Design and Fabrication of Bicycle Driven by Shaft and Gear System · Abstract: A chainless bicycle...

Design and Fabrication of Bicycle Driven by Shaft and Gear

System

1R. Panchamoorthy,2 P. Balashanmugam,3 S. Muthukumar ,4 N. Sivakumar

1,3,4 Assistant Professors,2Associate Professor(1234Deputed)

Mechanical Engineering, Annamalai University, Chidambaram, Tamilnadu, India.

Abstract: A chainless bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power

from the pedals to the wheel. Shaft drives were introduced over a century ago, but were mostly

supplanted by chain-driven bicycles due to the gear ranges possible with sprockets and derailleur.

Recently, due to advancements in internal gear technology, a small number of modern shaft-driven

bicycles have been introduced. Shaft-driven bikes have a be where a conventional bike would have its

chain ring. This meshes with another bevel gear mounted on the drive shaft. The Bevel gears are the

most efficient way of turning drives 90 degrees as compared to worm gears or crossed helical gear.

The shaft drive only needs periodic lubrication using a grease gun to keep the gears running quiet and

smooth. This “chainless” drive system provides smooth, quite and efficient transfer of energy from

the pedals to the rear wheel. It is attractive in look compare with chain driven bicycle. It replaces the

traditional method.

Keywords: chain drive, drive torque, bicycle, forming process, internal gear technology

1. Introduction Elimination of Chain Drive in bi-cycle uses two sets of spiral bevel gears and a shaft rod to smoothly transfer power from the cranks to rear wheel. The bevel gears are made of heat treated comely and

paired with high quality sealed cartridge bearings coupled to a steel shaft rod – all sealed inside

lightweight, durable aluminum alloy. Our shaft drive, now in its third generation, has been in

production since 1991, and is already on tens of thousands of bikes all over the world. By integrating

our shaft drive with Shimano's internal hubs, our bikes not only have a sleek, modern look, but they

deliver an incredibly smooth ride, great performance and eliminate the number one complaint people

have always had about their bikes the chains and derailleur. With our shaft drive bikes; there is no

more grease; no more mess; no more cuts on fingers or tears in clothes; and no more chain and

derailleur maintenance. Just pure, worry-free riding fun. An elimination of chain drive in bicycle is a

bicycle that uses a drive shaft instead of a chain to transmit power from the pedals to the wheel.

Chain drive in by-cycle has a large bevel gear where a conventional bike would have its chain ring.

This meshes with another bevel gear mounted on the drive shaft. The use of bevel gears allows the

axis of the drive torque from the pedals to be turned through 90 degrees. The drive shaft then has

another bevel gear near the rear wheel hub which meshes with a bevel gear on the hub where the rear sprocket would be on a conventional bike, and canceling out the first drive torque change of axis.

The 90-degree change of the drive plane that occurs at the bottom bracket and again at the rear hub

requires the use of bevel gears. Bevel gears are the most efficient way of turning drives 90 degrees as

compared to worm gears or crossed helical gears. The drive shaft is often mated to a hub gear which

is an internal gear system housed inside the rear hub.

2.Literature Review

The first shaft drives for cycles appear to have been invented independently in 1890 in the United

States and England. The Drive shafts are carriers of torque; they are subject to torsion and shear

stress, which represents the difference between the input force and the load. They thus need to be strong enough to bear the stress, without imposing too great an additional inertia by virtue of the

weight of the shaft. Most automobiles today use rigid driveshaft to deliver power from a transmission

to the wheels. A pair of short driveshaft is commonly used to send power from a central differential,

transmission, or transaxie to the wheels.

Shaft drives were introduced over a century ago. The first shaft drives for cycles appear to

have been invented independently in 1890 in the United States and England. A. Fearnhead, of London

Compliance Engineering Journal

Volume 11, Issue 2, 2020

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developed one in 1890 and received a patent in October 1891. His prototype shaft was enclosed

within a tube running along the top of the chain stay. Later models were enclosed within the actual

chain stay. The first shaft drives for cycles appear to have been invented independently in 1890 in the

United States and Britain. A. Fearnhead, of North London developed one in 1890 and received a

patent in October 1891. His prototype shaft was enclosed within a tube running along the top of the chain stay; later models were enclosed within the actual chain stay.

The shaft drive was not well accepted in Britain, so in 1894 Fearnhead took it to the USA where

Colonel Pope of the Columbia firm bought the exclusive American rights. Belatedly, the British

makers took it up, with in particular plunging heavily on the deal. Curiously enough, the greatest of

all the Victorian cycle engineers, Professor Archibald Sharp, was against shaft drive; in his classic

1896 book "Bicycles and Tricycles", he writes "The Fearnhead Gear.... if bevel-wheels could be

accurately and cheaply cut by machinery, it is possible that gears of this description might supplant, to a great extent, the chain-drive gear; but the fact that the teeth of the bevel-wheels cannot be accurately

milled is a serious obstacle to their practical success".

