Santa Susana High School

Engineering a Bicycle Stem

The Design and Manufacturing Process

Kevin Pauls

AP Literature

Mrs. P. Bradley

October 28, 2016

For my senior project, I will be engineering a bicycle stem using computer aided design.

It would be a great achievement for me to grasp the skills of what will be required to create a
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stem, specifically for bicycle motocross (BMX). I would like to develop an insight in the

engineering process of a product and the way to machine it once thoroughly analyzed and the

model completed.

Challenges that I will have in order to successfully carry out this project will include

learning how to use SolidWorks, a popular CAD (computer aided design) program for students. I

will also have to design the stem with the proper strength to avoid any stress fractures and flex in

the aluminum that will be used. Along with this strength, the stem must conserve weight to keep

the front end of the bicycle lighter.

To complete this project, I must develop a preliminary model of the stem on paper with

precise measurements, followed by recreating and testing the model in SolidWorks. This must be

followed by making any modifications to the model to make it as optimal as possible. After final

modifications and when the model is finished, it will be CNC-machined and physically tested on

my BMX bike.

I expect the final outcome to be a fully-functional BMX stem that can be raced with on

any BMX bicycle. There should be no stress fractures and minimal stress throughout the stem,

and it should be able to support a large amount of body weight from any given racer.
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I have always been very interested in the process of engineering and the way that

products are manufactured. As an avid BMX racer, I am infatuated with the mechanics of my

bicycle motocross (BMX) bicycle. Combining both of these interests together, I felt that

designing a bicycle part, specifically a stem, would be ideal for my senior project. When I

graduate high school and transfer my knowledge over to college, I plan on studying mechanical

engineering and earning a Master's degree. With the experience that I plan to gain from this

project, I will already have a strong sense of what I will be able to do with my degree and the

whole process behind it. At the end of my project, the outcome will be a fully-working BMX

race-specific stem that I will be able to race with on my own BMX bicycle.

I already possess many skills on how to maintain a bicycle and what parts are required to

make a bicycle function properly. Along with these bicycle maintenance skills, I have had a lot of

experience in the past working with stems in specific. My experience mainly consists of

tightening down handlebars onto the stems front, securing the stem to the fork on a bicycle, and

tightening the stem lock to hold the stem in place. In terms of the manufacturing process, I know

the basics of the assembly line as I have had past experience of assembling bicycle and medical

products in a machine shop.

This project will be a great learning stretch for me due to the fact that instead of simply

working with already-physical products, I will gain the skills and understanding of the steps of

how to fully engineer a product. I will also learn what tools and machines to use to develop a

solid model of the product and after abundant amounts of testing, I will learn how to determine if

the product is ready for mass production or if it needs to be redesigned. To create a three-

dimensional model of the bicycle stem, I will have to gain the knowledge of how to use
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SolidWorks, a program for computer-aided design (CAD) and the modern-day industry standard

for engineering. In order to be able to engineer the bicycle stem, I must learn the steps of

engineering, the basics of computer-aided design, and the ways that I can apply this information

to the making of a BMX stem.

To be able to successfully carry out the engineering of a product, one must have a

knowledge of what steps need to be conducted in order to reach a final product. The first step in

the engineering process is usually the conceptualization stage, the stage where an idea is

developed in the human mind and sketched out to create a visual model of the resulting product

(Regli). Typically, there are four stages to create a product in conceptualization: pen and paper,

drawing pads, two-dimensional sketching systems, and three-dimensional sketching systems. In

the usage of pen and paper, one will use tools such as a compass, a protractor, a straight-edge

ruler, and a caliper for precise measurements. The sketching of a model into paper has been a

very common way in which engineers will create their models (de Weck). In the usage of

drawing pads, the model of a product is sketched out with computer software. This form of

conceptualization is subsequent to the pen and paper process, but instead of paper, a drawing pad

is now utilized to directly input a drawing into a CAD program using graphic design and other

computer-related tools (Lipson). In the usage of two-dimensional sketching systems, concepts of

a model are further analyzed by the computer and broken down into the basics of two-

dimensional primitives, including arcs and straight lines. At this point, the system will cleanse

the rougher edges of the model and refine it to make it more realistic and presentable to the

human eye (Lipson). In the usage of three-dimensional sketching systems, the model designer

will have to identify the elements of the sketched model including any various corners, curves,

and edges. It is crucial for the model designer to determine the parts of the two-dimensional
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model to help the CAD program transform it into a three-dimensional model, making sure it

results in the way that he or she wishes (Lipson). After the conceptualization stage will follow

the next step of the engineering process.

