Light weight motorcycle handle bar and manufacturing process thereof

Abstract

Present invention discloses a lightweight Handle bar assembly, achieving a weight reduction of up to 13-14% through the integration of curved profiling on the outer surface via drawn tube / bar processes. The Handle bar assembly consists arms (1) on both sides and a base mounting area (2). The introduction of corrugated / curved profiling over the surface of Handle bar creates a crest-and-trough like structure i.e., curving along the side wall and edge of the Handle bar, the outward crest is present at 20 locations, each with a radius of 1 mm, while the inward trough appears at 10 locations, with a radius of 2 mm, such profiling reduced the peripheral wall thickness from 2mm to 1.6mm, extending throughout the length of Handle bar.

Description

[0001] LIGHT WEIGHT MOTORCYCLE HANDLE BAR AND MANUFACTURING PROCESS THEREOF

[0002] FIELD OF INVENTION

[0003] The invention generally relates to the field of Mechanical and Automobile Engineering. More specifically, it pertains to a light weight motorcycle handle and manufacturing process thereof.

[0004] BACKGROUND OF THE INVENTION

[0005] The following background includes information which is important for the better understanding of the present invention.

[0006] Motorcycle handle bars- Motorcycle Handle bars are tubular components of motorcycle's steering control mechanisms mounted on the front fork of motorcycle that allow the rider to steer and maneuver the bike and also provides a grip for the rider's hands. Handle bars can vary in shape, height, and width, affecting the rider's comfort and control. They often include controls for the throttle, brakes, and other functions, making them essential for safe and effective riding.

[0007] Problems in commercial heavyweight motorcycle handles

[0008] The commercially existing Handle bars manufactured by various companies are quite heavier in their weight, which affects the overall performance of bike, making the bikes heavier in weight, thus provide problems to the rider as well and further, heavier handle bars bike feel less nimble and affect acceleration. The extra weight of the Handle bars may affect the front suspension and forks of the motorcycle and this additional stress can lead to premature wear on the suspension components, leading to a less comfortable ride and potential maintenance issues. Further, heavyweight Handle bars require more expensive and robust components for mounting and securing, which increases the cost and complexity of customization, making it more difficult to install lighter or more specialized Handle bars. The extra weight increases inertia, making the motorcycle harder to maneuver, particularly at low speeds leading to delayed response times when navigating tight corners or during sudden direction changes, reducing overall handling performance. Heavier Handle bars may lead to increased vibration being transmitted to the rider's hands and arms, especially at high speeds or on rough terrain, which can cause discomfort or even numbness in the hands over long rides, commonly known as "Handle bar buzz" or hand fatigue. Further, the rider may need to exert more force to control heavier Handle bars, especially during longer rides. Heavier Handle bars contribute to the overall weight of the motorcycle, which can slightly reduce fuel efficiency. In summary, while heavyweight Handle bars might offer durability, they can negatively affect the comfort, control, and performance of the motorcycle. Riders often opt for lightweight materials like aluminum or carbon fiber to mitigate these issues while still maintaining strength.

[0009] Thus in view of aforementioned drawbacks associated with heavy weight Handle bars, there was an immense need for manufacturing of lighter weight, cost effective and more efficient Handle bars as lighter Handle bars have the high capability of absorbing vibrations, thus lowers the hand and muscle fatigue and also improves the ease of the performance of the motorbike and ease of driving.

[0010] Currently, variety of approaches for manufacturing light weight Handle bars are disclosed by various researchers such as using light weight alloys of light weight material including aluminum to reduce overall weight of the Handle bar, however use of aluminum is associated with several drawbacks as aluminum is not capable of absorbing vibrations and shocks, which affect both the bicycle as well as the rider and also the same corrodes over the time easily, thus use of aluminum based Handle bars is quite limited. Further, the conventionally existing techniques used for Handle bars manufacturing are quite complex, involving utilization of massive amount of raw material and also leads to wastage of a large amount of raw material during manufacturing process.

