The diminutive rolling resistance and wheel bearing drag characteristics of a bicycle wheel assembly make it a lucrative choice of component in numerous 3-wheeled (3W) and 4-wheeled (4W) automotive applications. However, when a bicycle wheel is subjected to the loads encountered in such applications, complications pertaining to strength, durability and, performance are encountered.
Since a bicycle wheel is intended to be arrested at either end of its axle, cantilever loading of the component, as practiced in automotive applications, diminishes the ability of the spindle to withstand longitudinal and vertical forces encountered. Furthermore, while cornering on a bicycle, the maneuver of leaning in a corner significantly reduces the lateral stiffness requirement of the hub flanges. Therefore generic hub assemblies are designed without accounting for the action of lateral forces that are experienced at the hub with the wheel held vertical.
Since most bicycle wheel assemblies are designed oblivious to the loading conditions experienced in 3W and 4W vehicles, the component is rendered susceptible to mechanical failures in automotive applications, thus impeding its performance.
Based on the parameters of load cases, stress, strain, and material selection, this paper explores the design optimization of the axle and hub of a bicycle wheel for its application in 3W and 4W vehicles. In addition to CAE analyses of CAD iterations, considerations of material selection is herewith enclosed. The geometric modifications that were implemented to the various components of the bicycle wheel assembly using the mathematical model-based technique used in this paper resulted in designs that mitigate the possibility of structural failure in the intended application.