1.
0)DISTRIBUTION OF WORK
In this semester especially for subject manufacturing process MEM 560, assigned a desktop
research assignment industrial case study for Mechanical Engineering student. The task given is to
perform research about a product of manufacturing company. Due date for the task is at the end of
July which is 21 July. This is a group of assignment consist maximum 5 members in a group. Through
the platform of online discussion which is zoom, we decide a product and company to do research.
Topic of our research is how bicycle frame of mountain bike made up and we choose Trek Bicycle
Corporation as main company to study. For a fair responsibility, all groups member distributed task
equal and nicely. Below is the list for group members and their perspective task.
GROUP MEMBERS TASK
Mohd Haniff Bin Rameli (leader) -As a leader, distributed tasks given fairly
amount the group members.
-Take responsibility to ask supervisor if cannot
understand a certain thing about the assignment.
-Do research about bicycle company and write
introduction about company such as history and
etc.
- For finding, do research about defects and
other problems about the product.
Mohamad Azizi Bin Anas -Write objective about this experiment and
justify at the end of research what input students
can get.
-Find suitable manufacturing process and
technology used and elaborate them with more
details.
Muhammad Zulazri Bin Zulaily -Also do findings about design concept and
quality assurance. Able to justify the concept
use and how to control quality of the product.
-List of other products that company made from
bicycle frame.
Mohd Faizal Bin Abdullah -Do discussion and briefly explain another
method can be used to manufacture the product.
-Justify what other problem that company faced.
Muhammad Umair Zaidi Bin Mohd Nor Rasyid -Comment about improvement on the task.
-Write reference in correct format.
-Record the video meeting.
2.0)BACKGROUND OF COMPANY
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Trek Bicycle Corporation is one of the largest bicycle manufacturing in this world. Their
product can be categorised as popular product among cyclist and the quality of product is a top global.
The main company is from United State and they have other branches all over the world. The
company history begins in 1976 where this is the year Trek Company established by it founder Dick
Burke which is president of Milwaukee based appliance and electronics. Their financial for starting
the business came from Roth’s parent company which is one of closer sibling to the Dick Burke. They
started this business with 5 workers. Amazingly, they can create high quality and lightweight steel
bicycle by their hand skill without using machine at that time. Within their quality product produced,
they immediately become supplier of favourite brand among connoisseur market.
Middle Stage Development (1983-1985)
This is the year where Trek corporation introduced mountain bike as product from their
company. For first starter they manage to introduced 850 model and expand their branches to Asia
which located at Taiwan. Trek Corporation mountain bike came with outstanding comfortable seats,
thick tires and extra number of gears to defeated other brands company at that time. In spite of their
continuous growing, they still happened to face internal conflicts among founders. One of the
founders have different idea from Dike Burke and decide to leave the company and opened another
bicycle company. Event with this major change in managing department, Trek Corporation cannot
stop to grow more. They managed to produced first aluminium road bike model 2000 in California.
Then, followed next year this company manufacture a carbon composite road bike which more strong
and lighter compare to aluminium body.
Peak Stage Development (1996-2005)
Trek Corporation faced biggest problem when their sales no increasing anymore. Dike Burke
said in 1996 Capital Times (Madison, Wisconsin) interview, main factor of their fall because the bike
still not using future technology compare with other brands. With very low morale, Dick Burke decide
to take a week free to start managing back into basics and find solution to their problems. Amazingly,
Burke managed to find it and increase their sales double for next three year. In 1980, Trek
Corporation developing new technology with introducing advances material that can enhance
lightness and strength of it bicycle frames. In 1992 their outgoing effort bring new technology process
name as Optimum Compaction Low Void (OCLV) carbon fiber lamination process. After this new
asset, company sale hit up as fast as wind.
