DESIGN AND MANUFACTURING OF HALFBIKE

Major Project report submitted at Rajiv Gandhi Proudyogiki Vishwavidyalaya,

A Minor
Bhopal in partial fulfillment of the degree of Bachelor of Engineering in
Mechanical Engineering

Submitted by:

Arjun Singh Chauhan (0812ME131031)

Arvind Patware (0812ME131033)
Ashpreet Singh Gill (0812ME131036)
Brajendra Raghuvanshi (0812ME131044)

Under the guidance of

Prof. Kapil Shrivastava

Automobile Engineering Department

Medi-caps Institute of Technology and Management

Indore

MAY 2017

i
 MEDI-CAPS INSTITUTE OF TECHNOLOGY &
MANAGEMENT, INDORE

CERTIFICATE
This is to certify that Ashpreet Singh Gill (0812ME131036) has
major project work, titled
completed his minor

“DESIGN AND MANUFACTURING OF HALFBIKE”

As per the syllabus and have submitted a satisfactory report on this

project as a partial fulfillment towards the degree of

Bachelor of Engineering
In
Mechanical Engineering
From
Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal

Guided by: Submitted to:

Prof. Kapil Shrivastava Dr.Anshul Gangele
(Head of Department)

ii
 ACKNOWLEDGEMENT

Every work accomplished is a pleasure and a sense of satisfaction, however a number of people
always motivate, criticize and appreciate a work with their objective ideas and opinions, hence
we would like to use his opportunity to thank all who have directly or indirectly helped us to
accomplish this project.

Firstly I would like to thank our project guide Prof. Kapil Shrivastava without whose support
this project could not been completed. Next I would like to thank Project Coordinators
Prof.Jayesh Barve and Prof. Prabhat Patel for their valuable suggestions from time to time. I
would also like to thank Dr. Anshul Gangele (Head of the Department) for encouraging us
with his valuable suggestions and feedback. I would like to thanks Dr. Sunil K. Somani (Vice
Chancellor) for their blessings and support in the form of resources like machines, tools and
manpower which beyond any doubt have helped us.

Let me also use this opportunity to thank our team members who have contributed to this project
with their invaluable opinions and suggestions, which has gone a long way in smoothing our
rough edges as a teammate.

Thank You

Ashpreet Singh Gill

(0812ME131036)

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 ABSTRACT

Halfbike is a new type of vehicle to awaken your natural instinct to move. It combines biking
and running. It has the core driving mechanism of a classical bicycle (a wheel connected to a
crankset) but redesigned pretty much everything else. The standing rider position is essential for
the Halfbike. It brings you closer to natural walking and you control the vehicle with your whole
body, not just your hands. A vehicle that trains your balance and reflexes in a new way. Not only
on a physical level but it also affects the way you perceive movement and enhances your senses.

Halfbike is both compact and light, so you can take it practically everywhere with you. Since it’s
foldable, it’s allowed onboard in most public transit systems. When folded, a Halfbike fits easily
in the trunk of even a small car, under a desk at work or in an overcrowded closet. Basically a
Halfbike would fit into most spaces too small for a regular bike.

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 LIST OF NOTATIONS

Notation Name of the notation SI Unit

θ Lean Angle Degree
R Radius of Turn Mm
Ac Centripetal Acceleration M2/s
M Mass of Bike-Rider System kg
G Acceleration of Gravity m/s2
Distance from one point to
L Mm
effective contact point
N Normal Force N
F Friction Force N
F1 Force Applied to Pedal N
R1 Pedal Radius Mm
Force acting on main
F2 N
crank
R2 Main Crank Radius Mm
F3 Force acting on front gear N
R3 Front Gear Radius Mm
R4 Front Wheel Radius Mm

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 LIST OF TABLES

Table No. Name Page No.

HalfBike Parts with
4.1 07
Functions
5.1 HalfBike Dimensions 08

6.1 Weight of Components 10

Centre of Gravity of
6.2 10
Components
Advantages and
Disadvantages of Chain
8.1 15
Transmission
Mechanism

Material Properties for

11.1 21
HalfBike Frame

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 LIST OF FIGURES

Fig. No. Name Page No.

