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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI
Gym Cycle
Section 2 Group 3
ANUMOLU AKHIL SAI 2012A4PS272P
NEMISH KANWAR 2012A4PS305P
P VIKRAMADITYA REDDY 2012A4PS290P
SHASHANK BAVEJA 2012A4PS288P
SAHIB SINGH DHANJAL 2012A4PS289P
TAIZOON CHUNAWALA 2012A4PS298P
KUNAL MANCHANDA 2012A4PS279P
Prepared in Partial Fulfillment
Of
Production Techniques 2
ME F313

Acknowledgement
We would like to express our special thanks of gratitude to Dr T C Bera, who gave us the opportunity to
do this project, which also helped us to get Hands-on experience of various Production Technique
process
Secondly, we would like to thank the entire Workshop instructors who helped us a lot in finalizing this
project within the limited time frame
Introduction
The gym cycle as the name suggests is used for incorporating cycling as a physical exercise in the gym.
The physical exercise gained from cycling is generally linked with increased health and well-being. It
improves fitness and cardiovascular health.
The gym cycle converts muscular energy to kinetic energy. Cycling drives a heavy flywheel, generally
with the help of a chain. The torque required to drive the flywheel can be varied with the help of a brake
which increases the strain on the muscles and hence gradually enhances its strength.
ABSTRACT
We aim to fabricate a self- styled functional gym cycle using the materials, instruments and machines
present in our workshop. Here, in this abstract, we will describe in brief how we went about making this
model.
The design of the model was done on Solid Works. The design involved taking into consideration
material and fabrication facilities available in our workshop. The cycle was designed to suit the
dimensions of the average male. After the design was approved, we began its fabrication.
Construction involved using a variety of machines and tools for creating the ideal size and shapes of all
our individual parts.
x Welding was used primarily for joining since steel has been extensively used because of the strength
requirements.
x The lathe was used for turning of our pedal shaft to ensure that it just press-fits into the bearing.
x Shear cutter was used to cut mild steel sheets for the flywheel and the pedal. The finishing of these
approximate cuts was done on band saw and then later on the grinding wheel
x We also used wood for our seat, pedals and the flywheel.
x Drilling was one of the most important processes in this project like in most other projects.
Various tools such as drill bits, chucks, turning tools, vernier calipers were used throughout our
construction process.
The entire team thoroughly enjoyed this long, interesting and educational experience especially so since
the project produced a working model as planned.

University BITS pilani
Assembly Gym Cycle Quantity 1
Details For exercising the the Leg Muscles
Assembly
ItemOrder Part Quantity
1 Rear Bearing assembly 1
2 Front axle assembly 1
3 Belt Drive 1
4 Fly Wheel 1
5 H-Shaped Base 1
6 Seat 1
7 Pedal 2
8 Pedal Shaft 1
9 Handle Assembly 1
10 Chassis 1
ItemOrder Process Operation Quantity
1 weld1 Arc Welding: H-Shaped Base to Chassis 4
2 weld2 Arc Welding: Rear bearing to chassis 2
3 weld3 Arc Welding: Belt drive1 to Flywheel 2
4 weld4 Arc Welding: Belt drive1 to axle 1
5 weld5 Arc Welding: Chassis to Hand Assembly 2
6 weld6 Arc Welding: Chassis to Seat 1
7 D-spanner Fastening: Front Axle Assembly to Chassis 4
ItemOrder Fastener Use Quantity
1 Bolt (M6) Fastening: Front Axle Assembly to Chassis 4
1 Nut (M6) Fastening: Front Axle Assembly to Chassis 4
29/11/14 Page 1 of 11

Subassembly Rear Bearing assembly Quantity 1
Details To mount the rear axle
Assembly
1 Circular Billet 1
2 Bearing 2 (push fit)
3 Rod 1
1 Boring Machining 2
2 Facing Machining 1
3 Turning Machining 1
Part : Circular Billet
ItemOrder Material Type Size1 dim1 Size2 dim2 Quantity
1 Mild Steel Circular 3" Diameter 2" length
ItemOrder Process Size Quantity
1 Facing ʔ - 4.5 cm 1
2 Boring ʔ - 3 cm 2 (push fit bearing)
Part : Bearing
ItemOrder Bearing Type Size1 dim1 Size2 dim2 Quantity
1 - - 3 cm Diameter - - 2
Part : Rod
1 Mild Steel Rod 1cm Diameter 15 cm length
1 Turning ʔ - 9 mm 1
29/11/14 Page 2 of 11

Subassembly Front axle assembly Quantity 1
Details To mount the front axle
Assembly
1 Pillow Bearing 2
2 Circular Tube 1
1 Cutting Machining 1
Part : Circular Rod
1 Mild Steel Circular 1" Diameter 30 cm length 1
29/11/14 Page 3 of 11

