Showing posts with label total freakin nerd. Show all posts
Showing posts with label total freakin nerd. Show all posts

Wednesday, December 01, 2010

Browser video cleanup

Yep. Once again I find that I've got way too many browswer tabs open. Instead of bookmarking these videos or Zoteroing them.. I'll just paste them here.


I liked the first half of this one, specifically the wheel building, gets pretty meh once the bike is runnign though:

AFFINITY CYCLES x KENZO MINAMI = DIGITIZER from Cinecycle on Vimeo.



Not a terrible song or vid:


Completely ridic and awesome:

Erik Elstran's Dragon Shredit (internet edition) from North of Ten on Vimeo.



Cool way to win a bike:

More Mountain Biking Videos

Wicked leaning electric assisted cargo trike from Onya Cycles in SF:

Monday, September 27, 2010

Suitably nerdy

Some super nerdy reading for you.



I've updated Vallie components, and published an article on the torque testing of some M5 bolts.

I've also found this really interesting article on chain wear measurement.

I also found out about Civia Cycle's Halstead cycletruck:


Yeah.. I pretty much spend my time online looking at pages like this.

...and who can forget the 'stringbike'. We had an interesting fellow come into the shop the other day and tell us about it. I had previously read the article and seen the animations, so I knew what he was talking about.. but it was super funny to hear his strange Hungarian pride when telling me of it.

Okay.. back to work.

Saturday, November 29, 2008

high speed lathing

Check out this ridiculous photo Alan snapped of my high speed steel lathe setup:


What blows me away is that you can actually READ the disk on the 4.5" disk grinder THAT IS SPINNING AT OVER 10000RPM!!!

Not having access to a lathe, I had to get creative. This steel BMX post has to be turned down from 22.2mm to 21.0 to be interference fit into a steerer tube. In order for the grinding to remain concentric, I've mounted the post into a drill chuck by way of a 1" star nut. This setup worked remarkably well, and it was easy to get the tube to the right diameter.

Thursday, October 16, 2008

Thoughts on laser cut dropouts..

Recently, while visiting the Brooklyn Machine Works shop, I had a look at a variety of Laser cut dropouts. I can't get into detail about the the designs I saw there, because I don't have pictures to illustrate them, and there was just TOO much awesomeness going on there to be described in one post.

Laser Cutting is the general technology used to churn out dropout after dropout for the majority of today's track and BMX frames. Obvious exceptions to this are the forged and machined examples found on some high end bicycles. For the most part however, the single thickness dropouts found on your track bike, were cut with a CNC driven laser.

Plasma cutting is another viable option, and may have been used in the past. However, the width of beam is slightly larger than with a laser, and therefore accuracy is less. With the ever decreasing price of laser cutting technology, its almost easy for designers to get carried away.

(BMW actually doesn't do any laser cutting in house. They do their designs in AutoCAD and contract another metal shop to do that)


I'm not going to name names, but here we have excessive laser cutting. Its as though the designer wanted some swoopy crescents to dress up his dropouts. A napkin was marked up with a fine tipped sharpie, and sent overseas. The factory reviewed said napkin, said "Sure thing chief!" and away they went with the CAM program. Never mind that the actual crescent shapes have no flow, and subsequently do nothing to create an air of classiness. Now, I don't personally know how much this will affect the strength of the design. I just get this vibe that its a bad idea.

A city ridden bicycle is subject to stresses many times greater than the riders weight when road imperfections are encountered. The axle pushes UP on the dropout with ridiculous amounts of force. These stresses occur at high frequency, every ride. These are the sort of forces that (over time) lead to dropout weldment failures, or similarly seat stay/seat tube junction failures.

A stress riser is essentially where localized forces can overcome the shear strength of a material. And nothing localizes forces more than sharp angles. The stress concentration factor goes up exponentially as the radius of a cut approaches zero. The idea of adding 8 tiny-radius-acute-angle cuts to a small piece of metal that is undergoing high frequency shear forces from the axle just seems like its ASKING to test the elastic modulus of the steel being used.

Just looking at that picture is bothering me enough that I have to model it. I MUST know just how much these cuts affect the strength of the part!

Here I'm starting by importing the photo of the unnamed bicycle dropout into a modeling program, rotating it and scaling it correctly. Then I just draw the existing dropout shape in a 2D sketch:


Now, lets suppress the photo and extrude the basic dropout. Shall we assume it's 5mm thick?


Looks decent.

Okay, here I'm just copying the random swoopy crescent shaped cuts in our unnamed dropout. Looking closely, there is only one straight line. The absolute randomness of these cuts really makes my brow furrow.


...and the final cutout:


Looks horrible doesn't it?
Anyways, on to the testing.