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Present Day
Now Trek Corporation existence cannot be denied anymore. Their products become top
brands not only in west region but the entire word. Present day their business is about bicycle but with
future technology and idea many other products they manufacture and released in the market. List of
their products other than bike helmets, water bottles and cages, cycling glasses, protective gear and
etc. Most popular brand under Trek Corporation such as Trek, Electra, Bontrager and Diamant Bikes.
Trek Corporation also become sponsor for popular cycling sport and their bike become one of fastest,
strong and light bring defeat to other companies.
Figure 1: One of Main Trek Factory in US
Figure 2: Mountain Bike Trex X-Caliber 8 Figure 3: Trek Bike Helmet
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3.0)OBJECTIVE OF THE CASE STUDY
To understand and explain the manufacturing process and the technology employed in
making the frame of mountain bike.
To understand and explain the design concept and quality assurance in respective processes.
To associate appropriate manufacturing process and/or technology.
To contribute ideas and suggest possible resolutions.
To present the report in an arranged and appropriate manner to be easy to understand.
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4.0)FINDINGS
a) MANUFACTURING PROCESS AND THE TECHNOLOGY EMPLOYED
In the late 1800s, the American Military try modifying bicycles to help infantrymen cross rough
terrain. Cyclist continued experimenting with various technology and engineering method to produce
a bike that reduce the effort to traverse. The popularity of mountain biking has grown ever since.
Mountain bikes are designed to perform on rough terrain. They have a suspension to keep the
wheel in contact with the ground, deep treaded tires for added traction and powerful disc brake for
safety. At the core of the mountain bike is the small robust frame. It needs to be lightweight yet highly
durable. In this report, we will discuss the method manufacturing the frame of the mountain
bike step-to-step until it is ready for assembly:
Cold drawing
First, the raw material used is aluminum metal alloy being
annealed by heating and then hollowed to get hollow form. Then
hollows are cut followed the setup measurement. Next hollows
placed over mandrel and attached to draw bench. Hollow will go
through dies that pushed them inti thinner and longer tubes.
Lastly, shaping and tapping process being done to get variety of
length and designs.
Cutting
The frame is made from tubes of aluminum alloy. Aluminum is
lighter than steel and cheaper than carbon fiber and it would not
burst like carbon in case of a large impact. They cut each tube to
the required length. They use jigs to get consistent dimensions
and precise cutting angles. This will be extremely important
when they assemble the frame.
Welding
Each model and size of frame has its own welding jig. They start
tack welding the tubes in place then they proceed to the final
welding. It’s a delicate step because the tube is very thin. To
more precise gas tungsten arc welding (GTAW) being used to
weld aluminum alloy because not involve mechanical wire
feeding.
First Heat Treatment
After welding, the aluminum frame will undergo heat treatment.
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First, the frame will be heated intensely then quickly quenched in
a cool bath. This make the metal easier to work with.
Alignment
This next step is necessary because slight defamations are created
in the frame during wielding. Using precise measuring
instruments and a rubber mallet to avoid denting the metal, a
technician ensures the frame is perfectly parallel to the alignment
table. It is not easy to align the shorter tubes, so he uses a longer
rod for this task.
Second Heat Treatment
After alignment, the frame will be heated one last time to harden
the aluminum. Once the aluminum exhibits the right mechanical
properties, it is ready for next step.
Boring
Boring is a crucial procedure to make the inside of the hole
perfectly straight and aligned with the frame geometric design.
Painting and Stickers
In the painting department, they spray auto grade paint which
then dries in an oven for 20 minutes. Next, they use ink transfer
tape to apply the logo on the bicycle frame. After the logo dries
in the oven, they will finish with the clear coat of varnish.
Everything must be perfect. When buying a new bicycle, most
mountain bikers pay very close attention to the quality of the
paint job.
Simulation
The factory uses a test bench to simulate the effects of repeated
impacts and vibration on the bike frame. The data will be input in
the simulation software and the quality assurance will tweak and
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ensure it is ready in terms of durability. 3 days of testing can
simulate ten years of intensive use. Hence the frame of the bike is
done and are ready for the assembly with other parts.