Following the sketchs transformation into a three-dimensional model, the engineer will

now carry out the analyzation and evaluation stage. Since the model is now three-dimensional,

the CAD program will then run several tests on the model to determine its strong and weak

points as well as the overall durability. Simulating various types of real-life conditions within the

CAD program, it will be able to tell how the product would hold up or last over a given period of

time. After the model of the product is analyzed, the program will then come to a conclusion

with the designs overall performance, which leads into the next step of the engineering process

(Regli).

Now that the this conclusion has been determined by the CAD program, the engineer will

now know whether or not improvements will be needed in order to fit the standards of what

product needs to be created, also known as the modification and revision stage. If the conclusion

given by the program states that the model violates the standards of the physical conditions that it

will go through, then the model will have to be modified to develop a newly-improved three-

dimensional version (Regli). This newer model will then go back to the evaluation stage where

the CAD program will run the same tests as before and form a new set of results in an updated

conclusion. If the product still has violations of the engineers standards, then it will continue to

cycle through the modification stage and the evaluation stage. Once the product finally meets the

standards of the engineer, it may then receive last-minute refinements before finishing its journey

on the CAD program. The finished models data is then saved in a digitalized state, better known
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as computer numerical control (CNC) onto a tape or disk that can be taken by CNC machines to

be produced (Regli).

Following the steps of the CAD program comes the production stage. This stage contains

the controlled process of the products physical machining and anything else that may relate to

the manufacturing of the product. To physically machine a product, the engineer must first take

raw material, such as aluminum, and place it properly into a selected CNC machine, usually

located in a machine shop or a specialized area similar to that of a machine shop (Lipson). Inside

the machine, the engineering machinist should ensure that the proper tools are found inside of the

main chamber of the machine that can drill out whatever bits of the raw material that will not

appear on the final product. The CNC-coded tape or disk that was saved from the CAD

programs model will then be inserted into the machine for it to read what product will be

manufactured (Simpson). It is important to know how many different stages will be needed for

the machining of the product depending on how large, complex, or even how many pieces the

model may be. At this point, it is up to the machinist to ensure that the machining of the product

is conducted in a smooth fashion. It is wise to check on the machining of the raw material into

the machined product to ensure that things are moving smoothly (Hoffmann). When the

machining of the product and the production stage are finished, the next stage will take place.

Now that a physical product of the model is created, the next step in the engineering

process is the post-production stage. Since this physical product is fresh from being modeled and

machined for the first time, this product is known as the initial prototype (Horvth). In the post-

production stage, the prototype will now go through a process that will prepare it to be used. It is

very likely for a CNC machine to leave sharp edges on machined products due to the fact of

following the CNC coding for the product very precisely. Since these edges on a product can
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sometimes be slightly too sharp for the safety of those purchasing the product on the market,

many machined products will go through the process of deburring. In deburring, the sharp edges

will literally be shaved off by a machinist with a knife in order to make them smoother.

Deburring a product also contains the process of removing any unnecessary shavings that the

CNC machine may have left on accident (Simpson). After the prototype is deburred, it will then

go under quality control. In the process of quality control, the prototype will be thoroughly

examined by the machinist to ensure of no manufacturing errors and proper deburring, including

the checking of properly-smoothed edges and the absence of extra shavings. Following quality

control is the possible assembly of the prototype. If the prototype has to be assembled from

various pieces or is in need of additional parts, the assembly is when everything will be placed

together (Horvth). When the prototype is fully inspected and assembled, the engineering

process may finally reach the testing step.

Possibly the final part of the engineering process is the testing stage. After being

conceptualized, refined in design, and machined, the prototype is finally ready to be put into use.

While being tested, the prototype will be studied for any types of stress fractures, overall

stiffness, and other durability factors (Regli). There is always a solid chance that the prototype

design will eventually have to be refined back in the CAD program in order to increase the

quality and effectiveness of the prototype. The engineer would then have to make improvements

to the original three-dimensional model, along with revision, production, post-production, and

the testing of the product once again. Every time that the product will be refined will eventually

lead to the closer the product will be to being released to the consumer market (Simpson). The

engineering of a product can be a very lengthy process, but in the end, the resulting product is

what will truly matter towards the engineer.