The simplest way to do this, will be to anchor the two faces where the dropout meets the rest of the frame. Next I'm going to put a very slight axle groove in the top of the dropout so that the forces of the axle can REALLY be localized. (as opposed to applying force along the entire upper edge of the dropout) Remember, I'm trying to simulate an axle impacting this thing.


Okay, lets assume our Proj-B test rider weighs about 190lbs. If he hits an object (like a wheel swallowing pothole in the South Bronx) then the force on the axle is going to be several times his mass. We don't actually need to use any particular value here, because I'm going to use the same value to test the dropout with and without the fancy cutouts, but lets assume that the force is twice the rider's weight, thats 1690N being applied at the upper edge of the dropout

This program has a handy stress analysis tool that allows one to calculate the Factor of Safety (FOS) of a part. Simply put the FOS is the Material's yield strength divided by the equivalent stress at a point.

-An FOS less than 1.0 at a location indicates that the material at that location has yielded.
-An FOS of 1.0 at a location indicates that the material at that location has just started to yield.
-An FOS larger than 1.0 at a location indicates that the material at that location has not yielded.

So, for the Plain old dropout, and a 1690N force, we get a FOS of: 5.25102
No problem. I would ride this all day.

The Von Mises stress distribution on the model look like this:


Lets repeat that test for the Fancy Cutout version:


Here our FOS is 4.43389 That's 15% less strength!

These pictures show the model in a total deformed state, though thats not actually the case for these applied forces. The dropout will NOT deform under these conditions. The program just uses this to illustrate how the stresses are distributed.

So what can we tell from this?

Well, its certainly more colourful. You can see where the stress is concentrated in this last picture. That lower crescent and the little arrow head appear to be areas of concern. It seems the cutout dropout is only 85% as strong as the solid one. Whether or not that is 'strong enough' is entirely subjective. Much like my opinion of the aesthetic design of this particular dropout.

I started playing around, finding the maximum force before the material would actually deform. It seems the solid dropout could withstand a force of 9kN or 2020lbs before it would yield.. and even then, just barely:


When that same force is applied to the cutout version, we see a couple more areas of deformation. Most notably is that little pointy arrowhead tip again:



I guess today I've learned that fancy cutouts aren't really as bad as I thought they were. I've also learned how easy it is for me to get sidetracked into theoretical testing and hypothesizing simply by staring at a picture of a bicycle for too long.

If any of this bicycle's designers are reading, please don't feel too slighted by my words. (I didn't even touch upon your PBR bike!) I am only doing this because I wish i was doing what you are doing.

Wednesday, January 30, 2008

Of interest to the nerdy, the injury-prone, and the fans of P.T. Barnum

http://velonews.com/tech/report/articles/13978.0.html

Tech Report - Challenging assumptions
By Lennard Zinn
VeloNews technical writer
Filed: January 29, 2008

The first day of the second annual Serotta Science of Cycling Symposium offered participants some welcome opportunities to take on a few sacred cows of the sport.

Among those taking jabs were gored by professors Maury Hull, Ph.D. of UC Davis and Jim Martin, Ph.D. of the University of Utah. The gored cows were partially resurrected by Andy Pruitt, Ed.D. of the Boulder Center for Sports Medicine, and Katrina Vogel, MS, DPT, a Seattle physical therapist, and perhaps by Jeff Broker, Ph.D. of the University of Colorado/Colorado Springs. Conrad Earnest, Ph.D., the director of the Exercise Testing Core at the Pennington Biomedical Research Center in Baton Rouge, Louisiana, gave a compelling synopsis of both the history of testing of Tour de France cyclists and the history of the Tour itself.


It was a high-powered panel in Boulder



Hull led off with a discussion of his Shimano-funded research into foot position pedaling mechanics. He studied twisting moments and bending moments about the knee during pedaling. Using sophisticated setups in the Biomechanical Engineering in Sports Laboratory and the Orthopedics Biomechanics Laboratory at UC Davis, Hull studied the effects of floating pedals and canting of the foot on the rotational and lateral moments of the knee and demonstrated that minimizing those moments is desirable for pedaling efficiency and for injury prevention.

Using the knee of a cadaver hooked up to tension devices to pull on muscles and tendons while the fixture applies internal rotational and varus (i.e., outward, or bowlegged) bending torques on the tibia, he measured pressure under the kneecap. He showed that together, internal rotational and varus bending torques on the tibia greatly increase the pressure under the kneecap and hence increase the likelihood of Patello Femoral Pain Syndrome, a common cycling knee injury.

He also measured cyclists pedaling on an ergometer with EMG electodes hooked up to show activity of the vastus medialis oblique (VMO), vastus lateralis (VL), and tensor fascialatis (TFL) muscles. These three muscles apply tension on the iliotibial band, inflammation of which is another common cycling knee injury.