3.1 Halfbike CAD Complete Model (Isometric View) 3

3.2 Top Side View 4

3.3 Right-Hand View 4

3.4 Left-Hand View 5

3.5 Rear Side View 5

3.6 Front View 6

6.1 Centre of Gravity of HalfBike 12

7.1 Lean while turning 13

9.1 HalfBike on an Inclination 16

9.2 Chain and sprocket force analysis 17

10.1 Brake lever 19

10.2 Brake rear assembly 20

10.3 Brake front assembly 20

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 CONTENTS

Abstract…………………………………………………………………………….….……iv

List of Notations……………………………………….……………………...……………v

List of tables…………….…………………………………………..………………………vi

List of figures…………….………………………………………………………….….….vii

Chapter 1

Introduction…………………………………………………………………………………..01

Chapter 2

Concept Generation………………………………………………………………………...02

Chapter 3

Halfbike CAD Model……………………………………………………………………….03

Chapter 4

HalfBike Parts………………………………………………………………………………..07

Chapter 5

HalfBike Dimensions………………………………………………………………………08

Chapter 6

Calculation for Centre of Gravity of HalfBike……………………………………….10

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Chapter 7

Lean while Turning…………………………………………………………………………13

Chapter 8

Transmission System……………………………………………………………………….15

Chapter 9

Forces and Power……………………………………………………………………………16

Chapter 10

Braking System in HalfBike………………………………………………………………20

Chapter 11

Material Properties…………………………………………………………………………22

Chapter 12

Advantages and Disadvantages…………………………………………………………..24

Reference………………………………………………………………………………………25

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 CHAPTER 1
INTRODUCTION

Halfbike is a new type of vehicle to awaken your natural instinct to move. It combines biking
and running. It has the core driving mechanism of a classical bicycle (a wheel connected to a
crank set) but it’s redesigned pretty much everything else. The result is a completely new
experience. The standing rider position is essential for the Halfbike. It brings you closer to
natural walking and you control the vehicle with your whole body, not just your hands. A vehicle
that trains your balance and reflexes in a new way. Not only on a physical level but it also affects
the way you perceive movement and enhances your senses. Halfbike is both compact and light,
so you can take it practically everywhere with you. Basically a Halfbike would fit into most
spaces too small for a regular bike. The feeling of riding a Halfbike is really nothing like riding a
bicycle but believe us, there is certainly difference that makes it enjoyable. If we must point out
the key advantages we would probably go for the fun of riding, its lightness and compactness.

Key features of Halfbike:-

 Light weight
 Riding quality
 Compact in size
 Foldability.
 Less maintenance.

1
 CHAPTER 2
CONCEPT GENERATION

This concept of designing a Halfbike basically came from a YouTube video which got our
curiosity for its design and working. And then we found the basic needs of the HALFBIKE
which were :-

1. In order to find a better way for travelling over small distance, the founder Mihail
Klenov, created the bike with fellow architect and business partner Martin Angelov
designed it.

2. Instead of our conventional bicycle which is quite heavy to carry in hands and long too,
there is a need of a light weight and short bicycle which drew our attention towards this
concept.

3. Being a Mechanical Engineer, we have interest in Automotive Sector and since this
Halfbike is yet to be launched in India so it will be a great asset to us to cover small
distance as we rely mostly on our bikes and cars which causes much of pollution and fuel
consumption may be controlled.

2
 CHAPTER 3
HALFBIKE CAD MODEL

Fig.3.1 Half Bike Isometric View

3
Fig.3.2 Half Bike Top Side View

Fig 3.3 Half Bike Right View

4
 Fig 3.4 Half Bike Left View

Fig.3.5 Half Bike Rear End View

5
Fig. 3.6 Half Bike Front View

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 CHAPTER 4
HALFBIKE PARTS

PART FUNCTIONS
Power Train
1) Chain Sprocket & Pedal

Provides Rolling action.

2) Wheels (1 front & 2 small back)

For controlling and balancing.

3) Handle

Provides support to all other adjoining parts.

4) Body Members

5) 2 Back Springs For bending of Halfbike to steer it.

6) Mechanical Brakes Installed at the rare end for retarding speed.

TABLE 4.1 :- List of Parts with Functions

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 CHAPTER 5
HALFBIKE DIMENSIONS

These dimensions are taken according to following considerations:-

1. Maximum bearable weight - 90 kg

2. Mass of the HalfBike - 24 kg

3. Material - Mild Steel

4. Ground clearance - 9 cm

PARTS SUB-PARTS DIMENSIONS UNITS

FRAME 1. Material Mild steel

2. Strength 350 MPa
3. Thickness 0.3-0.5 Cm
4. Width 5-10 Cm
5.Distance b/w parallel frame 12 Cm
members
WHEELS 1. Front wheel diameter 50 Cm
2.Rear wheel diameter 22 Cm
4. Width of front wheel 8 Cm
5. Width of rear wheel 8 Cm
6.Distance b/w centres of front & 100 Cm
rear wheels
7.No. of spokes (front) 20
8.No. of spokes (rear) Circ. disc
SPROCKET 1. Driving sprocket
a. No of teeth 54
b. Dedendum 20 Cm
c. Addendum 21 Cm
2. Driven sprocket
a. No. of teeth 18
b. Dedendum 6 Cm
c. Addendum 7 Cm