[0011] Thus, an immense need was there to manufacture light weight handle bars using simple techniques and modifying the technique specifically, to reduce the wastage of the raw material and to reduce the overall weight of the handle bar, without affecting its strength and effectiveness. Further, anti-corrosive, vibrations and shock absorbing material must be selected for manufacturing of the said Handle bar to preserve the actual properties of a Handle bar while reducing the weight of the same.

[0012] Innovative approach by Present invention In order to overcome the drawbacks associated with aforementioned commercially available heavy weight Handle bars, the inventors in present invention introduces a lightweight handle bar assembly, which helps in improving handling, reducing rider fatigue, and minimizing the negative effects of heavy Handle bars without compromising strength or effectiveness. The weight reduction is achieved by introducing curved profiling / corrugation over the outer surface of the handle assembly through bar / tube drawing process. The corrugation is created through drawn process using a die with different / modified profiles and radius, which helps in shaping the drawn tube / bar to desired structure, radius and profile. Further, one of the significant advantage of this method is that it reduces waste. Instead of removing material (which generates scrap), the length of the tube is extended during the profiling process. The longer tube can then be cut and bent to form the Handle bar.

[0013] Present invention is not anticipated by prior art patents and non-patents literature, however related prior art is as below:

[0014] Prior art patents

[0015] Patent Application No. US2009 / 0199089A1 discloses "Handle bars for cycles and motorcycles"

[0016] The aforementioned patent application discloses a light alloy tube of aluminum, at the end of which, a twist grip for motorcycle accelerator can be set and the said end is externally covered by layer of sliding material selected from steel, stainless steel, titanium alloy, composite material etc. Further, the layer of Sliding material comprises a tubular fixed sleeve fitted on said end of the tube. The light alloy tube further comprises a fitting Seat on which fixed sleeve is fitted, and an axial shoulder against which tubular fixed sleeve rests when fitted on end of the light alloy tube. The weight of handle bar in cited patent is reduced by altering the diameter and thickness of bent tube by tapering the same.

[0017] The above cited patent fails to disclose corrugation of Handle bar's tube surface to reduce the weight, thus the same differs from present invention.

[0018] Patent Application No. CN205769892U discloses "A Kind of motorcycle handle and motorcycle" The above cited patent discloses a motorcycle handle, consisting of handle body, handle connecting pipe and handle sleeve. The handle body comprises an inner layer made up of carbon fiber and outer layer made up of aluminum alloy. The handle body is tubular with hollow material.

[0019] The Handle bar with corrugated profile over the surface as disclosed in present invention is not anywhere disclosed in aforementioned patent.

[0020] Patent Application No. US2010 / 0186542A1 discloses "Handle bars and method for producing same"

[0021] The above cited patent discloses a Handle bar made using hollow metal pipe of aluminum alloy comprising longitudinal centre portion and opposite 1st and 2nd end and intermediate portions extending outwardly from 1st and 2nd ends. The outer diameter of each end is smaller than longitudinal centre portion. Both intermediate and end portions have same peripheral wall thickness and both are symmetrical to each other wrt longitudinal centre portion. The method of producing Handle bar comprises the steps of using hollow pipe with longitudinal centre and 1st and 2nd end and intermediate portions as raw material, bending intermediate and end potions wrt longitudinal centre position using bending machine, placing the bent pipe in upper (movable) mould and lower (stationery) mould of the moulding machine. After, the bent pipe is placed in shaping recess of stationary mould, the movable mold is moved into mating contact with stationary mould to provide a defined shape to the final product and finally feeding a pressurized liquid into the bent pipe while axially compressing the bent pipe to plastically deform the peripheral wall of the bent pipe into conformity with the mold cavity.

[0022] The Handle bar with corrugated profile over the surface as disclosed in present invention is not anywhere disclosed in aforementioned patent. Further, the method as discussed in cited patent, is also not disclosed in present invention. Thus both inventions are quite different from each other.

[0023] Patent Application no. US4023436 discloses "Articulated Handle bars for bicycles and the like"

[0024] The above cited patent discloses an articulated Handle bar for bicycle, motorcycles etc consisting of conventional support for Handle bar further comprising elongated, substantially horizontal attaching means for removable and adjustably fixing attaching means to support, supporting mean disposed at an angle wrt attaching means, and pair of handle shaft associated with supporting means.

