碳纤维的自行车零件是怎样炼成的 [复制链接]

Seat/seatpost combination for less weight:


As you can see, making mold MAY be simlpe. The green plastigue is 400%
strectsing valcuum bag plastique.



Pressure RULES! Don't ve think ANY composites W/O pressure! It can be air
pressure, weight=gravity...here it's made by foad and tape. No pressure= no
strenght. REMEMBER this! Mold on way...


How it comes, lazy as I'm, I will laminate against green vacuum plastigue so
no need to wax. Epoxy will not hold in plastique. Black "cross" is UD-CF for
stiffness. (Uni-Directinoall Carbon Fible, it rules...!) Most of mold is
twill glass fibre....80g/m2 on molding layer X2, like 200-300g least 2X layers
for streght....



There is 193g/m2 Cf on bottom, twinn layer nose on seaddle, some kevlaf
on midle,then Y-shaped 6mm debron on as core (white). 320g/m2 UD 30mm on top of
that +240g/m2 CF twill on top, top is bottom in rear life. Saddle is made upside
down....I always talk twill or UD. Twill looks commencical but UD is lot of
better for pulling forces.
Debron is good for insulatin floors and and making RC park flyers
(3 and 6 mm, white or gray) but it will compress fo for foad cores, it's not
ideal. There are better choices but Debron is easy to find and it twists
easilly to curvy shapes.



Here is how it should look.



Weight before some braising lamination. Post is glued, NOT lamionated yet.
Soon to come...like 20g more.

Supporting done. Some 10mm foam core, Ud tape and 193g/m2 twill. Nice?

122g final weight when almoust ready! Little sanding still to do.

Saddle is made for uphill races (llike Etappe De Siuro... :O) ), it's
very hard but again. it's a PROTOTYPE!
UPDATE! Saddle didn't feel so bad as I would expect. Since I'm used to ride
240欧元 82g Ax-Lightness Pallas (max 85kg, and I'm 80-88kg....) I didn't notice
anything new. I WILL do mtb version sooner you puch reload button...! But
I will think first a bit. That first one was totally brain death design, not any
desing really, jus did to see how everything works together.
Update @ 19.09.2007
I did new version as I learned first one. This is dene from leftover parts
but it's quite light anyway. 27.2X255mm tube and it's made for me, ~86-88kg.



CF-tubes:



Here are CF-tubes made for Vision TT-bar. 430mm!!! long ones, weighting 140g/pair. Made from in->out 240g/m2 twill+320g UD tape= 3X 30mm+twill sock for
nice outer layer. It feels that I could use it for mtb-bar before I cut it to 2
pieces as in picture...stiff enought, UD rules again. They where made inside of
plastiq pipe around of road bike's inner tube...

Super light seat post:



Here is seat post coming, no finnishing done yet. Like Thomson post but this
one will not let water in trought of clamp area. Sealled design. 69g as in pix.
Uses M6 alloy (2X =4g) or M5 titanium bolts. Target weight for seat
post is l~ 90g @
270mm. Tube is taperwall and ovalised from inside. Anticorrosion design for
alloy frames. Upper Clamp are alloy like my ti-post (143g@ 27.2X350g) but I
working CF ones and new design tomorrow...



Here is suggested clamp design drawing. Mold is done and prototype of
CF-clamp will be laminated soon. To be one full lenght upper clamp or two
piece units is still open. One piece holds better and 2-piece ones are more
difficult to adjus t/ assemble. W''ll see...

Well, now we see! 88g as pictured. M6 alloy bolts since my M5 ti bolts
where too short.



Upper clamp will have more cf in next one. I think it bit too thin walled for
me. One piece molded. Lower clam will be shaped better and rounder. That cuts
weight a bit... I would be very happy to 100g seatpost and it's easy to do. But
Why to use 100g post when you can use 120-130g seat/post combo...that's for me!
But why not frame+seatpost+seat combo...THAT'S for me! Just have to make
some bigger tubes...



New simpler clamps will be done soon. This is not desent solution...


TT-Brake levers:


Just from mold. Not sanded / clear coated yet. Made with rubber mold. They
will be nice! Weight savings like 10g/pair to orginal Profile Design Quig stop 2
lever cams. UD inside of twill sock for strenght and avoiding fiber separation.
UD runs along cam lines and twill is there to keep them together. Feels rigid as
made from steel.



Some sanding done. Good enought for prototyping.

TT-bar:


Soon I get few CF seat post ready/or in same time I will do one more TT-bar
prototype...integraded sifters and brake levers for safety and solidy.
Sifter mounting is for Shimano 7-10 speed in drawing.



CF base bar for TT-bar project. This is hardest piece to make right. Mainly
from geometrical reasons, not technological. Heavyest also. Rest of parts
will weight not much. Middle there is alloy piece for good clamping area for
stem. It's laminated with anticorrosion layer (glass fibre,80g/m2) then UD in
suggested force directions and twill sock. Next threre will be brake handles and
then aero extensions. After all of then are laminated ,there will be lot of
layers of CF. Just look that fibre edge's are not in same place. Then bar will
be sand and nice top layer is addet. Just keep mind that you always need to
remove epoxy from laminate...so keep suck fabric, removing plastique and

roughening fabric near when doing multilever
structures. Wing is 58X12mm to way air flows throught it. It will "grow" a
little when all layers are done, like ~1mm.
From based to cf tubes that I have done before, whole bar would weight
like 200g more, that's like under 400g for total bar. CF elbow cups weight only
like 15g/pair. But looking more desend weight and solidy I will add
integradet brake levers so with them bar would be
easilly under 500g. To comparison moust alloy TT-bars are closer to 1000g+
b-evers add near 200g. And they are weaker due to multielement strutures.
So I looking 700g weight savings!



Extension made roughly. 350mm long one. Containing mounting place for D-A
sifter. Std. D-A sifter mounts weight like 80g/pair ALONE! So here they came
almoust adding no weight. Wing,extensions and brake handles weight together now
little under 300g. Some lamination more to do but under 400g is piece of cake
WITH brake levers. Just add Syntace F99 stem...Saves like 900g for Vision alloy
TT-bar+levers+sifter mounts!!!

If I would again TT-bar with stem, It would cut like 120g from system
weight...like 450g with stem. My first cf TT-bar was like that in
contruction. But now I have learned MANY tricks how to do it better or least
lighter. It was very rigid...

Cyclocross frame:

This will be test how to join tubes and how to do rear triangle easy.
It will have integrated:
- saddle
-suspension seat post
-bottom bracket


Lower is 41mm diameter and 810mm long CF tube from my kitchen. It weights
250g. It has 42% epoxy from weight, offcource. Upper is TT-bar extension, just
for size comparison.

Competition slalom stick:

This is only sample made from order. 190mm long and 8g. Multilayer Kevlar
structure and UD CF. Interesting hollow core structure...made for hard core
slalom competitor so I not really allowed to tell how it's done IF they work.
:O) They are very thin as you see. It may be bit broblem as lack of stiffnes but
done as ordered anyway...sample feels rigid but it's so short. He orginally
asked from finnish CF company to do develope these for him but they asked ~2500欧元
from them. Pit expensive pair of ski sticks. He was happy that I would try to do
these BIT cheaper. If they work, I may sell some. Differense in them is
Kevlar protection and curvy design.

Slalom ski nose protector:



In picture there is first prototype. Inner lined nees some mold too as you
see. Made from Twill sock and kevlar inside.
W'll see how they hold...
I'm also developing some Kevlar/CF parts for his K2 racing skies.

谁抽空翻译一下？

都是包的啊