube-to-tube carbon frame construction using prefabricated frame tubes joined with additional carbon wrapping, introductions to epoxy matrix and carbon fiber materials, and laminate design and manufacturing techniques like bonding, vacuum bagging, and repairs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    186 views21 pages

    Tube To Tube Bicycle Frame Building

    Uploaded by

    Rusty_Iron_Works
    This document provides an agenda and overview of topics for a tube-to-tube carbon framebuilding technique seminar, including definitions of terms, introductions to composites and materials, laminate theory, design considerations, manufacturing processes like cutting/machining, bonding, joining, vacuum bagging, finishing, repairs, and a question and answer session. The key topics covered are tube-to-tube carbon frame construction using prefabricated frame tubes joined with additional carbon wrapping, introductions to epoxy matrix and carbon fiber materials, and laminate design and manufacturing techniques like bonding, vacuum bagging, and repairs.

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    © All Rights Reserved
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    Tube

    Tube
    -
    -
    To
    To
    -
    -
    Tube Bicycle
    Tube Bicycle
    Framebuilding Technique
    Framebuilding Technique
    Agenda
    Agenda

    Tube to Tube Carbon


    Tube to Tube Carbon

    Advanced Composites
    Advanced Composites
    intro
    intro

    Laminate Theory
    Laminate Theory

    Design Validation
    Design Validation

    Cutting/Machining
    Cutting/Machining

    Bonding
    Bonding

    Joining Process
    Joining Process

    Vacuum Bagging
    Vacuum Bagging

    Braze
    Braze
    ons
    ons

    Finishing
    Finishing

    Repairs
    Repairs

    Misc
    Misc
    Q
    Q& &
    A
    A
    Definition of Tube
    Definition of Tube
    -
    -
    To
    To
    -
    -
    Tube
    Tube

    Based on standard frame building


    Based on standard frame building
    technique
    technique

    Prefabricated individual frame tubes,


    Prefabricated individual frame tubes,
    mitered
    mitered

    Tacked in fixture
    Tacked in fixture

    Fully joined with additional carbon


    Fully joined with additional carbon
    wrapping
    wrapping
    Advanced Composites Intro
    Advanced Composites Intro
    Matrix
    Matrix

    Matrix
    Matrix
    Epoxy Epoxy

    Thermoset
    Thermoset

    Binding
    Binding

    Shape and structure


    Shape and structure

    Cross linking present


    Cross linking present

    Load transference
    Load transference

    Forms continuous
    Forms continuous
    phase
    phase

    Exceeds polyester
    Exceeds polyester
    Adhesion Adhesion
    Shear Shear
    Fatigue Fatigue
    Strength Strength
    Stiffness Stiffness
    Advanced Composites Intro cont.
    Advanced Composites Intro cont.
    Carbon Fiber
    Carbon Fiber

    Types
    Types
    Rayon Rayon
    Polyacrylonitrile (PAN) Polyacrylonitrile (PAN)
    Pitch Pitch

    PAN most common


    PAN most common

    Processed
    Processed
    Into filaments, tow Into filaments, tow
    Under tension Under tension
    Up to 6000f Up to 6000f

    Fiber properties
    Fiber properties
    Tensile strength Tensile strength
    Modulus Modulus
    Elongation at break Elongation at break

    Forms
    Forms
    Tow Tow
    Uni Uni
    PW, Twill and HS PW, Twill and HS
    weave weave
    Braid, 3D Braid, 3D
    Advanced Composites Intro cont.
    Advanced Composites Intro cont.
    Fiber properties
    Fiber properties
    .5 .5 64 64 500 500 Ultra high Ultra high
    modulus modulus
    1.0 1.0 55 55 550 550 High High
    modulus modulus
    2.1 2.1 42 42 880 880 Intermediate Intermediate
    modulus modulus
    1.6 1.6 33 33 600 600 Standard Standard
    modulus modulus
    Elongation% Elongation% Modulus Modulus Msi Msi Tensile Tensile
    strength strength ksi ksi
    Fiber Fiber
    Advanced Composites Intro cont.
    Advanced Composites Intro cont.
    Common Fiber forms
    Common Fiber forms
    3k PW 5.7oz
    .010
    3k twill 5.7oz
    .010
    6k 5HS 10.9oz
    .016
    Uni 150gsm .006
    Uni 300gsm .010
    Advanced Composites Intro cont.
    Advanced Composites Intro cont.
    Composite
    Composite

    Prepreg Carbon Fiber


    Prepreg Carbon Fiber
    Carbon pre Carbon pre- -
    impregnated with impregnated with
    epoxy epoxy
    Suspended in low Suspended in low
    temps temps
    Cures in elevated Cures in elevated
    temps temps
    Specific cure profiles Specific cure profiles

    Wet resin
    Wet resin
    Manual mix 2k resin Manual mix 2k resin
    Manual wet Manual wet- -out of out of
    fibers fibers
    Room temp to Room temp to
    elevated temp cure elevated temp cure
    forgiving forgiving
    Laminate Theory
    Laminate Theory