[0025] Such profiling as created in present invention is not disclosed in cited patent, hence the same differs from the present invention.

[0026] Aldo Salim, Sandy Yehezkiel, Bready Fernando, Tasya Monica, Joshua Ricardo, Agustinus Purna Irawan; Concept design for adjustable motorcycle Handle bar; Materials Science and Engineering 852 (2020) 012034

[0027] The above cited research article discloses a light weight handle bar for motorcycle manufactured using aluminum alloy 7075 as a raw material. The design Handle bar has length of 72cm and diameter of 2.5 cm and same is lighter in weight, as it is manufactured using aluminum.

[0028] Corrugation profiling over the surface of the Handle bar as created in present invention is not anywhere mentioned in the above cited article, making both the inventions different from each other.

[0029] Tushar Rajendra Chavan, Rahul B Barjibhe; Design, Analysis & Fabrication of Handle bar of Motorcycle by Changing Material; International journal of engineering and research; 2018; Volume 6, Issue 1

[0030] The aforementioned research article discloses replacing the traditional material i.e., steel with aluminum and glass fiber for preparation of Handle bars with reduced weight and without compromising the strength of the same. When aluminum was used for manufacturing handle bars, then, the young modulus was 68.9 GPa, Poisson's ratio 0.33, density 2700Kg / m3, yield stress of 214 MPa and ultimate tensile strength of 241MPa was achieved and when glass fiber was used for manufacturing Handle bars, then young modulus 40GPa, poison's ratio 0.3, density 2000Kg / m3, yield strength 1850MPa and ultimate tensile strength of 2000Mpa was achieved.

[0031] In present invention, a curved profile over the surface of Handle bar was created to reduce the weight of the same, however, such curved profiling is nowhere disclosed in cited article, making it different from present invention. Mr. Chandrakant S. Khemkar and Prof. Ganesh A. Kadam; Structural Analysis and Design Optimization for Handle Bar Assembly of Motor-Cycle; International Journal for Scientific Research & Development ! Vol. 3, Issue 09, 2015

[0032] The above cited research article discloses a handle bar consisting of handle bar pipe made using CRCA / stainless steel rolled pipe, Casing / housing for the pipe or base made using aluminum die casting / M.S. block machined to size and base for the housing made using M.S plate / sheet screwed or welded over the frame. Further, in cited article, the design of the handle bar is optimized by weight reduction.

[0033] The above cited research article fails to disclose creation of corrugated profile over the surface of handle bar, to reduce the weight of the same. Thus, both the inventions differs from each other.

[0034] Inui H, Sakurai T, Sato E, Minoda T, Nakai Y.; Development of motorcycle Handle bar in tapered shape with low cost; Trans. Soc. Automot. Eng. Jpn. 2018; 49(5): 1050-1055

[0035] Ref: https: / / www.safetylit.org / citations / index.php?fuseaction=citations.viewdetails&citationlds[]=ci tjournalarticle_743854_38

[0036] The aforementioned research article discloses a tapered Handle bar using high strength aluminum alloy for effective weight reduction and high texture appearance. Further, stress corrosion cracking resistance was secured by optimizing manufacturing conditions and as a result weight was reduced by 20% and cost was reduced by 30%

[0037] Above cited article disclosing tapering of Handle bar, whereas the present invention discloses creation of corrugated profile over the surface of the Handle bar. Thus, both the inventions differs from each other.

[0038] Traverse 7 / 8" Handle bars cold-forged cross bar off-road motorcycle Handle bars tubes with foam pad and rubber grips for motorcycles Ref: https: / / www.amazon.ca / TRAVERSE-Handle bars-Cold-Forged-Motorcycle-

[0039] M otoc ross / d p / B091 N 96T1 L

[0040] The cited commercial product is a traverse motorcycle handle bar made using aluminum by cold forging process, whereby the same has 20% enhanced tensile strength and 16% weight reduction. The disclosed handle bar comprises a solid support bar and integral foam bar pad.

