Mechanical Engineering Design 36: Electric Bike Project

This project details the design of an electric bike, emphasizing environmental conservation through the use of electrical energy. The project encompasses both conceptual and final design phases, leveraging CAD, FMEA, and ANSYS simulation software for structural analysis. The report includes a comprehensive overview of the design process, from initial conceptualization to the selection of key components like the frame, motor, battery, and brakes. It details the use of SolidWorks for 3D modeling and ANSYS for finite element analysis (FEA) to assess the structural integrity of the design under various conditions. The project also incorporates Design for Assembly (DFA), Design for Environment (DFE), and Design for Disassembly (DFD) considerations, along with a Failure Mode and Effect Analysis (FMEA) to ensure safety and reliability. The final design is presented with recommendations and conclusions, highlighting the project's focus on creating an efficient and environmentally friendly mode of transportation. The design also includes Gantt chart, tables and figures illustrating the project's progress and findings.

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MECHANICAL ENGINEERING DESIGN
By Name
Course
Instructor
Institution
Location
Date

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EXERCUTIVE SUMMARY
This project is addressing the design of an electric bike which will be to operate
exclusively on the motor and battery (electrical energy). Therefore the proposed designed of the
electric bike will help in conserving the environment since there is no emission of carbon (IV)
oxide. There will be the use of some analysis software where the simulation will be done to
check if the structure of the electric bike can really work in the real design. Some of these
simulation software includes the CAD, FMEA, among other software. This project has
conceptual design and the final design. The conceptual design is the process of coming up with
idea of the project while the final design is where the actual design of the electric bike is done.

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TABLE OF CONTENT
EXERCUTIVE SUMMARY...............................................................................................................................2
TABLE OF CONTENT...............................................................................................................................3
TABLE OF FIGURES................................................................................................................................5
LISTS OF TABLES....................................................................................................................................5
INTRODUCTION.......................................................................................................................................6
AIMS AND OBJECTIVES.........................................................................................................................7
Aims of the project..................................................................................................................................7
Objectives of the project..........................................................................................................................7
TEAM ACTIVITY......................................................................................................................................7
Member Roles.........................................................................................................................................8
GANTT CHART.......................................................................................................................................10
CONCEPTUAL DESIGN.........................................................................................................................11
Regal requirement.................................................................................................................................11
The design conception...........................................................................................................................12
Frame design.........................................................................................................................................14
Electronic bike Wheel (rear and bake)...................................................................................................15
Motor & Control....................................................................................................................................16
Battery...................................................................................................................................................17
Drive Train and the Hub........................................................................................................................19
Brakes....................................................................................................................................................20
Handle...................................................................................................................................................21
FINAL DESIGN........................................................................................................................................22
IMPORTANT SELECTIONS...................................................................................................................25
Safety Requirement for electric bike.....................................................................................................26
Component selection of this design.......................................................................................................28
Wheels...............................................................................................................................................28
Brakes................................................................................................................................................28
ANSYS ANALYSIS.................................................................................................................................28
Design for Assembly (DFA)..................................................................................................................29
Design for Environment (DFE).............................................................................................................29
Design for Disassembly (DFD).............................................................................................................30

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Failure Mode and Effect Analysis (FMEA)...........................................................................................30
Simulation Results.....................................................................................................................................32
Final Product.........................................................................................................................................35
RECOMMENDATIONS...........................................................................................................................36
CONCLUSION.........................................................................................................................................36
REFERENCES..........................................................................................................................................37
APPENDIX...............................................................................................................................................40