The upshot of his research skewered two rather sacred beliefs of cycling fitters. One of his conclusions is that floating pedals do not reduce the rotational and lateral moments about the knee and are hence of no use in preventing knee injuries. The other conclusion is that 10 degrees of valgus canting (i.e., tipping the foot inward, or knock-kneed), reduced rotational and lateral moments about the knee and are therefore beneficial in preventing knee injuries.

Pruitt, director of the Boulder Center for Sports Medicine spoke from a clinical perspective about cycling knee injuries and what he has learned in a quarter of a century of treating them. Interestingly, his clinical findings were almost diametrically opposed to the lab conclusions of Hull.

Pruitt works as an exclusive design consultant to Specialized Bicycles on its Body Geometry products, and he notes that while the knee is the No.1 injury problem in cycling, cycling is the No.1 recommended therapy for knee injuries. To him, the knee is the victim, and the hip and ankle are the culprits.

He has found that floating pedals, both in rotational and translational freedom, have greatly reduced the incidence of ilio-tibial-band knee injuries, which became "epidemic" in the early 1980s with the introduction of clipless pedals without float. He showed gruesome photos of the surgery he helped pioneer at that time of cutting an oval hole in the IT band to reduce its tension and hence its irritation when rubbing along the side of the knee during pedaling.

Pruitt also reported a reduction in a variety of knee injuries as well as an increase in cycling efficiency by canting feet outward (varus canting); that's also the opposite of Hull's research findings. The Specialized Body Geometry shoes that are his brainchild have this feature built into the sole. They also have insoles with medial (i.e., longitudinal) arch support as well as metatarsal arch support. While he did not address the latter in his talk, he did discuss how the collapsing of the medial arch, while it serves a purpose in walking by storing energy to be given back when springing off of the foot, has no use in the cycling downstroke. "You don't want to store energy during the downstroke," he said, "you want to deliver it."

Martin skewered sacred cows about crank length, pedaling technique and rider positioning. We were forewarned, though, as he said at the outset that many of us would find his conclusions "irritating."

His studies of 16 bike racers of various heights doing maximal sprint power tests of under four seconds duration on cranks of 120, 145, 170, 195, and 220mm showed no statistical difference between crank lengths. Seat height to the pedal was maintained throughout, but fore-aft saddle position and handlebar height were not readjusted with crank length changes, despite variations with crank length of pedal-to-knee relationship and saddle-to-bar drop. This also led to Martin's assertion that he could see no point to positioning the knee over the pedal spindle.

Further Martin tests showed no statistical relationship between metabolic cost and either pedaling rate (RPM) or crank length, using nine trained cyclists riding 145, 170 and 195mm cranks who pedaled at 30-, 60-, and 90 percent of their lactate threshold at 40, 60, 80 and 100 RPM. On the contrary, power output and pedal speed (pedaling rate times crank length), accounted for over 98 percent of the variation in metabolic cost.

In another test, Martin had 10 racers perform a 30-second maximal sprint on 120mm and 220mm cranks at 135RPM for the 120mm and 109RPM for the 220mm. he found that, while the rate of fatigue was less for longer cranks, the fatigue per revolution was identical. This led him to suggest that track sprinters, rather than spinning at high RPM, should select the gear at or just below the one at which they produce maximum power output. The higher gear, as fatigue per revolution would be constant, would get the rider to the finish sooner, as fatigue would take more time to set in.

Finally, Martin's studies of pedaling technique indicated that regional cyclists had "better" pedaling mechanics than elite cyclists. It indicated that elite riders pull up less on the pedals on the backstroke and push down harder on the downstroke.

By studying 13 trained cyclists and 35 fit athletes who did not own bicycles, he also showed that non-cyclists, who started out lower on the first day, produced higher power outputs by the 4th day than trained cyclists. They also hit their maximum power at a higher RPM than the cyclists. The total time to learn to produce more power by the non-cyclists was three days and a total of 36 seconds of hard pedaling! This seemed to dispel the ideas that cycling adaptation takes time, that pedaling technique refined over time is important, particularly to learn to pedal efficiently at high RPM, and that avoiding "working against yourself" on the backstroke (revealed in graphs showing a net negative torque past bottom dead center) is useful.

Martin says that you are then left with two things to go faster. Hard training and good nutrition, hydration and recovery are the keys to maximizing the power you can produce. And reducing aero drag and reducing braking are some ways you can minimize the power you must produce. That's it. Simple.

Earnest, in his "105 Years of Cycling, Science and Legend - Lessons from the Tour de France" talk, gave audiences glimpses into the history of sports science as well as into the history of the Tour itself. He related study after study over a century from which we have gleaned much of what we know about cycling and training for it. He drew gasps, for instance, with his photos of a cyclist riding with the first "portable" heart rate monitor. The thing was strapped to his back, weighed 75 pounds, and was the size of a large backpack!