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I researched the process of engineering for my senior project due to the fact that I had

little knowledge of what actually happens when a product is made. When the time comes for me

to engineer a bicycle stem, I will need to know what stages I will expect myself to go through in

order to successfully complete my senior project. Also, since I plan on attaching the bicycle stem

that I engineer onto my own BMX bicycle for racing, I want to be able to trust myself to design a

product that will withstand larger impacts with firm rigidity as well as possess the conservation

of weight.

The steps of engineering a bicycle stem will fall directly underneath the pattern of the

stages in engineering and will begin with the same first step: the conceptualization stage. In this

stage, I will have to sketch the ideas to guide the design so that the outcome is the

preliminary/conceptual model (Regli). This is the point of the project where I will use tools

such as straight-edge rulers and calipers in order to precisely measure out the dimensions of the

stem and keep the sketch relatively tidy. I will then enter the ideas into a computer. The CAD

program will then transform the data into a computer model (Regli). After sketching out what I

would like my stem to appear as, I will then input the sketch through a drawing pad onto a CAD

program called SolidWorks to eventually convert the whole concept into a three-dimensional

model.

The next step that I will follow is the analyzation and evaluation stage where I will

execute a number of tests to understand the behavior and properties of the design under realistic

working conditions (Regli). With the concept of the stem now on SolidWorks, I will run various

life-simulating tests on the stem and determine whether or not it would be able to withstand the

stress from a BMX racer applying all of his or her weight onto it in a race. The results from these
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tests will then be given to me as a conclusion of how the stem will function, which leads into the

next step.

Just as any other product in the engineering process would, the stem model will then be

in the modification and revision stage. At this point, I have to make sure there are no violations

in product requirements and make modification of the design model to improve its performance

(Regli). If my stem concept does not meet the standards of how much weight it can withstand,

then I will have to go back into the three-dimensional model and add reinforcement or cut weight

to stiffen areas of high stress. I will then have to run the same tests again to progressively

improve the design of the stem, whereas once the stem passes all stress tests, I can move the stem

model into the next step.

After conversion into CNC coding, the stem will then reach the production stage. I will

then obtain the proper material in order to manufacture my stem, which will most likely be 6061

or 7075 aluminum and will typically come in the form of a long metal rod. Machine

requirements planning, which includes design and procurement of special tools, capacity

resource planning, systems management and control, and the basic manufacturing processing,

occurs in the production engineering function (Simpson). The CNC machine that I will use for

the manufacturing of the stem will have the special tools and correct CNC coding to properly

machine the stem. I will constantly be checking on the process of when the stem is machined

with is two main pieces: the stem body and the piece that holds onto the handlebars.

In the post-production stage, I will have to undergo the three main parts to post-

production: deburring, quality control, and the assembly line (Horvth). If the physical stem has

rough edges that are unsafe to the BMX rider or any extra metal shavings, then I will have to

deburr the stem. I will then check the stem to ensure the it has been properly deburred and that
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there were no errors in the machining process. I will the assemble the stem by screwing on the

handlebar piece to the main stem body.

The portion of the engineering process that I feel will be the best part is the actual usage

and testing of the stem prototype. As I ride with it on my BMX bicycle, I will constantly be

checking for any signs of stress fractures or any other product malfunctions that will put my

riding in danger. I might have to possibly make various prototypes of the stem by repeating the

whole process of engineering, but I will do so in order to have the most efficient stem that I can

possibly make.

(insert conclusion here when you wake up at like 4am lol)

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Works Cited

de Weck, Olivier. l4.pdf. MIT OCW. Massachusetts Institute of Technology, Jan 6,

2005. Web. Oct 25, 2016.

Hoffmann, Christoph M. Index of /homes/cmh/distribution/books. CS Purdue. Purdue

University, Mar 1 2002. Web. Oct 25, 2016.

Regli, William C. CAD tutorial. Geometric and Intelligent Computing Laboratory,

Department of Mathematics and Computer Science. Drexel University, Aug 20 1999.

Web. Oct 26, 2016.

Horvth, Imre. EdiProd2000_Paper.PDF. The College of Information Sciences and

Technology. Delft University of Technology, Feb 2001. Web. Oct 26, 2016.