[0041] Corrugated profile over handle bar as disclosed in P.l is not mentioned in cited patent.

[0042] Carbon Handle bars-Forged Pattern

[0043] Ref:https: / / www.goworks.com.tw / product_d.php?lang=en&tb=l&cid=148&id=1564

[0044] The aforementioned commercial product discloses a carbon fiber handle bar bent inward by 17 degrees. The inner diameter of the handle on the two sides is specially processed to a depth of 17mm*30mm L to facilitate installation and modification of balance terminal.

[0045] The corrugated profile as disclosed in present invention is not there in cited commercial product.

[0046] Tapered Handle bar Fat Bar Low Type

[0047] Ref: https: / / www.webike.in / products / 24009361.html

[0048] The above cited commercial product discloses a light weight Handle bar made using aluminum alloy ALLOY6061 having width 800mm, height 80mm, pull 60mm, grip 100mm, clamp diameter 28.6mm and grip diameter 22.2mm.

[0049] The grip from the ends comprises a specific profiling, however curved profiling over the surface as disclosed in present invention is not mentioned anywhere in the cited commercial product.

[0050] OBJECT OF THE PRESENT INVENTION

[0051] The main object of the present invention is to disclose a light weight motorcycle Handle bar and manufacturing process thereof.

[0052] Another object of the present invention is to reduce the overall weight of motorcycle Handle bar assemblies without compromising strength and durability of the same. One more object of the present invention is to introduce curved profiling over the surface of the Handle bar which reduces the overall weight of the handle bar by altering the dimensions of the peripheral wall thickness of the Handle bar / tube.

[0053] SUMMARY OF THE INVENTION

[0054] The present invention discloses a lightweight Handle bar assembly, achieving a weight reduction through the innovative integration of curved profiling on the outer surface via drawn bar / tube processes.

[0055] As per the exemplary embodiment of the present invention, the handle bar assembly consists arms (1) on both sides and a base mounting area (2) having length of 702mm, height of 172.8mm, outer diameter 22.2mm and inner diameter of 19mm, 58o angle between arm (1) and base (2) on both sides and 19o bending angle. The introduction of corrugated / curved profiling of the surface of the Handle bar creates a crest-and-trough like structure i.e., curving along the side wall and edge of the Handle bar, the outward crest is present at 20 locations, each with a radius of 1 mm, while the inward trough appears at 10 locations, with a radius of 2 mm, such profiling reduced the peripheral wall thickness from 2mm to 1.6mm, which extends throughout the length of Handle bar. This novel approach not only reduces the peripheral wall thickness of the Handle bar from 2 mm to 1.6 mm but also minimizes waste generation by repurposing excess material to extend the tube's length. The corrugated profiling introduces a crest-and-trough structure, contributing to the overall lightweight design without compromising stability or effectiveness.

[0056] The handlebar assembly disclosed in the present invention is not restricted to the dimensions specified in the foregoing example. The motorcycle handlebar assembly can be configured in various dimensions depending on the size or type of motorcycle and specific application requirements. The disclosed profile is applicable to both tubular and solid (bar-type) handlebars, whether hollow or solid in construction. Based on the profile concept, the dimensions may vary such as depth, length, or diameter to achieve different levels of weight reduction or to meet design and performance needs.

[0057] DESCRIPTION OF FIGURES- Prior art figures

[0058] Figure 1 Corrugated Handle bar assembly of present invention (all dimensions in mm)

[0059] Figure 2 Enlarged cross sectional view of the corrugated Handle bar tube (all dimensions in mm)

[0060] Figure 3 (a) and (b) Side views of cross sectional end portion of corrugated Handle bar tube

[0061] Figure 4 Front view of cross sectional end portion of corrugated Handle bar tube

[0062] Figure 5 Other views of corrugated handle bar

[0063] DETAILED DESCRIPTION OF THE INVENTION

[0064] The present invention discloses a light weight Handle bar assembly, whereby the weight of the same is reduced up to variable percentage depending upon the length of the handle bar, preferably 13-14 % by introducing a curved profiling over the outer surface of the Handle bar through cold drawing and drawn bar process.

