Abstract

The design, analysis and fabrication of a human-powered Kick Scooter is

done as a project for Machine Design course. A kick scooter is a simple
human-powered vehicle, composed of a small platform to stand on and
handle bars to hold onto and steer, used as a means of transportation
over short distances.
The basic scooter design consists of a frame, pivoting mechanism,
polyurethane wheels and a brake. The handlebar and head tube fold when
a quick release latch is opened, allowing for easy carriage and storage. For
the sake of simplification, the handle height is constant and not adjustable
unlike most commercially available scooters.
The project is fundamentally divided in three main phases listed below:
1) Design and Analysis

2) Fabrication

3) Assembly
After the assembly, analysis was done and the scooter was subjected to
forces to ascertain that the product holds true to the calculations and to
confirm the completion of a successful product. A user study was also
conducted for the sake of recommendations and suggestions.

Objective
To design and fabricate a Kick Scooter for a human of average weight which is to
be used in acceptable riding conditions.

DELIVERABLES
Ideally, one fully assembled and ready to use Kick Scooter
prototype.
Division of Parts

Handle Bar
Steering Column (T-Rod)
Pivoting Mechanism (Bearings)
Deck/Baseboard
Wheels
Joints (Welding)
Fasteners (Bolts and Nuts)

Breakdown
Phase 1

Designing
Material Selections
Analytical Calculations
Iterative Process
Modeling on a CAD software

Phase 2

Fabrication
Acquiring required material
Fabricating each part according to design requirements

Phase 3

Assembly
Assembling the already fabricated parts

Scooter Operation

The rider places hands on the handle bars and the inside foot on the deck for stability

To propel the scooter, the rider pushes off with the outside foot and repeats this step until desired
speed is reached

The rider then lifts the outside foot off the ground and either lets it hover in the air or rests on the
deck along with the inside foot until more speed is desired

In order to stop, the rider either jumps, runs, or walks off the deck of the scooter applies break.

Requirements
The following requirements are to be fulfilled:

Safe

Low cost

Reliable and Durable

Portable/Collapsible

Initial Decisions and Assumption

Selected stainless steel as building material on the basis of strength and durability.
The height of the scooter should at least be around 90 cm
The scooter width should be wide enough for a person to stand on (approx width 11 cm)

A person with no more than 100kg of weight will use the scooter

The height of the user will be no more than 6 feet

Only one person will use the scooter at a time

The scooter is intended for use on solid, flat, clean and dry surfaces such as pavement or level

ground without loose rubble such as rocks or gravel.

The user of the scooter will ensure all necessary personal safety measures such as wearing a

helmet, knee pads and elbow pads.

Design and Analysis

The design and analysis of the entire scooter was divided based on the parts
division.

BASE FRAME
Design
This design of frame was selected after considering market availability and

extensive research.
For simplification, we shall use constant cross-section

We will start with stiffness based design and later check for strength.
Force on one beam will be

P=

100 x 9.81
2

Schem
atic

S.F.D

B.M.D

Deflect
ion

x =

Pl
48 El

We need to limit the deflection to 1.5 mm for a comfortable ride.

I = Pl3/48E x
E = 200 GPa

P = 490.5 N
L = 0.545 m
x = 0.00 15 m
Putting values

= 5.5139 X 10-4m4

Of the available materials, the hollow rectangular tube we could find had

I
= 7.3 X 10-9m4
With dimensions
b
= 13 mm 0.2 mm
h
= 24 mm 0.2 mm
t
= 1.5 mm 0.1 mm
Total Length = 54.5 cm 2 mm
And generally
For this,

= 1.1 mm

x < max design deflection

As

We select the tube.

Analysis
Now,
We check for strength.

Maximum moment
= 245.35 N x 0.565/2 m
= 69.28 Nm

bending (max)

My
l

= 113.89 MPa
When no load is applied

min

FIG 7

Sut = 505 Mpa

For calculating

Se,

Se = 0.5 Sut = 252.5 MPa

1)
Ka = aSutb
As cold drawn
Ka = 0.866
2) Kb

=0

de = 0.0142
Kb = 1.24d-0.107
= 0.933
As bending
3) Kc = 1
4) Kd = 1 (room temperature)
5) Ke = 0.897 (90 percent reliability)
6) Kf = 1
So,

Se= KaKbKcKdKeKfSe
Se= 183 MPA
1

nf =

+
Se Sut

nf = 2.36 (safe)
FEM Analysis
The design of the base frame was checked on fem to make sure that the base would not
fail or deform beyond limit. As the fem analysis show that the maximum deformation
would be 0.16 mm and maximum stress would be 34 MPa, so we are safe. The difference
in the theoretical calculations and the fem analysis is due to the extra bar we used to
make
the
deck
strong
and
rigid.