Table 1: Manufacturing process of bike frame
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b) CONCEPT DESIGN & QUALITY ASSURANCE
Figure 4: Emonda by Trek Bike Corporation
The figure shows one of the design concepts that has been presented for Trek Bike
Corporation which is called Emonda. It same like the most bicycle concept design where it has
diamond-shaped frame that links all the components and part together in a proper geometric
configuration. The frame was built with heavy strong steel and alloy steel so that it can provide
rigidity and strength to the bicycle. The design must consist of the front and rear triangle. The front
must be formed more of quadrilateral of four tube such as the top, down, the head tube and seat. For
the rear triangle, it must consist seatstays, chainstays and rear wheel dropouts. The steering tube and
the fork are attached to the heat tube which at the front of the frame.
This product saves money, time and resources by automating the quality assurance process
for carbon molding and machining. The automated data collection that has been converted from a
paper based system has provided the efficient analysis which saving over $19000 for quality
department in paper cost only a year.
By reducing the scrap and improving the product quality, trek has achieved a significant
savings. Only using the simple calculation within InfinityQS ProFicient, now, the quality engineer are
able to closely oversee track resin flow during the molding process. The most exciting part is when
Trek be able to maintain make high-performance bikes that meet the strict requirement and quality
standards each time. Thus, no wonder the Trek be able to maintain in the market in leadership.
In 2014, Trek has presented as the world’s lightest production road bike that exist in the
market. Trek could consistently maintain an excellent standard quality with this confidence to avoid
any risk of unsustainable scrappage or warranty claims.
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c) PRODUCTS PRODUCED
There are few products that has been produce by Trek Bike Corporation such as Eco-friendly
products and bontrager. Trek team up with multiple supplier in 2010 to provide the eco-friendly
product which the product are economically priced and made out of steel. Trek also starting to provide
funds to bike shops so that recycling process of old tube can be start and sent to Alchemy Goods in
Seattle, Washington. It can recycle the old tube and made into seat bags, panniers and bag.
Next, the company also provided bontrager branded product such as tires, handlebars, wheels,
seatposts, helmets, electronics, protective gears, saddles and cycling shoes. Water bottles and other
cycling accessories and clothing also to be included.
Figure 5: List of part at bicycle.
Figure 6: Trek helmet Figure 7: Trek water bottle Figure 8: Trek knee-guard
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d) PROBLEM FACED
In any products, there is no thing such as perfect condition because it depend on situation and
time. Even though most of material for Trek Bike Corporation made from advance material that very
strong for their body, frame defect still occurs due to certain errors such as error while connecting
tubes of body frame. There are a few defects occur in bicycle that commonly happen in industry when
users used it for a long period of time. Below is the list of common defects occur on bicycle.
Defects Reasons
Frame failure -Most often crack happen in body frame is at head tube and its very dangerous
because it effects other parts.
-Bad welding during combining frame body lead to short amount of time
withstand load before cracked.
-Ignore the rust happen on body frame make the body frame weak from inside
and outside.
-Metal fatigue where condition of crack expands slowly until frame suddenly
fail.
Fork failure -Fork most responsible for steering. Common failure for carbon fiber composite
material is when lower legs detached away from steer tube.
- Most common cause is imperfect welding during attach body frame.
Handle bar -Unfitting threaded fastener torque lead to cracks in aluminum and carbon
failure composite material.
Seat post failure -Fatigue cracks when using aluminum as material of seatpost. Aluminum have
high probability to create aluminum oxide blooms that greatly damage steerer
tube in the frame.
Brake failure -Most common case due to the brake pads wear out.
Table 2: Defect and failure
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5.0)DISCUSSION
The common material used when choosing for bicycle frame will be aluminum alloy.