The Pennington Biomedical Research Center focuses on studying diabetes and other overweight-related diseases and syndromes. Noting that, "there is no nice thing about cycling in Baton Rouge," after originally starting his sentence with, the "nice thing about cycling in Baton Rouge," Earnest pointed out that there is only one safe road to ride on, and it is flat. This has led to a proliferation of cyclists who focus on time trialing. He also pointed out that Louisiana consistently comes in second to only Mississippi for having the most obese population in the USA. These two characteristic populations has made it an ideal place to stuffy obesity vs. time trial performance. The resulting study showed that, in a flat time trial, taking 3kg of mass off of the body results in almost twice as much time reduction as removing 3kg from the bike. As the Tour's pivotal stages are generally either time trials or mountain stages, this is an important finding.

And looking at mountain stages, another interesting study was the climb of René Pottier in 1905 up the Grand Ballon d'Alsace. On a single-speed fixed-gear bike, he was the first to reach the top of a mountain in the Tour by not only being the only one to make it up without dismounting, but also by pedaling up it at an astounding 20kph. Earnest's research shows that ride to be an amazing accomplishment even by today's standards, despite the fact that he punctured on the way down, thus losing the stage, and that he withdrew the following day due to tendonitis. Pottier apparently put out an average of 370-390 watts up that entire climb. No wonder he came back to dominate the next year's Tour, winning five stages. Sadly, he committed suicide in 1907, hanging himself from a bikehook.

Other studies focused on the Banesto team in the Vuelta and the Tour, thanks to Earnest's close collaboration with the lead researcher in those studies. One interesting one showed that, over the three weeks of the Tour or the Vuelta, a rider's maximum achievable heart rate drops. Another showed that a wide range of cadences can work for a rider. It demonstrated no difference between 80 and 100RPM in oxygen uptake at a certain power output and a small dropoff at 60RPM, but that adaptation takes time is required for maximum efficiency, and could probably erase this difference as well. A nutrition study indicated that performance is improved by taking in fructose and other high-molecular-weight sugars, rather than simple (low-molecular-weight) sugars.

Vogel, like Pruitt, discussed the value to the majority of cyclists of varus foot canting on the pedals and pointed out a number of clinical cases. She discussed the rarity of valgus canting as an indicated therapy and the possible, albeit dangerous due to likelihood of low-back injury, of "spring loading" the tendons and ligaments of the hip through valgus canting. She noted the theoretical opportunity to slingshot energy from the one side of the hip to the other this way.

Broker spoke at the same time about cycling biomechanics, and as pedaling mechanics was the focus of much of his work while working for the U.S. Olympic Committee, it would have been interesting to see how it squared with Martin's surprising revelations. But alas, I could only be in one place at a time.

The symposium continues tomorrow and Wednesday. Tomorrow I will also meet with Active-Spoke, a company whose product is a little weight with a spring attached to it. The weight goes on a spoke and moves more rotating mass out to the edge of the wheel when it is spinning fast. When the wheel is spinning slowly, the springs bring the weights back to the center of the hub.

Tuesday, January 29, 2008

Snow'd In..

Well, not really. In fact, I should really be riding in this weather.
Except my new bike isn't ready.
I keep getting side tracked.

One moment I'm turning a 15mm wrench. The Spicer's last nut is torqued to BMX tight. Then I see my rim cracking. Don't want to be a Mander. Next I'm in Ty's shop looking at rims, Then I've got his last Ambrosio Excellence but my spokes are too short, then they're too long, then they're just right. ..and I build the wheel for the second time.
I'm out on the Cunny, in the West end, thinking about drift physics while my front fork packs with snow.
This is starting to sound like a dream.
Then I'm in Dream. Darren actually hooks me up with a cog.
Then I'm in Dream. Darren actually hooks me up with rim tape.
Now I'm back at the wheel. These bearings are shit.
8000km on a set of Nachis. I'm going to try running a little less chain tension to see if i can't get more life out of a set of rears.
I can't even pound them out they're so corroded. Eventually I coax the shaft and bearings out with some concrete blocks and wood. (wrenchin dirty)

Did I talk about the axle before?
I'm pretty sure I did.
Well. If I didn't go into enough detail then. I will now.

Between the bearing surface and shoulder, there is a little trough. This allows any debris/grease during bearing installation to have a place to go. Its also a really pretty way of distributing stress. I also really enjoy the nice slope from the shoulder to the unused centre section of the axle. The real point is, having it out prompted me to measure and model it.



The helical swept cut of the 10x1mm threads was problematic, and I now understand why there is a 'Cosmetic Thread' feature. The rebuild time is getting out of hand. I won't even get into how the COSMOSXpress analysis handles all those faces. In fact, I just tried to simulate a 200lb loading of the axle, and its still busy computing.

Ah well.. I guess this gives me time to put my hub back together and tension up a wheel. Maybe I'll even be able to ride the Spicer before the snow melts.