[0065] The curved profiling on the surface of the Handle bar is introduced by shaping the drawn bar using dies with specific radii and profiles during the cold drawing process. A drawn bar is first prepared by passing a metal bar through a series of dies with different radii and profiles, ensuring that the raw material is precisely sized and shaped before cold drawing.

[0066] One of the significant advantages of this method is that it minimizes material waste. Instead of removing material (as in conventional machining), the length of the tube is extended during the profiling process, which can then be cut and bent to form the handlebar.

[0067] The use of cold drawing with drawn bars also enhances material efficiency as cold drawing improves mechanical properties, including strength and hardness, without sacrificing performance, drawn bars ensure consistent diameter and surface finish, reducing defects and further improving material quality. By combining drawn bars with cold drawing, the handlebar is lightweight yet robust, achieving optimal material utilization, cost savings, and reduced environmental impact, while maintaining high-quality standards.

[0068] Preferred embodiment of the present invention- The light weight Handle bar assembly by way of preferred embodiment is now disclosed in detail with reference to the accompanying drawings.

[0069] Constructional features of present invention-

[0070] The handle bar assembly as disclosed in figure 1 consists of arms (1) on both the sides and a base mounting area (2).

[0071] The handle bar assembly of the present invention is technically modified by introducing corrugation / curved profiling over the surface of the handle bar assembly by cold drawing process in order to reduce weight and several other characteristics such as strength, durability and stability of the same.

[0072] This corrugated structure is achieved by cold forging drawing process, which modifies the outer surface into a crest-and-trough formation extending along the entire length of the handle bar, the profiling imparts enhanced mechanical properties without material wastage.

[0073] The cross-sectional view of the handle bar's end portion illustrates that the corrugation occurs along the side walls and edges, forming multiple outward crests and inward troughs.

[0074] Exemplary embodiment / Example 1:

[0075] Referring to figure 1 and 2 i.e., Corrugated handle bar assembly and Enlarged cross sectional view of the corrugated Handle bar end portion, the present invention is disclosed in detail with explicit dimensional specifications.

[0076] The Handle bar of example 1 consists of a pair of arms (1) extendingfrom a central base mounting area (2). The same consists the following specifications:

[0077] Length of the Handle bar is 702mm;

[0078] Height of the Handle bar 172.8 mm;

[0079] Angle between the base (2) and the arm (1) is 58o on both the sides;

[0080] The angle at which the Handle bar bends is 19° on both sides, likely indicating the degree of sweep or bend from the central section to the handgrips Referring to figure 2 i.e., Enlarged cross sectional view of the corrugated Handle bar end portion

[0081] Figure 2 of the present invention discloses an enlarged cross sectional view of corrugated Handle bar's end portion. The introduction of corrugated / curved profiling of the surface of the Handle bar creates a crest-and-trough like structure i.e., curving along the side wall and edge of the Handle bar and such corrugated structure extends throughout the length of the Handle bar. The overall outer diameter of the Handle bar assembly measures 22.2 mm, and the inner diameter is 19 mm. The outward crest is present at 20 locations, each with a radius of 1 mm, while the inward trough appears at 10 locations, with a radius of 2 mm. Although the corrugation reduces the peripheral wall thickness of the Handle bar from the original 2 mm in a commercial tube to 1.6 mm, this thickness reduction extends throughout the length of the tube, contributing to a decrease in the overall weight of the Handle bar. Importantly, the corrugated profiling does not lead to material wastage instead, the scrapped material is repurposed to extend the tube's length, thereby minimizing waste generation as well.

[0082] To summarize, the key changes in various parts of handle bar assembly w.r.t existing Handle bars is as below for ref

[0083] METHOD FOR MANUFACTURING:

[0084] The manufacturing process used for manufacturing of low weight Handle bar is illustrated as below for better understanding of the present invention:

[0085] Raw material used:

[0086] In present invention, the Handle bar is manufactured using carbon steel i.e., ERW-1, Seamless Tube (CDS) & Carbon Steel i.e., Electric resistance welded steel tube, which is a cost effective, strong and durable material and is corrosion resistant as well, thus is a suitable material for manufacturing of low-weight Handle bars.