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 3. Centre Distance b/w sprockets 35 Cm
REAR AXLE 1. Length of rear axle 44 Cm
2. Distance b/w centres of 2 rear 52 Cm
wheels
SPRING 1. Pitch 0.6 Cm
2.Wire diameter 0.5 Cm
3.Free length 5.5 Cm
4.Stiffness 600-700 N/Cm

Table 5.1 :- List of Parts with Dimensions

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 CHAPTER 6
CALCULATIONS FOR CENTER OF GRAVITY OF HALFBIKE

The Center of Gravity (CG) of a vehicle is the point at which weight is evenly dispersed and all
sides are in balance. To calculate the CG of Halfbike, weight and relative positions (respective
CG of component) of all the components along fixed axes are found out and by using formula
the CG is calculated for the whole vehicle.

COMPONENTS WEIGHT(approximate)
(Kg)
1. Chassis 10 Kg

2. Rear wheel assembly 8 Kg

3. Front wheel assembly 4 Kg

4. Sprocket Pedal assembly 2 Kg

Table 6.1:- Weight of Components

COMPONENTS RESPECTIVE CG OF COMPONENTS

X Y
1. Chassis** 55 45

2. Rear wheel assembly 11 11

3. Front wheel assembly 100 25

4. Sprocket Pedal assembly 65 30

Table 6.2 :- CG of Components

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**The CG of chassis is calculated with the help of CREO Parametric 2.0 using the CAD model.

CG of Vehicle (x component) =
= (m1x1+m2x2+m3x3+m4x4)
(m1 + m2 +m3 + m4)

= (10*55 + 8*11 + 4*100 + 2*65)

(10 + 8 + 4 + 2)

= 48.6 cm

CG of Vehicle (y component) =
= (m1y1+m2y2+m3y3+m4y4)
(m1 + m2 +m3 + m4)

= (10*45 + 8*11 + 4*25 + 2*30)

(10 + 8 + 4 + 2)

= 29.08 cm

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Fig 6.1 :- Half Bike Center of Gravity

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 CHAPTER 7
LEAN WHILE TURNING

To analyze the physics behind a lean consider the following schematic.

Fig 7.1 :- Free Body Diagram for lean while turning

Where:
θ is the lean angle
R is the radius of the turn measured from the center of mass G of the bike-rider system
ac is the centripetal acceleration of the center of mass G of the bike-rider system
m is the mass of the bike-rider system
g is the acceleration due to gravity, on earth, which is 9.8 m/s2

13
L is the distance from point G to the effective contact point P between bicycle and ground
N is the normal force between bicycle and ground

F is the friction force between bicycle and ground, in the direction of ac

Since there is no acceleration in the vertical direction the sum of the vertical forces is zero. Thus,

N = mg
Apply Newton's second law in the horizontal direction:
F = mac = mv2/R
where v is the velocity of the bicycle around the turn.
Sum the moments about point G:
N.SinQ*L - F.CosQ*L = 0
Combine the above three equations to find an expression for the angle of lean θ. We have,

tanQ = v2/Rg

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 CHAPTER 8
TRANSMISSION SYSTEM

Chain drive is used to transmit mechanical power from one place to another. It often conveys
power to the wheels of Halfbike. The drive chain or transmission chain also known as roller
chain is passed over a sprocket gear, with the teeth of the gear meshing with the holes of the
chain links. The gear turning results pulls the chain putting mechanical force in to the system.

Advantages and Disadvantages of Chain Transmission Mechanism

ADVANTAGES DISADVANTAGES

Transmission system is Compact. Frequent maintenance is required.

Can easily adapt the multi gear system. Chance to disengage from the sprocket gear
is higher.

Chain gear mechanism is cheap. Slack and backlash is more.

Table 8.1:- Advantages and Disadvantages of Half Bike

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 CHAPTER 9
FORCES AND POWER

The figure below shows a halfbike going uphill at an angle of inclination Φ, and with a velocity

Fig 9.1:- Halfbike going uphill at an inclination

To propel the Halfbike uphill the rider must push down on the pedals. The pedals are offset 180°
which means that only one pedal can be pushed at a time, from the top position to the bottom
position, and then switching to the other pedal.

Given a force F1 acting on the pedal we can calculate the resulting force F4 between the front
wheel and ground. This is the force that propels the halfbike forward.

We can perform a torque analysis with good accuracy based on the assumption that acceleration

16
(linear and angular) is negligible. Hence, we can treat this as a static problem.

Consider the figure below, with forces and radial dimensions shown.