Lipson, Hod. download. Computer Aided 3D Sketching for conceptual design. Israel

Institute of Technology, Sept 1998. Web. Oct 25, 2016.

Simpson, Timothy. ie466.CE.overview.doc. IE 466 - Concurrent Engineering.

Pennsylvania State University, Aug 15 2001. Web. Oct 25, 2016.

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de Weck, Olivier. l4.pdf. MIT OCW. Massachusetts Institute of Technology, Jan 6,

2005. Web. Sept 12, 2016.

These lecture notes contain the basics of computer aided design (CAD) and some

theory of geometrical representation. The definition of CAD and the basic elements of a

CAD system are outlined, including the benefits of CAD and the typical process under

how CAD is carried out. A brief history of CAD is also given. Some CAD-theory of

geometrical representation is outlined which includes curve equations and different types

of curves.

The author, Prof. Olivier de Weck, holds a PhD in Aerospace Systems from the

Massachusetts Institute of Technology. These lecture notes were published by MIT, a

private research university in Cambridge, Massachusetts. These notes were published

eleven years ago but do not seem outdated. The notes are fairly thorough and seems well-

researched.

Hoffmann, Christoph M. Index of /homes/cmh/distribution/books. CS Purdue. Purdue

University, Mar 1 2002. Web. Sept 12 2016.

This online book is about geometric and solid modeling. It outlines the brief

history of solid modeling and the various levels of abstraction. It covers basic concepts

such as constructive solid geometry (CSG) representation, boolean operations, and robust

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faces as well as surface intersections.

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The author, Prof. Christophe M. Hoffmann, holds a PhD in Computer Science

from the University of Wisconsin. This book was published online by Purdue University,

a public research university in West Lafayette, Indiana. The book was published fourteen

years ago but appears to be up to date. The book is thorough and seems well-researched.

Regli, William C. CAD tutorial. Geometric and Intelligent Computing Laboratory,

Department of Mathematics and Computer Science. Drexel University, Aug 20 1999.

Web. Sept 12 2016.

This article covers the basic process and routine of the computer aided design of a

product. Eight basic steps are given on the design process with the usage of a pen and

paper. Eight more steps are outlined in what to do after sketching a product and inputting

it into the CAD program.

The author, Prof. William C. Regli, holds a PhD in Computer Science from the

University of Maryland at College Park. This article was published by the Drexel

University College of Computing & Informatics. This article was published seventeen

years ago and seems a bit out of date, but it still provides the bare basics of product

design. The article is very simple with adequate research.

Horvth, Imre. EdiProd2000_Paper.PDF. The College of Information Sciences and

Technology. Delft University of Technology, Feb 2001. Web. Sept 12 2016.

This article covers the issues related to the understanding and computer support of

conceptual design. The full definition of conceptual design is explained in depth. The

notions of the development of computer tools and methods that support conceptual design

are covered. There are explanations of studies such as mental activities related to
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conceptualization, the potential application of artificial intelligence, and the development

of incomplete conceptual models.

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support from the Technical University of Budapest in Hungary. This article was published

by Delft University of Technology. This article was published fifteen years ago, but it

seems fairly up to date. The article is thorough and seems well-researched.

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Engineering. Missouri University of Science and Technology, Apr 2006. Web. Sept 12

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The author, Dr. Ming C. Leu, holds a PhD in Mechanical Engineering from the

University of California, Berkeley in Berkeley, California. The manual was published by

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This document is about computer aided 3D sketching for the conceptual design of

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design. The documents thesis includes being able to provide CAD systems with the

ability to convert freehand design sketches into three-dimensional models. It will propose

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The author, Dr. Hod Lipson, holds a PhD in Mechanical Engineering from

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University of California, Berkeley in Berkeley, California. The manual was published by

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Engineering Professional. This article was published by Carnegie Mellon University. As

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in Mechanical Engineering. San Jose State University, Jul 2014. Web. Sept 12 2016.

This article is about the coordinate transformation of a three-dimensional object.

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and transformation. It also covers rotational transformation and the rotation of an object

around an arbitrary axis.

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Texas A&M University in College Station, Texas. This article was published by San Jose

State University. As this article was released two years ago, it is up to date. It seems to be

thorough and well-researched.