[0087] Drawing the carbon steel bar:

[0088] A large carbon steel bar / tube is taken and is drawn into a drawn bar / tube by using a specific machine, where a metal bar is pulled through a series of dies to reduce its diameter and increase its length.

[0089] Manufacturing of light weight handle by profiled tube / bar:

[0090] The light weight handle bar manufacturing process by profile tube / bar draw specifically consists the following steps:

[0091] Providing blank bar as an input material; Cutting blank bar in bend saw machine;

[0092] Induction heating of bar at temperature ranging between 1240°C to 1260°C;

[0093] Hot pearcing the bar by piercer mill to form red hot rough hollow tube;

[0094] Annealing at furnace at temperature ranging between 750oC to 780oC to improve material's ductility and reduces its hardness;

[0095] Tube straightening;

[0096] Surface treatment of hollow tube by STP process;

[0097] Acid pickling by dipping in HCI acid tank for 30 minutes;

[0098] Water rinsing of hollow tube by dipping in water for 1 minutes;

[0099] Activation of hollow tube by dipping in activator chemical Bonderlite M-AC for 1 minute;

[0100] Dipping of hollow tube in phosphate chemical for 30 minutes at temperature ranging from 60oC to 70oC;

[0101] Dipping in neutralizer tank containing Bonderite M-AD 5021 JC chemical for 1 minute;

[0102] Rinsing of hollow tube by dipping in water for 1 minute;

[0103] Dipping in soap bath for 40 minutes at 60-70oC for soaping;

[0104] Blowing hot air to dry the inside diameter of the tube;

[0105] Push pointing the tube for making a notch for draw process;

[0106] Cold drawing the hollow tube using die of specific radius and profiling for making final profiled tube;

[0107] Final tube strengthening of tube by straightener machine;

[0108] Cutting of profile tube as per the requirement to form the motorcycle on CNC turning machine / automatic lathes machine.

[0109] If the handle is required to be made from a solid bar, then the bar can be drawn as per the process applicable for bars drawn, and the profile can be formed over the outer diameter accordingly.

[0110] STRENGTH SIMULATION TEST AND RESULTS:

[0111] The strength analysis by way of bending strength analysis and flattening test, to determine the strength of the said handle bar. The strength results are conducted for both plain tube and corrugated / profiled tube, to provide a comparative analysis between the two and to determine how profiled motor cycle handle tube is superior to plain motor cycle handle tube.

[0112] The material used and yield strength of both the motor cycle handle bars is as follows:

[0113] Material used for manufacturing of both plain and profiled tube: ERW-1 (Electric resistance welded steel tubes)

[0114] Density of selected material: 7.85 x 10~6kg / mm3

[0115] Yield strength of selected material: 160MPa

[0116] For bending and flattening tests, the following parameters are crucial, which are being analyzed for both plain and corrugated / profiled motor cycle handle tube:

[0117] Load applied: It is defined as the external force or pressure applied intentionally on the tube during simulation to determine the strength of the same. In bending test, load applied is the force causing the tube to flex and in flattening test, it is the internal pressure simulating compressive or internal bursting forces.

[0118] Von mises stress: It is defined as a calculated value that represents overall stress within a material, combining all types of stress into single number for comparison against material's yield. If von mises stress is equals to yield strength, it indicates that material is right on the edge of yielding and if it exceeds the yielding strength that indicates the material is prone to permanent failure or deformation.

[0119] Maximum displacement: It refers to maximum amount the tube deforms or moves from its original position due to the applied load. In bending test, it means how much far the tube deflects and in flattening test, it indicates how much the tube compresses or bulges under internal pressure.

[0120] Tensile Strength test for plain and profiled handle bar:

[0121] Tensile strength is the maximum amount of tensile (pulling) stress a material can take before it breaks. This test ensures how much a material can withstand tension during forming and its usage.

