Fabrication of Bicycle Frame of A356 Aluminum Alloys by Using Sand Casting

Abstract

Bicycle frames on the market are generally made from a pipe connected by welding process. Bicycles are made by big companies, because it requires forming technology of raw materials for the pipe production and complex welding technologies. In order to reduce the dependence on raw materials and pipe welding processes, an alternative technology for bicycle frame manufacturing process is investigated. This study is aimed to examine the use of casting technology in the manufacturing process of bicycle frame. Production of bicycle frames in limited quantities is possible by using the casting process. To achieve these objectives, it is necessary to redesign the bicycle frame suitable for the casting process. Prototypes have been produced and the first bike is in the testing phase. Initilly , the bicycle is relatively heavy (7 kg). The optimization of the design reduces to a light and strong frame. The frame has a weight of 3.74 kg. The prototype of the frame has been succesfully casted by sand casting method.