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TABLE OF FIGURES
Figure 1: Showing the Gantt chart.................................................................................................10
Figure 2: Showing the first conceptual design of the e bike..........................................................11
Figure 3: Showing the second conceptual design of the project...................................................12
Figure 4: Showing the frame part of the e bike.............................................................................13
Figure 5: Showing the real and back wheels of the e-bike............................................................15
Figure 6: Showing the brushless motor installed in the wheel of the electric bike.......................16
Figure 7: Showing selected lithium battery used in the operation of the electric bike..................16
Figure 8: Showing the assembly of sprocket, hub and drive train of the electric bike..................18
Figure 9: Showing the brake of the e bike.....................................................................................19
Figure 10: Showing the handle of e bike.......................................................................................20
Figure 11: Showing Boundary conditions defined for the FEA simulation..................................21
Figure 12: Showing equivalent vonmess stress contour................................................................21
Figure 13: Showing a total deformation........................................................................................22
Figure 14: Showing Equivalent stress contours.............................................................................23
Figure 15: Showing Total deformation Contours..........................................................................23
Figure 16: Showing e bike helmet.................................................................................................26
Figure 17: Showing the e bike reflector jackets............................................................................26
Figure 18: Showing results for normalstress aluminium...............................................................31
Figure 19: Showing results for normalstress steel.........................................................................31
Figure 20: Showing results in normalstress titanium....................................................................32
Figure 21: Showing total deformation for aluminum....................................................................32
Figure 22: Showing total deformation for aluminum....................................................................33
Figure 23: Showing total deformation for titanium.......................................................................33
Figure 24: Showing boundary.......................................................................................................34
Figure 25: Showing final product after the design........................................................................34
LISTS OF TABLES
Table 1: Showing group members and their ID...............................................................................7
Table 2: Showing the work divided Into terms of researching........................................................7
Table 3: Showing the work divided In terms of CAD.....................................................................8
Table 4: Showing the work divided Into terms of analysis.............................................................8
Table 5: Overall work done by every member................................................................................8
Table 6: Showing the cost analysis of this electric bike................................................................24
Table 7: Showing Failure Mode & Effect Analysis......................................................................30

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INTRODUCTION
This project is mainly focusing on the designing of the electrical bike, this is very
important as it will enhance the quicker and safer movement of people within Australia as well
as other countries of the world. This report will give the design as well as the implementation of
the designed mathematical models. This is made possible with the use of the engineering
concepts that aid in realizing the aims effectively. With the higher population in most states in
Australia, public transport has always shown some traffics and this public transport uses fossils
fuels in their transportation and this really pollutes our environment.
The use of fossil motorcycles also pollutes our environment due to the combustion of
fossil fuels. It is hence very significant to have a way of transportation which will reduce the
traffics on the road and also reduce the pollution of our environment. This project gives the real
design of the e-bike which starts from the conceptual point design to the final design which will
be employed to give the real design that will be implemented to the actual e bike. During the
design of this e-bike there are some software which will be employed to make the design
perfectly without making some errors in the final design. Some of this software include the
DFD, CAD, DFX, and FMEA.
BACKGROUND
The use of electric bike is becoming common in most parts of Australia and the whole world.
These bike are always designed and constructed with the consideration of the strength, aesthetical
values, light weight as well as making the bike to be affordable for most people. Some of the pioneers
who came up with idea of bicycle include William Ayrton and John Perry around 1880s. The increasing

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number of e bike in the market is due to the advantages of its being environmentally friendly.
These bikes are today playing a big role in the transportation industry because they are relatively
cheap, they are easier to operate, and they also have low maintenance as well as the
convertibility. Therefore the convertibility of this type of bike offers the society the chance to
use e bike with higher satisfaction.
The popularity of this type of bike is chiefly due to the effects which it gives to the
operators like the cost benefits and the health importance. And because these bikes do not use
fossil fuels which are relatively expensive as compared to the use of electricity, the operation and
maintenance of the e bike become cheaper than the fossil automotive. Therefore for these
reasons and benefits of the e bike, this bike is hence very crucial in the transportation industry.
Electric bike makes transportation easier the fuel used here is relatively cheaper and more
environmental friendly. As opposed to the cycled bikes , the electric bike moves at a very higher
speed and also can operate in hilly without applying effort by the rider hence this makes it easier
and more comfortable to use.
AIMS AND OBJECTIVES
Aims of the project
The project aim of this project is to study and design the e bike using the solidWorks as well as
the use of the ANSYS workbench software.