In the USA, they had been made by the League Cycle Company as early as 1893. Soon after, the

French company Metropole marketed their Acatane. By 1897 Columbia began aggressively to market

the chainless bicycle it had acquired from the League Cycle Company. Chainless bicycles were

moderately popular in 1898 and 1899, although sales were still much smaller than regular bicycles,

primarily due to the high cost. The bikes were also somewhat less efficient than regular bicycles: there was roughly an 8 percent loss in the gearing, in part due to limited manufacturing technology at

the time. The rear wheel was also more difficult to remove to change flats. Many of these deficiencies

have been overcome in the past century.

In 1902, The Hill-Climber Bicycle Mfg. Company sold a three-speed shaft-driven bicycle in which

the shifting was implemented with three sets of bevel gears. While a small number of chainless

bicycles were available, for the most part, shaft-driven bicycles disappeared from view for most of the

20th century. There is, however, still a niche market for chainless bikes, especially for commuters,

and there is a number of manufacturers who offer them either as part of a larger range or as a primary

specialization. A notable example is Biomega in Denmark.

Shaft drives operate at a very consistent rate of efficiency and performance, without adjustments or

maintenance, though lower than that of a properly adjusted and lubricated chain. Shaft drives are

typically more complex to disassemble when repairing flat rear tyres, and the manufacturing cost is

typically higher.

A fundamental issue with bicycle shaft-drive systems is the requirement to transmit the torque of the rider through bevel gears with much smaller radii than typical bicycle sprockets. This requires both

high quality gears and heavier frame construction. Since shaft-drives require gear hubs for shifting,

they gain the benefit that gears can be shifted while the bicycle is at a complete stop or moving in

reverse, but internal hub geared bicycles typically have a more restricted gear range than comparable

derailleur-equipped bicycles.

The Drive shafts are carriers of torque, they are subject to torsion and shear stress, which represents

the difference between the input force and the load. They thus need to be strong enough to bear the stress, without imposing too great an additional inertia by virtue of the weight of the shaft. Most

automobiles today use rigid driveshaft to deliver power from a transmission to the wheels. A pair of

short driveshaft is commonly used to send power from a central differential, transmission, or

transaxiel to the wheels.

3. Components and Description The Fabrication of Bicycle Driven by Shaft and Gear System consists of the following components

(shown in figure 1).

Pedal Fender

Frame

Hub

Driven Shaft

Bearing



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Bevel gear

Fig 1. Components of bicycle

3.1. Pedal

A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the bicycle. It provides the connection between the cyclist's foot or shoe and the crank allowing the leg to turn the

bottom bracket spindle and propel the bicycle's wheels. on which the foot rests or is attached, that is

free to rotate on bearings with respect to the spindle. Part attached to crank that cyclist rotate to

provide the bicycle power as shown in figure 2.

Fig 2. Pedal

3.2. Fender

Piece of curved metal covering a part of wheel (shown in figure 3) to protect the cyclist from being

splashed.

Fig 3. Fender



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3.3. Front Brake

Mechanism activated by brake cable compressing a calliper of return springs. It forces a pair of brake

pads against the sidewalls to stop the bicycle.

3.4. Hub

Centre part of the wheel from which spoke radiate, inside the hub are ball bearings enabling to rotate around in axle as shown in figure 4.

Fig 4. H u b

3.5. Driven Shaft A shaft-driven bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power from the pedals to the wheel is shown in figure 5. Shaft drives were introduced over a century ago, but were

mostly supplanted by chain-driven bicycles due to the gear ranges possible with sprockets and

derailleur. Recently, due to advancements in internal gear technology, a small number of modern

shaft-driven bicycles have been introduced.

Fig 5. Driven Shaft

3.6. Bearing

For the smooth operation of Shaft, bearing mechanism is used as shown in figure 6. To have very less

friction loss the two ends of shaft are pivoted into the same dimension bearing.



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Fig 6. B e a r i n g

3.7. Bevel gear

A kind of gear in which the two wheels working together lie in different planes and have their teeth

cut at right angles to the surfaces of two cones whose apices coincide with the point where the axes of

the wheels would meet is shown in figure 7.

Fig 7. Bevel Gear

4. Manufacturing Process

4.1. Introduction Manufacturing involves turning raw material to finished products, to be used for various purposes.

There are a large number of processes available. These processes can be broadly classified into four

categories.