T TUBE
Design
Using a factor of safety of 2

Sy = 215 MPa
Allowable Stress = 215/2 = 107.5 MPa

Using this equation:

Where,

I=

64

My
l

(dout4 din4)

We get

dout = 0.02937 m
Available size,
dout = 3.05 cm 0.15 mm

din = 2.65 cm 0.15 mm

Thickness = 0.2 cm 0.1 mm
Analysis

Sut = 505 MPa

Sy = 215 MPa
F = 200

Schem
atic
=

My
l

= 121 MPA

S.F.D
n = 215/121 = 1.77

Considering the person does

not exert the entire force
perpendicular to rod then
there will be a compressive
force on the rod.

Let F = 200 N

B.M.D

P=

 = F/A
= 1.11 MPA << 251 MPa
So our material of rod is safe.
Analyzing Fatigue

m = (max + min)/2
m = 60.5 MPa
a =| max - min |/2
a = 60.5 MPa
Se = 0.5 Sut
Se = 252.5 MPa
Se= KaKbKcKdKeKfSe

a) Ka = 0.8646
b)
Kb = 1.24d-0.107
Not applicable since d< 2.79

c) Kc = 1
d) Kd = 1
e) Ke = 0.814 (99 percent reliability)
Se = 177.7 MPa
Using Goodman criteria we get factor of safety

nf =

+
Se Sut

nf = 2.17 (So our material is safe)

Handle
To comfortably fit the handle in hand we selected a hollow rod with an outer
diameter of 4.5 cm and an inner diameter of 3.7 cm.

F = V = 200 N
M = Fx = 172 Nm
And

I=

64

(dout4 din4)

C = 0.0225 m
Also

y1 = 4/3 rout = 9.549x10-3 m

y2 = 4/3 rin = 7.85x 10-3 m
A1 = r2out = 7.952 x 10-4 m2
A2 = 5.376 x 10-4 m2
Q = y1A1 y2A2 = 3.37 x 10-6 m3
So shear stress is found out to be

= VQ/It
= 6.561526 MPa
= ( x2 + 3 2xy)1/2
= 37.189 MPa
First checking for static failure.

n = Sy/37.189
n = 5.78 (safe)

Now for fatigue

nf = 1/( a/Se + m/Sut)

a = m = 18.59 MPa
nf = 7.05 (safe)

TIRE
The tires have been selected solely on the basis that these tires are used in
commercial scooters. They are made of a material known as Urethane. Urethane
is a polymer often found, quite literally, at our feet. An important component in

running shoe treads, it is now paving the way for

new and improved tires. A closed-cell urethane tire
can be made in one piece, driven on even without
air, and has approximately one-fifteenth the
production price of a traditional rubber tire. The
avoidance of tread separation, which can lead to
severe accidents, is an added benefit of urethanes
one-piece tire compositiona traditional tire can
often suffer blow-outs along treads. Because
urethane is smooth, automotive tire traction poses a
potential problem. Development is being done to overcome this problem.

Assembly and Fabrication

BEARINGS
Design of Bearing
C10=F D

D nD 60
R nR 60

1
3

R nR 60= Related revolutions by the manufacture.