[0122] Table 1: Tensile strength results for both plain and profiled motorcycle handle bar

[0123] From above table, it was concluded that both plain and profiled handle bar tube as disclosed in example 1 reach the same stress level of 160MPa. Profiled handle bar handles a higher load of 700N, while staying at same stress level, this implies that the profiled tube distributes load more effectively due to a geometry that resists tensile force better.

[0124] From these results, it was concluded that the profiled motorcycle handle bar tube has 16% more tensile strength as compared to the plain motorcycle handle bar.

[0125] Bending test for plain tube and profiled handle bar:

[0126] The bending test is done to evaluate strength, ductility, and fatigue resistance under mechanical stress. The purpose of this test is to determine that the handle can withstand bending forces without cracking, yielding or permanent deformation.

[0127] For plain and profiled motor cycle handle tube of example 1, the results were as follows:

[0128] Table 2: Comparative analysis for bending test results

[0129] Based on Table 2, the profiled motorcycle handle bar tube of example 1 demonstrates a 13.3% higher bending load capacity compared to the plain tube. Although it exhibits a greater displacement under load, this is expected and acceptable in bending scenarios. The critical observation is that the Von Mises stress remains at the material's yield limit, indicating that the tube is fully utilized without structural failure. This highlights the superior bending resilience of the profiled tube, making it more suitable for applications where flexibility under stress is essential.

[0130] Flattening Test:

[0131] The flattening test is a mechanical test used primarily on metallic pipes and tubes, especially in quality control, to assess ductility and resistance to cracking under deformation. It's often applied to steel tubes to check whether they can withstand being flattened (compressed between two plates) without cracking or fracturing.

[0132] The flattening test results showing applied pressure, von mises stress and max displacement on profiled tube is as follows:

[0133] Table 3: Results for flattening test

[0134] From table above, it was concluded that the Profiled motor cycle handle bar tube as disclosed in example 1 demonstrates exceptional resistance to internal pressure with minimal deformation. The displacement of just 0.016 mm under 150 MPa shows very high stiffness and dimensional stability, making it suitable for high-pressure applications.

[0135] From above simulation analysis, it was concluded that the profiled motorcycle handle is capable of handling more tensile strength and bending loads without exceeding yield stress, capable of handling high internal pressure with negligible deformation. Thus, the said profiling drawn over the surface of motorcycle handle, reduces the weight of the same and also enhances its strength, thus is superior over the existing plain handles.

[0136] The technical modifications and improvements in die design used during wire drawing and cold forging results in significant reductions in weight of the Handle bar will be reduced as per the length of the same, however, as per exemplary embodiment of present invention, the weight of the handle bar is approximately reduced by 13-14% without compromising the strength of the same. Overall, this corrugated design is a clever way to balance strength, weight reduction, and material efficiency, making the Handle bar lighter and more ergonomic while maintaining the necessary structural integrity of the same.

[0137] Novelty of the present invention is duly clear as per the non-disclosure of above features in the prior art patent and other non-patent literature.

[0138] The present invention's inventive step lies in the integration of cold drawing and drawn bar processes to introduce a curved profiling over the Handle bar assembly's surface, effectively reducing its weight by 13-14% while maintaining its strength, durability, and stability. The Handle bar surface is corrugated using cold drawing process using dies of different profiles and radii to introduce crest-and-trough i.e., curved structure along the length of the Handle bar, which specifically reduces the weight of the Handle bar without compromising mechanical strength of the same. Further, the corrugated profiling, while reducing the peripheral wall thickness from 2 mm to 1.6 mm, does not generate material waste. Instead, the process extends the length of the Handle bar, allowing the material to be repurposed and cut to form the final product. This efficient use of material not only reduces the overall weight but also lowers the environmental impact by minimizing waste. The inventive step, therefore, is the unique combination of cold / hot drawing and drawn bar processes to achieve a lightweight yet strong Handle bar, with enhanced material efficiency and reduced waste. This approach is technically distinct from traditional manufacturing methods that rely on material removal, which typically leads to increased scrap and reduced material utilization.