Casting process

Forming process

Fabrication process

4.2. CASTING PROCESS These processes only processes where the liquid metal is used. Casting is also the oldest known

manufacturing process. Basically, it consists of inducing the molten metal into a cavity of mould of



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the required form and allowing the metal to solidify. Casting is the most flexible and cheapest method

and given high strength of rigidity to the parts which are difficult to produce by other manufacturing

processes. The principle process among these sand casting where sand is used as the raw material. The

process is equally suitable for the production of a small batch as well as on a large scale. Some of the

other classified casting processes for specialized need are

• Shell mould casting

• Precision mould casting

• Plaster mould casing

The various types of casting processes are given in the table1.

Table 1 Types of casting process

Process

Advantages

Disadvantages

Examples

Sand

Many metals, sizes,

shapes, cheap

Poor finish & tolerance

Engine blocks, cylinder heads

Shell Mold

Better accuracy, finish, higher production rate

Limited part size

Connecting heads,

brake components

Expendable

Pattern

Wide shapes of

metals, sizes, shapes

Patterns have

low strength

Cylinder heads,

brakes

components

Plaster

Mold

Complex shapes,

good surface finish

Non-ferrous metal,

low production rate

Prototype of

mechanical

parts

Ceramic

Mold

Complex shapes,

high accuracy, good

finish

Small sizes

Impellers,

injection mold

tooling

Investment

Complex

shapes,

excellent finish

Small parts, expensive

jewellery

Permanent

Mold

Good finish,

low porosity,

high

production rate

Costly mold,

simpler shapes only

Gears, gear

housings

Die

Excellent

dimensional

accuracy, high

production rate

Costly dies, small

parts, non-ferrous

metals

Gears, camera

bodies, car wheels

Centrifugal

Large cylindrical parts,

good quality

Expensive, few shapes

Pipes,

boilers,

flywheels

4.3. Forming process

These are solid state manufacturing processes involve minimum amount of material wastage. In

forming process metal may be heated to temperature which is slightly below. These solidify

temperature and large force is applied such the material flows and act in desired shape. The desire

shape is controlled by means of a set of tool ties and dies, which may be closed during manufacturing.



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These processes are normally used for large scale production rates. These are generally economical

and, in many cases, improve the mechanical properties. These are some of the metal forming

processes.

Rolling forging

Drop forging

Press forging

Upset forging

4.4. Fabrication Process

These are secondary manufacturing processes where the starting raw materials are produced by any

one of the previous manufacturing processes desired. Its assembly involves joining pieces either

temporary or permanent. So that they would be perform the necessary function. The joining can be achieved by either or both of heat and pressure joining materials. Many of the steel structure

construction, we see are first rolled and then joined together by a fabrication process are

Gas welding

Electric arc welding

Electrical resistance welding

Thermo welding

4.5. Material Removal Process

These are also a secondary removal manufacturing process, where the additional unwanted material is

removed in the form of chips from the blank material by a hard tool so as to obtain the final desired

shape. Material removal is normally a most expensive manufacturing process. Because more energy is

consumed and also a lot of waste material is generated in this process. Still this process is widely used

because it delivers very good dimensional accuracy and good surface finished. Material removal

process are also called machining processes as shown in figure 8,9,10 and figure11. Various processes in this category are

Turning

Drilling

Shaping and planning

Milling

Grinding

Fig 8. Drilling Operations



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Fig 9. Turning Operations

Fig 10. Grinding Operation

Fig 11. Milling Operation



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4.6. Welding

Welding is a process of joining two metal pieces by the application of heat. Welding is the least

expensive process and widely used now a days in fabrication. Welding joints different metals with the

help of a number of processes in which heat is supplied either electrically or by mean of a gas torch.

Different welding processes are used in the manufacturing of Auto mobiles bodies, structural work, tanks, and general machine repair work. In the industries, welding is used in refineries and pipe line

fabrication. It may be called a secondary manufacturing process as shown in figure 12 and 13.

4.6.1. Types of Welding Process GAS WELDING

Oxy-Acetylene

Air-Acetylene

Oxy-Hydrogen

4.6.2. Resistance Welding

Butt Welding

Spot Welding

Seam Welding

Projection Welding

4.6.3. Arc Welding Carbon Arc Welding

Metal Arc Welding

Plasma Arc Welding

Gas Metal Arc Welding

Gas Tungsten Arc Welding

3.6.4. Newer Welding Electron Beam Welding

Laser Beam Welding

Fig 12. Arc Welding

Fig 13. Gas Welding



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5. Working Principle A chainless bicycle is a bicycle that uses a drive shaft instead of a chain to transmit power from the

pedals to the wheel. Shaft drives were introduced over a century ago, but were mostly supplanted by

chain-driven bicycles due to the gear ranges possible with sprockets and derailleur. Recently, due to

advancements in internal gear technology, a small number of modern shaft-driven bicycles have been

introduced. Shaft-driven bikes have been where a conventional bike would have its chain ring. This meshes with another bevel gear mounted on the drive shaft. The 2D view of Shaft driven bicycle is

shown in figure 14. The Bevel gears are the most efficient way of turning drives 90 degrees as

compared to worm gears or crossed helical gear as shown in figure 15. In this shaft driven bicycle, the

spur gear is mounted with the bicycle. It is mainly used to the gear transmission for increasing the

speed of the bicycle. The shaft drive only needs periodic lubrication using a grease gun to keep the

gears running quiet and smooth. This “chainless” drive system provides smooth, quiet and efficient

transfer of energy from the pedals to the rear wheel. It is attractive in look compare with chain driven bicycle. It replaces the traditional method.