    Metals
    Metals

    Isotropic, equal strength in all directions


    Isotropic, equal strength in all directions

    Fibers
    Fibers

    Anisotropic, strength in axial direction


    Anisotropic, strength in axial direction

    Quasi
    Quasi
    -
    -
    isotropic through multi orientations
    isotropic through multi orientations

    More strength/stiffness where needed


    More strength/stiffness where needed
    Laminate Theory cont.
    Laminate Theory cont.
    Tube To Tube Design Considerations
    Tube To Tube Design Considerations

    Tube walls .040


    Tube walls .040
    -
    -
    .065+
    .065+

    Characteristics
    Characteristics
    Bending Bending
    Torsion Torsion
    Hoop Hoop

    Wrap material
    Wrap material
    Cured ply thickness Cured ply thickness
    Form characteristic Form characteristic
    Aesthetics Aesthetics
    process process
    Design validation
    Design validation
    Cutting/Machining
    Cutting/Machining
    Cured composites
    Cured composites

    Carbon/epoxy considered abrasive


    Carbon/epoxy considered abrasive

    Abrade dont cut


    Abrade dont cut

    Mitering
    Mitering

    Diamond or Carbide grit hole saws


    Diamond or Carbide grit hole saws

    1000rpm + 1000rpm +

    Abrasive belt, spindle 80grit


    Abrasive belt, spindle 80grit

    Drill with diamond plated bits or points


    Drill with diamond plated bits or points
    Bonding
    Bonding

    Considerations
    Considerations
    Secondary bonding Secondary bonding
    Similar/ dissimilar Similar/ dissimilar
    materials materials
    Galvanic corrosion Galvanic corrosion

    Thixotropic
    Thixotropic
    2 part
    2 part
    toughened structural
    toughened structural
    epoxy
    epoxy

    Bonding
    Bonding
    Acetone/MEK Acetone/MEK
    Abrade Abrade
    Acetone/MEK Acetone/MEK
    Wet both Wet both
    Twist together Twist together
    Joining Process
    Joining Process
    Wet
    Wet

    Vacuum bagging
    Vacuum bagging

    Winding
    Winding

    Wet
    Wet
    layup
    layup
    Prepreg
    Prepreg

    Vaccum
    Vaccum
    bagging
    bagging

    Trapped rubber
    Trapped rubber
    Vacuum Bagging Theory
    Vacuum Bagging Theory

    Uses Atmospheric pressure to clamp


    Uses Atmospheric pressure to clamp
    laminates
    laminates

    Vacuum in an airtight envelope


    Vacuum in an airtight envelope

    Clamping method
    Clamping method

    Theoretically even pressure


    Theoretically even pressure

    29Hg theoretical 14.5


    29Hg theoretical 14.5
    psi
    psi
    on the laminate
    on the laminate
    Vacuum Bagging Schematic
    Vacuum Bagging Schematic
    Tool
    Laminate
    Peel Ply
    Perf Release
    Breather
    Vacuum bag
    Through bag
    Gauge
    To vacuum Pump
    Sealant
    Vacuum Bagging Caveats
    Vacuum Bagging Caveats

    Leaks
    Leaks

    Bridging
    Bridging

    Pleats, low mod, high


    Pleats, low mod, high
    elong
    elong
    bag,
    bag,
    cauls
    cauls

    Blow through
    Blow through

    Joints sealed
    Joints sealed

    Alignment
    Alignment

    Service temp, fixture


    Service temp, fixture
    Braze
    Braze
    ons
    ons

    Cable stops
    Cable stops

    Riveted
    Riveted

    Rivet grip depth, pull strength Rivet grip depth, pull strength

    Bottle bosses
    Bottle bosses

    Nutsert
    Nutsert

    Bonded Bonded

    Make your own in carbon


    Make your own in carbon
    Finishing
    Finishing

    Deflash
    Deflash
    , sand
    , sand

    Fill
    Fill

    Clearcoat
    Clearcoat
    400g, soap and water 400g, soap and water
    Adhesion promoter Adhesion promoter
    UV acrylic UV acrylic polyU polyU, build and sand, topcoat , build and sand, topcoat

    Paint
    Paint
    400g, soap and water 400g, soap and water
    Adhesion promoter Adhesion promoter
    Hi build primer, sealer, base and topcoat Hi build primer, sealer, base and topcoat
    Repairs
    Repairs

    Identification of damage
    Identification of damage

    Tap, squeeze, understand extent and


    Tap, squeeze, understand extent and
    cause
    cause

    Patch or tube replacement


    Patch or tube replacement

    Impression patch
    Impression patch

    Scarf joint laminate patch


    Scarf joint laminate patch

    Tapered or stepped Tapered or stepped

    Follow best practices


    Follow best practices
    Q
    Q
    &
    &
    A
    A

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