[0139] The present invention is particularly applicable in the manufacturing of lightweight and durable Handle bar assemblies for a wide range of industries, including automotive, cycling, motorcycles, and sports equipment. The lightweight yet strong Handle bar design can be applied to vehicle steering systems, offering reduced overall vehicle weight, which improves fuel efficiency and reduces emissions. This innovation aligns with the industry's growing emphasis on eco-friendly and sustainable manufacturing processes. The inventive process significantly reduces material waste by eliminating the need for material removal methods, which typically produce scrap. By extending the length of the Handle bar through corrugated profiling and repurposing the material, the process ensures maximum material utilization, making it a more sustainable manufacturing option. This aligns with the global trend of minimizing environmental impact in production processes. Overall, the invention provides a cost-effective, environmentally-friendly manufacturing solution that combines weight reduction, enhanced strength, and efficient material use, making it ideal for industries that require high-performance tubular components.

[0140] As used herein, the word "a" or "an" should be understood as not excluding plural elements or operations, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0141] The present disclosure is not to be limited in scope by the specific embodiments described herein. Other embodiments and modifications apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of above, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any pump for similar purpose.

Claims

1. AIM:

1. A lightweight motorcycle handle bar assembly consisting a pair of arms (2) and base mounting area (1) characterized in that: curved profiling is drawn over the surface including base mounting area (1) and pair of arms (2), defining crest and trough like structure along the side walls and edges extending throughout the length of the handlebar; peripheral wall thickness is reduced from 2mm to 1.6mm due to reduction of material between the curved radius and flat diameter of the handle bar; weight is reduced up to 13-14% and tensile strength is enhanced by 16%.

2. The lightweight motorcycle handle bar as claimed in claim 1 wherein the curve profiled handle bar having length 702mm, height 172.8mm, outer diameter 22.2mm, inner diameter 19mm, angle between base and arms and 19° angle at which the handle bends, has curved profiling with outer crests of 1mm radius at 20 locations and inner troughs of 2mm at 10 locations drawn over the surface of the handle bar throughout the length to enhance the strength of the handle bar.

3. The lightweight motorcycle handle bar assembly as claimed in claim 1 wherein the curve profiled handle bar it exhibits 13.3% increase in bending load capacity and is capable of withstanding internal pressure up to ISOMPa.

4. The lightweight motorcycle handle bar as claimed in claim 1 wherein the same is manufactured using bar or coil made up of Electric resistance welded carbon steel (ERW- 1 grade), seamless Tube or CDS tube.

5. The lightweight motorcycle handle bar as claimed in claim 1 wherein the said profile is drawn over the surface by placing the drawn bar in die having a specific profile and radius and pushing it into the die using a punch block to impart the desired profile.

6. The method of manufacturing the curved profiled lightweight handle bar assembly as claimed in claim 1 wherein the same consist the following steps: cutting blank bar in bend saw machine; induction heating of bar at temperature ranging between 1240°C to 1260°C;hot pearcing the bar by piercer mill to form red hot rough hollow tube; annealing at furnace at temperature ranging between 750°C to 780°C to improve material's ductility and reduces its hardness; tube straightening; surface treatment of hollow tube by STP process; acid pickling by dipping in HCI acid tank for 30 minutes; water rinsing of hollow tube by dipping in water for 1 minutes; activation of hollow tube by dipping in activator chemical Bonderlite M-AC for 1 minute; dipping of hollow tube in phosphate chemical for 30 minutes at temperature ranging from 60°C to 70°C; dipping in neutralizer tank containing Bonderite M-AD 5021 JC chemical for 1 minute; rinsing of hollow tube by dipping in water for 1 minute; dipping in soap bath for 40 minutes at 60-70°C for soaping; blowing hot air to dry the inside diameter of the tube; push pointing the tube for making a notch for draw process; cold drawing the hollow tube using die of specific radius and profiling for making final profiled tube; final tube strengthening of tube by straightener machine; cutting of profile tube as per the requirement to form the motorcycle on CNC turning machine / automatic lathes machine.

7. The lightweight motorcycle handle bar assembly as claimed in claim 1 wherein the handle bar is hollow or solid and is tubular type.

8. The lightweight motorcycle handle bar assembly as claimed in claim 1 wherein the profile is formed over the outer diameter in case of solid type handle bar.

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