Although there are some company that use carbon fiber and steel as a main material for the body
frame. All in all, when compare in term of weight aluminum alloy is much lighter than steel but a bit
heavier than carbon fiber. However the difference between aluminum and carbon are not that huge
only slightly. Meanwhile in term of price, none of carbon and steel can compare to aluminum as it is
the cheapest among all three. Aluminum is also easier to get and get access to. In term of stiffness and
strength, carbon fiber reign at top as it strength and stiffness when tested double of aluminum.
However, the downside of carbon fiber is that it was very brittle. When it reach it limit of deformation
it will break and shatter. Opposite to the carbon, aluminum is very ductile and when reached it limit of
deformation is will only bend. Thus, when consider safety of the user it is safely to say that aluminum
is much suitable as the effect is much easy to look on the appearance.
Of course, in production nothing is perfect as company face many problems that have to
overcome when manufacturing a product. This is very true for Trek Bike Corporation as they have
many defects when producing their product such as frame failure, fork failure, handle bar failure and
seat post failure. So it is very important that this company take a suitable measure to overcome the
problem to provide more comfort for the user when use their product. Frame failure usually happen
when crack appear at head tube. This is due to excessive stress and to overcome this company must
design a good body frame which can handle better stress. While bad welding contributed to this
problem too, the only way to improve this is a person welding the frame must have sufficient
technique to cope with the problem. Fork failure is commonly seen when carbon fiber is use because
unlike aluminum alloy, carbon fiber cannot be welded with different metal. To overcome fork failure
in carbon fiber, selecting a suitable and good epoxy is must and when assemble the carbon tube. In
addition, besides using epoxy carbon fiber can be joint using bolt and nut. However, if aluminum is to
be consider the method is much easier as only better welding should be apply. Lastly to overcome
handle bar failure, selecting a suitable threaded fastener is very important. There are many types of
fastener and selecting the suitable type and size of threaded fastener is a must to prevent handle bar
failure.
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6.0)CONCLUSION
Overall, our project is a success. However, there is always room for improvement. Since, this
is desktop search project due to the recent pandemic, we have only little knowledge of what our
project was made. We only uses Google and Youtube search for the information for our project. We
only barely scratch the surface of how the product was made. Before we decide our project, we must
use virtual meeting application to discuss the possibility of our product. This makes it harder to
express our idea between the group members as there is problem with the internet connection
sometime. We also use the Whatsapp application to exchange information and divide our task. Even
though, this modern media helps us to lighten our load. It does not beat the face to face meeting. This
would be better if the pandemic does not occur in the first place. We can develope deeper into the
information that we want about our project by visiting the industrial factory. By this method, we can
see and experience how the product was manufactured from A to Z.
Even though we cannot visit real industry manufacturing process, we still learn a lot of thing
from online desktop search. Most important things to learn is about trust and cooperation between
group members since we cannot meet face to face. Furthermore, through this assignment, we believe
that our knowledge about real industry developed higher than before. This will bring benefit to us
when we involve in real work life in the future.
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7.0) REFERENCES
1. TREK, Trek Bikes - The World's Best Bikes And Cycling Gear. [Retrieve from: July 14,2020]
https://www.trekbikes.com/us/en_US/
2. How It’s Made, (March 5,2015)How Its Made Mountain Bikes. [Retrieve from: July 14,2020]
https://www.youtube.com/watch?v=ivPlSYSOBHA
3. InfinityQS, Trek Bikes Pave the Road to Cycling Excellence. [Retrieve from: July 14,2020]
https://www.infinityqs.com/resources/case-studies/trek
4. How bicycle made. Manufacturing process and assembly. [Retrieve from: 14 July,2020]
http://www.madehow.com/Volume-2/Bicycle.html
5. Manufacturing liability. Bicycle part defect and failure. [Retrieve from: 16 July, 2020]
http://www.framelaw.com/articles/bicycle-defects/
6. Cold drawing. Cold drawing process for seamless tube. [Retrieve from: 16 July 2020]
https://www.precisionkidd.com/technology.htm
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