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Objectives of the project
To ensure that the above aim is met it is hence very significant and advisable to meet the
following objective.
 To research on various types of e-bikes and their parts, and working principles.
 To identify the main and important parts of the e-bike and their respective dimensions.
 To identify the load, material properties and the boundary conditions.
 To create 3D models of the parts in SolidWorks and simplify them to import them into
the ANSYS workbench as analysis geometry.
 To carry out finite element analysis in ANSYS workbench by using static structural
analysis, and the decisions to be done are based on the results.
TEAM ACTIVITY
This project was conducted in a group of three where every member has his own part to
undertake. These are illustrated in the following table;
Member Roles
The activities conducted by the three members of this group 4
Table 1: Showing group members and their ID
NAME OF THE STUDENTS THE STUDENTS´ ID
SULTAN M ALAJMI 19607678
MOHAMMED ALSALEH 19642042

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MOUHAMAD GHUNEIM 19811680
The tables below illustrate the activities which were done by each group member;
Table 2: Showing the work divided Into terms of researching
Member Name Duty
1 Sultan Alajmi Search on E-bike concepts, companies,
novelties
2 Mohammed Alsaleh search on kind of motors, frames
3 Mouhamad Ghuneim Search on approximate cost of an E-bike,
transmission
Table 3: Showing the work divided in terms of CAD
Member Name Duty
1 Sultan Alajmi Frame, Wheels, chain pattern, roller bearing, rubber
handles, Stem, crank bearing
2 Mohammed Alsaleh Fork, Seat spot, motor, seat, wheels cover, battery
3 Mouhamad Ghuneim Handlebar, Brake disks, crank, Spoke, brakes, gears

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Table 4: Showing the work divided in terms of analysis
Member Name Duty
1 Mohammed Alsaleh Static structural analysis
Do analysis on a separate frame
2 Mouhamad Ghuneim Static structural analysis and some parts
separate
3 Sultan Alajmi Static structural analysis on the whole
body, and some parts separate
Table 5: Overall work done by every member
Member Name Duty
1 Sultan Search on E-bike concepts, companies,
novelties, introduction, background,
FMEA, aim and objectives, GANTT chart
2 Mohammed search on kind of motors, frames,
executive summary, performance criteria,
basic design decisions
3 Mouhamad guh Search on approximate cost of an E-bike,
transmission, design constraints

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GANTT CHART
The project design timeline is best illustrated through the use of Gantt chart, this is very
significant since it helps the group members to check the progress of the project and to ensure
that the project is completed within the anticipated timeline. The diagram below illustrates the
Gantt chart for the completion of the e bike project design and implementation. The given
timeline given include both conceptual design and the final design
E-bike project ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ## ##
Project Lead: Jul-19 [W31] Aug-19 [W32] Aug-19 [W33] Aug-19 [W34] Aug-19 [W35] Sep-19 [W36] Sep-19 [W37] Sep-19 [W38]
29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
WBS Task Name Start Finish Duration Percent
Complete M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S
1 Form our group Mon 29/Jul/19 Tue 30/Jul/19 2 100%
2 Divided the work among the group members Wed 31/Jul/19 Wed 31/Jul/19 1 100%
3 Research, and background of the e-bike Thu 01/Aug/19 Wed 14/Aug/19 10 100%
4 Literature review, of other e-bikes Sat 10/Aug/19 Thu 22/Aug/19 9 100%
5 Modelling the parts in SolidWorks Thu 08/Aug/19 Tue 10/Sep/19 24 100%
6 Doing the ANSYS workbench Sat 17/Aug/19 Wed 18/Sep/19 23 100%
7 Start writing the whole report Sun 11/Aug/19 Thu 26/Sep/19 34 95%
8 Start writing the discussion and analysis Mon 19/Aug/19 Mon 23/Sep/19 26 100%
9 Doing the manufactring drawings Mon 12/Aug/19 Thu 26/Sep/19 34 90%
10 Organizing the report, and revising it Mon 23/Sep/19 Sun 29/Sep/19 5 95%
Figure 1: Showing the Gantt chart

