Integrally Forged Bike Suspension Fork for Crown Joint Strength
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Solution Overview
Problem
Existing methods for manufacturing bike suspension forks are prone to deformation or breakage due to insufficient strength, particularly at the connection between the steer tube and the bridge-shaped crown, which can compromise safety.
Innovation Solution
A method of manufacturing integrally forged bike suspension forks using an aluminum ingot, where a crown prototype is initially forged and then deep drawn to form a front fork section and suspension tube sections, with reinforcement processing and milling to enhance strength and facilitate damper installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the steer tube is connected with the bridge-shaped crown by insertion, then the manufacturing process is simple, but the connection strength is insufficient leading to deformation or breakage
Solution Approach 1:
The patent merges the steer tube and crown into a single integrally forged piece, eliminating the insertion connection between these two components. The crown is forged with a built-in steer tube structure, ensuring continuous material flow and eliminating weak connection points while maintaining manufacturing efficiency through a single forging operation.
Solution Approach 2:
The patent employs aluminum alloy materials with specific compositional ranges (including Si, Cu, Mg, Mn, Zn, Ti, and Fe) to create a composite material structure that provides both high strength and shock resistance. The material composition is optimized to ensure the integrated structure can withstand external forces without deformation or breakage.
2Ease of manufacture
If multiple separate components are used to form the suspension fork, then the manufacturing process is simpler for each component, but the overall strength and shock resistance are insufficient
Solution Approach 1:
The patent combines multiple suspension fork components (crown, steer tube, sliders, and dampers) into a single integrally forged structure. The crown is forged as one piece with built-in steer tube, and sliders are integrated with the crown structure, eliminating weak connection points between separate components while maintaining manufacturing efficiency.
Solution Approach 2:
While integrating components, the patent maintains functional segmentation through internal structural design. The crown includes distinct functional zones: a steer tube receiving portion for the steer tube, slider receiving portions for sliders, and reinforcement ribs strategically positioned to handle different force vectors. This segmentation of function within an integrated structure optimizes both strength and shock resistance.
3Adaptability or versatility
If the crown is designed with multiple connection points for sliders and dampers, then the suspension function is enhanced, but the structural complexity increases leading to more potential failure points
Solution Approach 1:
The patent merges multiple connection functions into the integrally forged crown structure. The crown is formed with built-in slider receiving portions and damper mounting points as integral features rather than separate attachment points. This integration eliminates the need for separate connection components while maintaining all necessary suspension functions.
Solution Approach 2:
The patent applies local quality enhancement through strategically positioned reinforcement ribs within the crown structure. These ribs are placed at specific locations to strengthen areas subject to high stress from slider movements and damper forces, providing localized strength enhancement without increasing overall structural complexity. The material composition is also optimized locally in high-stress regions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a suspension fork with high strength and shock resistance, reducing the risk of deformation or breakage under external forces, while also being cost-effective by integrating multiple components through forging.
Implementation Method 1
initially forming a crown prototype by forging of the base material
Implementation Method 2
By deep drawing, the solid protuberant base and the lateral shoulders are respectively drawn and extended to form a front fork section and suspension tube sections
Implementation Method 3
a top surface of each of the lateral shoulders is milled to communicate with the corresponding suspension tube section by milling
Implementation Method 4
Perform reaming on an open end of each of the suspension tube sections for increasing a tube diameter and convenient installation of dampers
Data Source
AI summary
A method of manufacturing integrally forged bike suspension forks is provided. First initially forming a crown prototype by forging of an aluminum ingot. The crown prototype includes two lateral shoulders and a solid protuberant base. By deep drawing, the solid protuberant base and the lateral shoulders are respectively drawn and extended to form a front fork section and suspension tube sections. By milling, a top surface of each of the lateral shoulders is milled to communicate with the suspension tube section. Thereby an integrally-forged suspension fork is obtained. Therefore, the aluminum ingot is processed to obtain the integrally formed suspension front fork with the suspension tube sections and the front fork section. The suspension front fork is having high strength and shock resistance under impact of an external force applied to a front wheel of the bike.