In our case its

103

F D =200 N =.2 kN
D=desirelifehours =20000 hrs
n D = desired

rev
min

As it is a manual scooter (no electrical motor is used) so its rpm will be small.

rev
n D =50
min
C10=0.2

20000 50 60 13
=7.829
103

From ABMA standard boundary dimension data, we selected a bearing with outer
diameter 35.1mm but available size was 45.4mm also our shaft/rod dia is
30.5mm so to allow the free rotation of rod and to provide tolerances we used
the available bearing of 45.4mm outer dia.
Hence,

Analysis of Bearing
dia out =4.54 cm

=4.

dia =4.28 cm
Bearing stress area =

(dia out dia )

4

=1.801

cm 2

P=200N (total)
On bearing
P= 200 sin 30=100 N
Bearing stress=

P
100
= =
A 1.801 104
= 0.5MPa (safe)

Dired Shear in Bearing

A=1.801

cm 2

V max =200 N
max =

V
=1.1 MPa
A

AXLE BOLTS

(safe)

=4.54 cm

There are two types of axle bolts, with each

performing nearly the same job. Axle bolts are
strong bolts made of hardened steel which are
used to connect the drive axle of a vehicle to a
wheel hub or to connect axle half shafts
together. Commonly consisting of the axle bolts
and locking washers, the bolts are often installed
using liquid thread-locking compound as well as
a lock washer.

Front Axle Bolt

Rear Axle Bolt

These bolts are selected and purchased on the basis of strength and load bearing
capacity. They are not specifically designed. They are selected as best fits and other
design considerations.

Specifications
Approximate Load
Load: 981 N
Front Axle Bolt
Length: 9.5 cm
Dia: 0.7 cm
Rear Axle Bolt:
Length: 11.56 cm
Dia: 0.7 cm
Material:
AISI Type 304 Stainless Steel

Bolts x 2 (Keeping in
place the T-Tube & Deck
together)

Design

Shear force acting on the joint is

Vshear = 981 N
There is also moment associated with it

M = 981 N x 28.05 cm = 275.17 Nm

There will be two bolts that would be countering the force. The distance of each
bolt from center is

r=

5.25
2

cm = 2.625 cm

The primary shear force acting on each bolt is

F =

Vshear
2

F =

Mr
4 r2

981
2

N = 490.5 N

= 2620 N

Using vector addition we get results

Fa = 2987 N
Fb = 2299 N
If we choose SAE grade 5 bolts, then

Sy = 558 Mpa, so Ssy = 0.577 x 558 = 322 Mpa

Let the factor of safety be 2

Sallow = 161 Mpa

Sallow =

F
As

Since As = r2

r=(

F
Sallow

)1/2

r = 2.43 mm
Hence we need two bolts having
Minor diameter = 5 mm
Bolt Length between members = 45 mm
(necessity)
Nut Height = 10 mm (from table)
Total bolt length = 45 mm + 10 mm + Clearance =
65 mm

Members Analysis
Bearing stress area = td = 5(15) = 75mm2

Stress =

F
Ab

2987
75

= 39.8 MPa (very safe)

So, our design is safe as we had already checked for bending of the base.
Note
Due to practical constraints we selected one bolt of the specified diameter and
another one of a large diameter of 7.5 mm, it will only add to strength.

WELDING

Stress on the weld

= V/A
Weight = (100 x 9.8) = 980 N
From Table (9-1) Shigley

Area = 0.707 x h x (b+d)

Area = 0.707 x (10) x (10+10)
Area = 141.4 mm2
Now assuming number of beads = 10
Force on one bead = 980/10 = 98 N
So = 98/141.4mm2 = 693.06 kPa
[Weld material ANS E 308 15]

Sut = 592.54 MPa

Permissible stress = 0.30

Sut = 177.726 MPa

Now,
Allowable Stress = 177.726 MPa
Primary Stress = 693 kPa

Hence, < allowable

So the weld is safe.
Now for plate
By applying 980 N force, there will be a shear as well as bending moment in rod.

= Mc/I

c = 0.75 cm
I = 7.3 x 10-9 m4
M = 980 x 4.35 x 10-2 Nm
M = 42.63 Nm
So = 43.79 MPa

= V/A
= 980/130.8
= 74.923 k Pa
Von Mises Stress

= (2 + 32)1/2
= 43.29 MPa
As Sy for stainless steel = 215 MPa
< 215 MPa
So the design is safe.
Considering it as a single bead bearing a load of 1000N we see that

V
A

1000
throat area

Now throat area= 0.707 x h x l

Height= h= 1cm
Length= l= 6cm

Throat Area=

= 4.242
=

0.707 1 10 6 10
104 m2

1000
=2.35 MPa
4
4.242 10

max

hence the weldment is safe.

BRAKES
Purchased from market after checking compatibility.