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CONCEPTUAL DESIGN
Regal requirement
As discussed above the use of e-bike to reduce the combustion of fossil have several positive
effects on our environment due to the reduction of pollution. Hence the use of the electric bike
law help in the reduction of the following issues in most country including Australia;
An electric bike needs to have a maximum power consumption of about 200kW without limit for
the bikes speed and the pedal sensors to operate effectively (Dill, 2012). The law hence helps in
promoting the use of more electric bikes to help reduce pollution. Some of the key legal aspect
of the electric bike to make them operate effectively include the following actions put forward by
the authority;
 There must be a rear reflector for the reader both during the day and night just to identify
themselves as riders and also for visibility at night.
 The e bike needs to have a maximum radius of illumination of the light of about 200
meters.
 The back and front installed flashing light of the electric bike need to operate effectively
at night when these bikes are on the road, where the red lights are preferred at the back of
the bike.
The design conception
The idea of the design was first put on paper from where the group member could then
fathom what is required and which parts need to be designed as well as simulated. The first
concept put on paper is illustrated in the diagram below;

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Figure 2: Showing the first conceptual design of the e bike
The conceptual design of the group is based on the literature review and some idea of the
companies. We investigated the E-bike also the normal bike, their comfort, and the way to
improve the quality and how to reduce production cost. So, we decided to choose bikes with
small tires as our main idea and we tried to add an electric motor to assist the bike (Yang, 2015).
In this project we decided to design an E-bike which electric motor assists the bike rider, there
are many cases which the E-bike is just working with an electric motor and the usage of the
pedals will be reduced to save effort (Chiang, 2011). The group also chose the simple frame
instead of a complicated frame exists today, because we wanted to have a lower cost of
production. The second conceptual design is illustrated in the following diagram.

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Figure 3: Showing the second conceptual design of the project
And some of the advantages of the frame are illustrated below;
 The frame length can change and it’s appropriate for many ages.
 Therefore, the frame can assemble to be smaller for transport on train or bus.
 The Fork height can be changed.
After having the first and the second conceptual drawing of the design, it is significant to
underline why and to who is this design subjected to. And as for this design, it was basically
done more for ladies as opposed to gents (Goodman, 2010). The electric bike also offers more
comfy experience during the travel having tubeless tires that are so much cosy having vibration
absorption when the suspensions are missing. With the design of the electric bike, the problem
of the rugged path is eliminated due to the presence of the tubeless as well as the special curved
design (Astegiano, 2015). The curved design will distribute the vibration and the stress on the

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bike. With the use of the geared motor, the step inclination is highly reduced automatically
through the use of the sensor. The final design will have slots where the rider will be able to put
on his or her baggage, there needs to be a slot for checking of the speed of the bike
(speedometer) (Zhang, 2015). And lastly, there needs to be a slot where the rider will have to
charge his or her phone during the journey.
Frame design
The frame part of this bike is very significant and it requires some a material which is strong and
light to enable the final design to have a light bike but generally strong (Shaw, 2013). The frame
was designed with the curvature denoted the ergonomic and also help in the distribution of the
vibration to the whole body of the bike (Haller, 2010). This is very important since when the
vibration is uniformly distributed in the whole body of the bike then the intensity of the vibration
will be generally reduced. This design is illustrated using the following diagram;
Figure 4: Showing the frame part of the e bike
The higher the strength of the frame of the e bike is very crucial as it helps in keeping the frame
durable for a relatively longer period of time (Papoutsi, 2014). The strength of the frame is very
significant since the load on the bike (including the weight of the rider) is applied directly to the

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frame of the bike. Therefore if the frame is strong enough the bike will be able to maintain the
weight the bike is subjected to. The type of aluminum used in this design is Aluminium grade
6000 material (Siman-Tov, 2017). This material is employed because this material has a
relatively higher strength to weight ratio. Since this part is structurally important then it hence
requires some simulation to ensure that the material used will maintain a specific weight when
applied to it. For this design, we settled on a weight of 2000 N which the e bike will be able to
maintain when applied on the seat and a load of 1000 N when the load is applied on the
handlebar. So with these Simulations is very significant as it will be seen in the final design of
this project.
Electronic bike Wheel (rear and bake)
The wheel design is a very significant concept since this part will allow the rider to have the
inbuilt suspension used in the design. The inbuilt suspension will contain the gas strut dampers
as opposed to having the inner wheel rim of the tyres. This design concept is so to help mimic
the vibration (uncomfortable) as well as the strains during the operation of this type of bike. For
the safety concerns in this design of the wheel ( spoke tyres) are basically in a raised position and
this will help in protecting the whole design of the bike with more care. The design of this part
of the bike is illustrated using the following diagram;