Subassembly Belt Drive Quantity 1
Details To drive fly wheel
Assembly
1 Wooden block 2
2 MS plate 2
3 Wooden ply 2
4 Rubber Belt 1
ItemOrder Process Use Quantity
1 D-spanner Fastening 3
1 Bolt (M6) Fastening Plates with wooden block 3
1 Nut (M6) Fastening Plates with wooden block 3
2 Drilling Machining 6
Part : Wooden block
1 Wood Block 8" x 8" Area 3cm Thickness 1
2 Wood Block 4" x 4"
1 Cutting ʔͲϲΗ 1
2 Cutting ʔ- 3 1
Part : Wooden Ply
1 Wood Ply Ply 10 x 10 Area 2mm Thickness
2 Wood Ply Ply 5 x 5 Area 2mm Thickness
1 Cutting ʔ - 8 1
2 Cutting ʔ - 4 1
Part : MS Plate
1 Galvanized MS plate 10 x 10 Area 2mm Thickness
2 Galvanized MS plate 5 x 5 Area 2mm Thickness
1 Cutting ʔ - 8 1
2 Cutting ʔ - 4 1
29/11/14 Page 4 of 11

Subassembly Fly Wheel Quantity 1
Details
Assembly
1 Wodden block 1
2 MS Plate 2
1 Bolt (M6) Fastening Plates with wooden block 4
1 Nut (M6) Fastening Plates with wooden block 4
1 Drilling Machining 5
Part : Wodden block
1 Wood Block 16 x 16 Area 1cm Thickness 1
1 Cutting ʔ - 35 cm 1
Part : MS plate
1 Mild Steel Plate 35 cm Diameter 3mm Thickness 2
1 Cutting ʔ - 35 cm 2
29/11/14 Page 5 of 11

Subassembly H-Shaped Base Quantity 1
Details Mechanism required to rotate Belt drive
Assembly
1 Rectangular Tube 1 2
1 Welding Joining 2
Part : Rectangular Tube 1
1 Mild Steel NA 2in x 1in x 2.5mm
cross sectional
area 60cm length
1 Cutting 60cm 2
1 Mild Steel NA 3.5in x 2in x 2.5mm area 90cm length 1
1 Cutting 90cm 1
29/11/14 Page 6 of 11

Subassembly Seat Quantity 1
Details Base required for the driver to sit
Assembly
1 Metal Seat 1
2 Wooden Seat 1
3 Foam 1
2 Sticking with Fevicol Foam to Wood 1
1 Bolt (M6) Fastening seat with metal Plate 2
1 Nut (M6) Fastening seat with metal Plate 2
Part : Metal Seat
1 Plate 24cm*24cm area 1in thick 1
Part : Wooden Seat
1 Wood Shesham 24cm*24cm area 1in thick 1
1 Drilling 2mm 2
2 Sawing Triangulation 1
Part : Foam
1 Foam Foam 1/2in thickness 1
ItemOrder Process Length Quantity
1 Cutting Triangulation 1
29/11/14 Page 7 of 11

Subassembly Pedal Quantity 2
Details To drive the pedal assembly
Assembly
1 Pedal Plate 1
2 Pedal rod 1
3 Wood Base 1
1 weld1 Pedal Plate to Pedal rod 1
2 weld2 Pedal Plate to shaft 1
Part : Pedal Plate
1 Plate MS 3cm*15cm area 3mm thick 1
ItemOrder Process Use
1 Sawing Cutting
Part : Pedal rod
1 rod MS round 12mm diameter 10cm length 1
ItemOrder Process Size
1 Drilling 2mm
Part : Wood Base
1 Wood Shesham 4cm x 6cm area 1in thick 1
1 Drilling 12mm
29/11/14 Page 8 of 11

Subassembly Pedal Shaft Quantity 1
Details Sits over Bearing
Assembly
1 Shaft 1
Part : Shaft
1 Rod MS 12mm diameter 8in length 1
1 Turning to 9.26mm
2 Grinding Finishing
29/11/14 Page 9 of 11

Subassembly Handle Assembly Quantity 1
Details Handle acting as arm rest
Assembly
3 Circular Tube 1
1 Welding Joining 6
1 Mild Steel NA 1in x 1in x 2mm area 150cm length 1
1 Cutting 70cm 2
1 Mild Steel NA 1in x 1in x 2mm area 5in length 1
1 Cutting 1.5in 4
Part : Circular Tube
1 Mild Steel NA 2in x 1in x 2.5mm area 60cm length 1
1 Cutting 60cm 2
2 Bending 5 from each side 2
29/11/14 Page 10 of 11

Subassembly Chassis Quantity 1
Details Main Supporting Structure
Assembly
1 Welding Joining 2
1 Mild Steel NA 2in x 1in x 2.5mm cross sectional
area 200cm length 1
1 Cutting 90cm 2
2 Drilling ƆͲϭϮŵŵ 2
1 Mild Steel NA 2in x 1in x 2.5mm area 110cm length 1
1 Cutting 50cm 2
2 Drilling ƆͲϯϬŵŵ 1
29/11/14 Page 11 of 11

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