Fig 9.2 :- Chain and Sprocket Force Analysis

Where:
F1 is the force applied to the pedal
R1 is the pedal radius
F2 is the force acting on the main crank, due to chain contact
R2 is the main crank radius
F3 is the force acting on the front gear, due to chain contact
R3 is the front gear radius
F4 is the force acting on the front wheel, due to contact with the ground. Note that the coefficient
of static friction between wheel and ground must be large enough to support this force, otherwise

17
slipping occurs
R4 is the front wheel radius
Using the static equilibrium assumption, we can write the following torque equations:

F1R1 = F2R2 & F3R3 =F4R4

Since F2 = F3, we can combine the above two equations to give an expression for F4:

F4 = F1.R1R3/R2R4
The force F4 is what propels the Halfbike forward. If we assume that the Halfbike is moving at
constant velocity (no acceleration) then the force F4 must equal the resisting forces opposing the
Halfbike's motion. These resisting forces are gravity, rolling resistance, air drag, and internal
Halfbike friction. If we neglect the latter we can then write the following mathematical
expression:

F = mgSinΦ + Cr.mg.CosΦ + (0.5)CdPAv2

Where:
F is the force propelling the Halfbike forward. Note that F ≡ F4
Cr is the coefficient of rolling resistance, which can be 0.0022 to 0.005 for Halfbike tires (ref:
http://en.wikipedia.org/wiki/Rolling_resistance)
Cd is the drag coefficient
ρ is the density of the air through which the bicycle is moving
A is the projected cross-sectional area of the bike + rider perpendicular to the flow direction (that
is, perpendicular to v), and v is the speed of the bicycle relative to the air
The first term on the right side of the above equation is the gravity contribution. The second term
is the rolling resistance contribution. The third term is the air drag contribution.
To evaluate the power P required to propel the Halfbike, multiply the above equation by v. We
get P = Fv, and

P = mg.SinΦ.v + mg.Cr.CosΦ.v+(0.5)Cd.pAv2

For a flat surface (no incline) set Φ = 0. We get

F = Cr.mg.v + (0.5)Cd.pAv2

P = F.v

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 CHAPTER 10
BRAKING SYSTEM IN HALFBIKE

A Halfbike brake reduces the speed of a bicycle or prevents it from moving. The three main
types are: rim brakes, disc brakes, and drum brakes. There have been various types of brakes
used throughout history, and several are still in use today.

Most brake systems consist of three main components:

1) A mechanism for the rider to apply the brakes, such as brake levers or pedals;
2) A mechanism for transmitting that signal, such as Bowden cables, hydraulic hoses, rods,
or the bicycle chain; and
3) The brake mechanism itself, a caliper or drum, to press two or more surfaces together in
order to convert, via friction, kinetic energy of the bike and rider into thermal energy to
be dissipated.

Fig 10.1:- Brake Lever

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In a Halfbike the brakes are installed at the rear end. The braking system consist of 2 shoes
pressing against the rim of the rear wheels for the retarding the vehicle. The brake lever is
installed on the handle of Halfbike.

Fig 10.2:- Brake Rear Assembly

Fig 10.3:- Brake Front Assembly

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 CHAPTER 11
MATERIAL PROPERTIES FOR HALFBIKE FRAME

Fatigue
Modulus
Yield Tensile Strength Weldability
of Density
Strength Strength At 50,000 and
Elasticity (kg/m3)
(MPa) (MPa) Cycles Machinability
(GPa)
(MPa)

Aluminum
–
6061
72 193-290 241-320 75 2700 excellent
-
T6

Aluminum
–
7005 72 290 350 75 2780 excellent
-
T6
Steel
-
205 800-1000 650 250 7800 excellent
4130

Titanium
–
91-95 483-620 721-750 250 4480 fair
Grade 9

Carbon 275-
Fibre 415 Varies varies varies 1,800 fair

Table 11.1 :- Material Properties for Half Bike

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 CHAPTER 12
ADVANTAGES & DISADVANTAGES

ADVANTAGES:-
 Halfbike is both compact and light, so we can take it practically everywhere with you

 Since it’s foldable, it’s allowed onboard in most public transit systems

 Trains our balance and reflexes in a new way and it affects the way we perceive movement
and enhances our senses.

 Basically a Halfbike would fit into most spaces too small for a regular bike.

DISADVANTAGES:-
 Cannot be used for long distances as it may cause fatigue.

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 REFERENCES

 The Bicycle Wheel by Jobst Brandt

 Bicycle Sharing 101: Getting the Wheels Turning by Bradley Schrodes
 Automobile Engineering Vol.1 by Kirpal Singh
 Theory of Machine by S.S.Ratan

Web References
1. www.halfbike.com
2. www.wikipedia.com
3. www.interestingengineering.com
4. www.youtube.com/user/EngineeringExplained
5. www.kickstarter.com/projects/774841427/halfbike-ii

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