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Figure 5: Showing the real and back wheels of the e-bike (Langford, 2015).
Motor & Control
The motor used in this design is the one having a brushless gearless wheel hub motor, the power
rating of the motor used in this electric bike is 1000 W (1 kW). This motor has a maximum
rotation of 600 revolutions per minute (rpm). And the motor maximum speed is approximated to
be 40 km/h. This type of motor is illustrated in the following diagram where it is installed in the
wheel.

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Figure 6: Showing the brushless motor installed in the wheel of the electric bike (Langford,
2015).
Battery
The battery is very important in this design since it acts as the "fuel" of this bike. It is the battery
which will be used in powering the selected motor and make the motor to rotate and then rotate
the wheels which make the whole system to move (Wu, 2012). Some of the advantages of the
lithium battery which made us settle on its use in this design are given below;
 This type of battery has a higher energy density (this shows that it has higher potential
capabilities)
 The electric bike has a relatively low self-discharge as compared to other types of
batteries like the nickel battery. This is very significant as it will make the battery to work
effectively.
 This type of battery does not require any type of priming either when it is new or old.
 Lithium battery has speciality cells that are able to provide a very higher current which
can make it work effectively in the electric bike.
The diagram below illustrates the lithium battery used in the electric bike

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Figure 7: Showing selected lithium battery used in the operation of the electric bike (Langford,
2015).
This battery has the following specifications;
 Power = 1000 W
 Voltage = 48 V
 Capacity = 10 Ah
 Weight = 2 kg
 Charge time (4-6) hr
Therefore with the above specification of the battery the distance this bike will take before the
battery is fully used up can be obtained from the following calculation;
Current drawn from the motor is given by equation 1 below
I = Power
Voltage …………………………………………………………....................... 1
I = 1000
48 = 20.833 A
And since the capacitor of the battery is given as 10Ah, then electric life span can be obtained by
the following equation;
Electric life span = Capacity
Current ……………………………………………………………...... 2
Electric life span = 10
20.833 = 0.48 hours
The linear speed is given as 40 km/h

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Therefore the maximum distance it will take this electric to travel before the battery is fully
drained can be calculated using the following equation;
Max distance = speed × life span ………………………………………………………………. 3
Max distance = 40 × 0.48 = 19.2 km
Therefore this designed electric bike will travel a distance of 19.2 km before the battery is
recharged again.
Drive Train and the Hub
These two parts are very significant in ensuring that the motion is transferred to the wheel which
will hence make the e bike to move as required. For the drive train, no changes are needed for
the sprocket and the chain drive system because several bikes have the best performing drive
chain. So these drive trains will just be picked and used in this design (Yao, 2012). Therefore
the change which can be done in this is just to attach the sprocket coincident to the motor shaft
then connect the chain in the sprocket to help in maintaining the old system. This can be
illustrated in the following diagram;

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Figure 8: Showing the assembly of sprocket, hub and drive train of the electric bike (Langford,
2015).
Brakes
This is a very significant part of the design as it allows the electric bike to stop the motion when
there is a need by the rider. In our design, there are 2 braking system where the rime brake
system has brake callipers and the disk system and situated in the rear wheel of the bike
(Langford, 2015). These brakes have to be bought and fixed into the system under the
instructions given in the sheet. In our design, a stainless steel disk having about 190 mm in
diameter was employed in the design (Spagnol, 2012). The higher the diameter the better for the
electric bike especially in case of dissipation of heat in the system. The diagram below
illustrates the brake of the electric bike;