Fig 14. Bicycle in 2D view

Fig 15. Gear Arrangement



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6.Comparison of Shaft Vs Chain Chain Drive in by-cycle operates at a very consistent rate of efficiency and performance, without

adjustments or maintenance, though lower than that of a properly adjusted and lubricated chain. Shaft

drives are typically more complex to disassemble when repairing flat rear tires and the manufacturing

cost is typically higher. A fundamental issue with bicycle shaft- drive systems is the requirement to

transmit the torque of the rider through bevel gears with much smaller radii than typical bicycle

sprockets. This requires both high quality gears and heavier frame construction. Since shaft-drives require gear hubs for shifting, they gain the benefit that gears can be shifted while the bicycle is at a

complete stop or moving in reverse, but internal hub geared bikes typically have a more restricted

gear range than comparable derailleur-equipped bikes.

Most of the advantages claimed for a shaft drive can be realized by using a fully enclosed chain case.

Some of the other issues addressed by the shaft drive, such as protection for thing and from ingress of

dirt, can be met through the use of chain guards. The comparison of shaft and chain is shown in figure

16.The reduced need for adjustment in shaft-drive bikes also applies to a similar extent to chain or

belt-driven hub-geared bikes. Not all hub gear systems are shaft compatible.

Fig 16. Comparison of shaft Vs chain

7.Merits of Drive Shaft • They have high specific modulus and strength.

• Reduced weight.

• Due to the weight reduction, energy consumption will be reduced.

• They have high damping capacity hence they produce less vibration and noise.

• They have good corrosion resistance.

• Greater torque capacity than steel or aluminium shaft.

• Longer fatigue life than steel or aluminium shaft.

• Lower rotating weight transmits more of available power.

8.Design Assumptions • The shaft rotates at a constant speed about its longitudinal axis.

• The shaft has a uniform, circular cross section.

• The shaft is perfectly balanced, i.e., at every cross section, the mass

• center coincides with the Geometric center.

• All damping and nonlinear effects are excluded.

• The stress-strain relationship for composite material is

• linear & elastic; hence, Hooke’s law is Applicable for composite materials.

• Acoustical fluid interactions are neglected, i.e., the shaft is assumed to be acting in

a vacuum.



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9.Advantages

• Drive system is less likely to become jammed.

• The use of a gear system creates a smoother and more consistent pedaling motion.

• Lower maintenance.

• Efficiency is more as compared to conventional bicycle design.

• High durability.

• Low cost of ownership when manufactured in large scale.

10.Applications

• It is used for racing purpose.

• Also used for Off-road riding.

• For Cycling.

• For public and bicycle rental purpose.

Conclusion This research work is cleanly explained about how the bicycle runs by the shaft and gear

system. We used bevel gear mechanism. It is used to transmits the power through the bevel gear to run

the bicycle. Existing material used in bicycle crown wheel and crown shaft, is used to transmit the

power to the bicycle. We are replacing the crown wheel and crown soft into bevel gear.

Use of bevel gear the starting torque is high when compared to the already existing bicycle

which is present in the market. It is made up of mild steel .so load carrying capacity of our bicycle of

shaft driven bicycle is high when compared to the other product.

The shaft driven bicycle is designed successfully. The bicycle works efficiently and transmits

the power from pedal to rear wheel smoothly, but it is requiring slightly more initial torque compare

to drive torque. The noise and the vibration of the gear pair are considerably reduced. This bicycle can

be used for racing purpose and off-road riding. As the speed of the shaft driven bicycle is more

enough, it can be utilized for generating pedal work.

The presented work was aimed to reduce the wastage of human power (energy) on bicycle

riding or any machine, which employs drive shafts; in general, it is achieved by using light weight

drive shaft with bevel gears on both sides designed on replacing chain transmission.

The design of drive shaft is critical as it is subjected to combined loads. The designer has two

options for designing the drive shaft whether to select solid or hollow shaft. The solid shaft gives a

maximum value of torque transmission but at same time due to increase in weight of shaft, For a given

weight, the hollow shaft is stronger because it has a bigger diameter due to less weight & less bending

moment.

References

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Design and Fabrication of Bicycle Driven by Shaft and Gear System · Abstract: A chainless bicycle...

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