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Figure 9: Showing the brake of the e bike (Yang, 2010).
Handle
This part is very significant in our design since at this part our hands will rest as we control the
operation of the electric bike. The braking system is also controlled from this point (Ji, 2014).
This part is also required to be strong enough just like the frame of this bike because there are
force applied to it when the rider is on the motion. It is illustrated in the figure below;

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Figure 10: Showing the handle of e bike (Yang, 2010).
FINAL DESIGN
In the final design of this bike, some simulations were conducted to ensure that the
proposed electric bike operates perfectly as required in the conceptual design (Yang, 2010). As
discussed above the frame of the e bike is very significant in balancing the weight of the bike
since it is the structure of the bike which needs to be very strong to help withstand the weight
applied to the bike (Du, 2013). Therefore the FEA simulation is conducted in the frame of the
bike. After the simulation of this part of the bike the below is the screenshot from the simulation;
Figure 11: Showing Boundary conditions defined for the FEA simulation
When the contours of the equivalent stress generated for an applied load then the stress will be
concentrated on the lower back of the frame as illustrated in the figure below;

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Figure 12: Showing equivalent vonmess stress contour
But when contour of the total deformation is experienced, a maximum deformation is
experienced at the handle of the bike and the seat and this will then be distributed over the frame
of the e bike;
Figure 13: Showing a total deformation

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The above three simulations are Static Structural Analysis Using Aluminum, these simulation
analyses can as well be done using titanium and then the results are compared against the
simulation done using the aluminum.
Figure 14: Showing Equivalent stress contours
Figure 15: Showing Total deformation Contours
From the simulations of the above two analysis, it can be seen that the deformation higher in the
titanium as compared to the deformation of the aluminum. This is because aluminum is lighter

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and it is relatively stronger as compared to titanium (Cherry, 2016). The aluminum is the best
selection due to low deformation seen after simulation.
IMPORTANT SELECTIONS
Under this section, some analysis like the cost analysis of the electric bike is discussed. The cost
analysis will make it easier to scrutinize if this design is actually good and cost-effective which
can make it possible to be used in the market. These analyses are illustrated below;
Table 6: Showing the cost analysis of this electric bike

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Safety Requirement for electric bike
The safety concern for the operation of this e bike is very crucial and it requires a keen analysis
to make the operator safe during the ride. Some of these safety concerns include the use of a
helmet. The electric bike helmet is very crucial since it helps the riders to protect their heads
during the ride in case the rider gets an accident. The diagram below illustrates the electric bike;
Figure 16: Showing e bike helmet (Cherry, 2016).
Another safety requirement for the e bike is the reflector jacket which helps other road users to
see the e bike rider, especially at night. The reflector is illustrated in the diagram below;

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Figure 17: Showing the e bike reflector jackets (Cherry, 2016).
The brake of the e bike needs to be checked every time to ensure that the rider has control of the
bike every time he or she wants to stop the e bike. The frame and the wheel alignment need to be
checked regularly to help avoid some unnecessary accidents. The level of the battery needs to be
checked to help the rider know how long the bike can operate.
Component selection of this design.
Some of the component selected for this design includes the following;
Wheels
The rim and the hub design of this project will be used for this electric bike this is because of
these areas arecapable to withstand stresses and shocks during the ride (Johnson, 2015). For this
design rubber wheels of tyres having tubeless which will help in absorbing vibration.
Brakes
For the raking system of the design have two e bike braking system was selected to be used in
this bike. These systems include the disk brake system which is put at the rear wheel and the Rim
braking system having the brake callipers. A stainless steel disk having roughly 200mm
diameter is selected for the design.

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ANSYS ANALYSIS
Ansys Structural Analysis is a software which enables an engineer to solve complex structural
analysis, for example, the strength of the frame of the e bike (Stolarski, 2018). This software
promotes a faster design, decision (Barbero, 2013). This software has a Finite element analysis
which can be customized and then automate the solution for the analysis of the structural design
of the e bike. Through the use of the ANSYS one can easily connect other analysis tools like
DFA, DFE, FMEA, and DFD among others to help give a higher fidelity of the simulation.
Some of these simulations are briefly discussed below;
Design for Assembly (DFA)
The main concept when designing and developing products is to ensure that they are cost-
efficient, require less maintenance with minimum time. We designed our E-bike based on the
market and almost all the part of the bike can be found on the market, and they have a catalogue
and install guide to use. So, assembling the bike will not be that so hard. All other parts including
seat, pedal, front fork, handlebar etc. Are standard and installation of this part doesn't take too
much time. In case of any changes, the guide sheet will be prepared.
Design for Environment (DFE)
The considerations regarding Design for Environment and Design for Safety have become an
important design factor in recent years. Nowadays, safety is very important for our environment
and many parameters should consider in our design to prevent the pollution of the environment
and global warming. The motor we used is brushless, which powered by Li-ion battery. So,
neither of motor and battery won't produce carbon to pollute the environment and they are harm-
free. Also, the frame of the bike is made of Aluminum which can be recycled later. Moreover,
Design for Durability or Sustainability is the next most important consideration that was

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incorporated in our design (Yingkui, 2011). The bike should be durable and have a long life
otherwise it makes customers unhappy and become a treat in a sudden accident to the user and
the environment. To increase the bike endurance, we introduced Aluminum for our frame which
is light and have high strength. In addition, some parts in our e-bike are easy to disassemble and
change it from the market such as the pedals, the rubber handles, the seat, the battery.
Design for Disassembly (DFD)
DFD means that a product, once assembled and in use, must be easy to uninstall and disassemble
in case of maintenance or failure of an individual part of the assembly. This bike is not designed
in a complicated way assuring easy assembly and disassembly in case of maintenance and
recycling after use. As a result of easy assembly, it is also very easy to disassemble the parts
when maintenance or repair is needed. For example, the seat is very easy to disassemble and that
can be done in few seconds, also the motor it is not in a very compact position it is easy to be
seen and reach for maintenance.
Failure Mode and Effect Analysis (FMEA)
Failure mode and effects analysis is the process of reviewing as many components, assemblies,
and subsystems as possible to identify potential failure modes in a system and their causes and
effects. The potential failure of our system will be and the whole table of the FMEA of the frame
as illustrated in the following simulation results (Dahmani, 2010). The FMEA for some parts of
the e bike is illustrated in the table below;

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Table 7: Showing Failure Mode & Effect Analysis
Simulation Results
After the simulation of the frame part of the e bike for a different type of material (metals) the
below are the result obtained;

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Figure 18: Showing results for normalstress aluminium
Figure 19: Showing results for normalstress steel

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Figure 20: Showing results in normalstress titanium
Figure 21: Showing total deformation for aluminum

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Figure 22: Showing total deformation for aluminum
Figure 23: Showing total deformation for titanium

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Figure 24: Showing boundary
Final Product
After the design and construction the below is the final e bike which is ready for use;
Figure 25: Showing final product after the design

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RECOMMENDATIONS
After the design and construction we as the group members recommended the following to
improve on the design and operation of this e bike;
 There need to be a crash and shock test for the final product
 Load testing prototype is also needed
 During the design of the frame of the bike, there need to be a load testing
 There is a need to have a rack on the frame where the rider can put his water bottle during
his journey.
CONCLUSION
The main aim of this project was to design an environmentally friendly electric bike which uses
electricity as its "fuel" for its operation. And actually, after the design and construction, the aim
has been achieved. During this design, several engineering analysis software was used to ensure
that this design is a success as one go. Simulating the design before building the actual bike has
some advantages like reducing errors which can lead to more time consumption during the
construction. The simulation also helps in reducing the costs of the construction as the
construction is made once since there is no error after the final simulation. From the analysis, it
was found that the use of aluminum was the best in making the structural part of this electric
bike. The designed bike also will be retailed at a reasonable price hence most citizens will be
able to afford one. There are some safety clothes which will be worn by the rider, and as seen
above this bike was made using a strong and durable material. Our design hence satisfies all the
requirement for both quality and the safety of the rider.

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APPENDIX

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