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Making spokes..

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29 December 2004
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5 January 2005
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joff
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  1. I found this description of making motorcycle spokes using Google. No
    mention of stress relief.

    http://www.central-wheel.co.uk/cwc/spoke_details/spoke_details.html

    Manufacturing spokes

    All our spokes are manufactured from the highest grade UK Stainless
    Steel or mid carbon galvanised steel, which ensures the optimum
    combination of strength and performance.

    The spoke material arrives in 500 kg coils of wire and is fed into a
    spoke machine that straightens the wire before cutting it to length.
    It then forms the head before forming the bend and rolling the thread
    as it ejects the 'spoke' from the machine.

    Stocks of blank spokes (headed but not threaded or bent) are made and
    held in stock ready to be bent and cut down for our smaller orders or
    spoke sets.

    Butted spokes are made from wire which is the thickness of the butted
    end but are intentionally cut short. The spokes are then hammered out
    to length, reducing the diameter of all except the butted end.

    The final part of the process is to clean and polish the spokes. Large
    vibrating metal bowls full of polishing compound and ceramic pellets
    clean the spokes through abrasive action. Similar vibrating bowls
    containing maize apply the final polish.

  2. Some spoke making machines are pictured here, but it's hard for me to
    tell what goes on inside them:
    http://www.bwgroupinc.com/amba.html
    http://www.madygroup.com/ps/mc/spoke.htm
    http://www.bicyclesb2b.com/work/b_paradeS.jsp?supplier=1242&industry=BI
    http://www.crc4mse.org/MEL/BIKE/MEL_bike_spoke_making.html

  3. dianne_1234 said:

    I found this description of making motorcycle spokes using Google. No
    mention of stress relief.

    http://www.central-wheel.co.uk/cwc/spoke_details/spoke_details.html

    Manufacturing spokes

    All our spokes are manufactured from the highest grade UK Stainless
    Steel or mid carbon galvanised steel, which ensures the optimum
    combination of strength and performance.

    The spoke material arrives in 500 kg coils of wire and is fed into a
    spoke machine that straightens the wire before cutting it to length.
    It then forms the head before forming the bend and rolling the thread
    as it ejects the 'spoke' from the machine.

    Stocks of blank spokes (headed but not threaded or bent) are made and
    held in stock ready to be bent and cut down for our smaller orders or
    spoke sets.

    Butted spokes are made from wire which is the thickness of the butted
    end but are intentionally cut short. The spokes are then hammered out
    to length, reducing the diameter of all except the butted end.

    The final part of the process is to clean and polish the spokes. Large
    vibrating metal bowls full of polishing compound and ceramic pellets
    clean the spokes through abrasive action. Similar vibrating bowls
    containing maize apply the final polish.

    Dear Dianne,

    And those are custom motorcycle spokes, made with loving
    attention to detail.

    I've broken a frame tube on my ancient Honda trials machine
    by carelessly treating it as a high-speed trail bike, but
    never any spokes--untouched since 1976.

    This isn't unusual. Motorcycle spokes tend to last.

    Typically, motorcycle spokes are so thick that hand
    spoke-squeezing would be impossible. Here are some details
    from a long-ago post:

    "It may help readers unfamiliar with such things to describe
    the difference in spokes. My road bicycle's 700c rear rim
    uses 2.0mm x 1.8mm x 2.0mm double-butted spokes, 295mmm long
    with a roughly 4mm hub-head and nipples about 3.5mm in a
    36-spoke cross-3 pattern."

    "My flimsy trials motorcycle's 18-inch rim rear wheel uses
    3.5mm x 3.5mm x 4.0mm hub-butted spokes, 165mm long with a
    roughly 7mm hub head and nipples about 6mm in a 36-spoke
    cross-2 pattern."

    "Here's a picture:

    http://home.comcast.net/~carlfogel/download/spokes.jpg

    The now-vanished wire-spoke wheels on small sports cars were
    even thicker. So far, no one has mentioned any stress-relief
    for them.

    (Given my prejudice against the mechanical reliability of
    small British sports cars circa 1960, I'm willing to believe
    that they snapped spokes on a daily basis, but I don't
    actually recall any complaints about their spokes. God knows
    everything else broke.)

    Of course, bicycle spokes may be so thin in relation to
    their load that they're more likely to fail due to stresses.
    But a wide range of mass-produced and assembled motorcycle
    spokes seem to be immortal without any known stress-relief.

    It's hardly conclusive, but it's the kind of thing that
    makes you wonder.

    Carl Fogel

  4. Quoted message said:

    "It may help readers unfamiliar with such things to describe
    the difference in spokes. My road bicycle's 700c rear rim
    uses 2.0mm x 1.8mm x 2.0mm double-butted spokes, 295mmm long
    with a roughly 4mm hub-head and nipples about 3.5mm in a
    36-spoke cross-3 pattern."

    "My flimsy trials motorcycle's 18-inch rim rear wheel uses
    3.5mm x 3.5mm x 4.0mm hub-butted spokes, 165mm long with a
    roughly 7mm hub head and nipples about 6mm in a 36-spoke
    cross-2 pattern."

    "Here's a picture:

    http://home.comcast.net/~carlfogel/download/spokes.jpg

    Is the darker one the motorcycle spoke?

  5. Quoted message said:
    Carl Fogel said:

    What do you predict will happen if two batches of stainless steel
    spokes, one "stretched", one not, are tested by boiling in a
    suitable pot of chemicals until the surface corrosion cracking
    associated with tensile stresses (internal in this case) leads to
    failure?

    Quoted message said:

    These stresses are relatively uninteresting until spoke tension is
    added to them to bring them up to the level that they can contribute
    to failure. I haven't given that much thought, but I suspect the
    highest stresses won't be close to half yield stress and therefore
    undetectable by this method.


    -snip-

    Quoted message said:

    The problem is that bending loads, especially at the elbows, are
    obscure because the length changes are so minute as to be immeasurable
    by reasonable means while the stresses are high. This is why this
    phenomenon escaped scrutiny previously and was believed to not exist.

    I find the criticism and disbelief of the information offered in "the
    Bicycle Wheel" to be what I anticipated and for which I was careful to
    include minutia that seemed to be insignificant... until the subject
    was attacked by the faithful of the status quo.

    I, for one, cannot 'prove' it. But it is true.

    Observation showed that even before The Book.

    Our mid-seventies wheelbuilding rate shows $5 for 'wheel
    build'* and $8 for 'pro build, oil nipples, stress wheel
    twice'.

    David Agger, our resident wheel master of the era,
    recommended bringing the oiled nipples to as high a tension
    as we could with a Surre spoke wrench, pressing the wheel
    over one's thigh and flexing the wheel as if to 'potato
    chip' it, then finishing the wheel by loosening nipples as
    much as possible. A second pass over one's thigh and we were
    effectively (the hard way) relieving the stresses and
    seating the spoke heads.

    A practical man's observation led to roughly the same
    prescription as Jobst's more thorough work and I'm sure
    others noticed these phenomena to some extent before he wrote.

    After The Book we had a more clear understanding of that.
    David empirically noticed that bringing high-tension spokes
    to a momentarily ultra-high tension and then backing off the
    tension slightly made a more durable wheel.

    * In those days we built every wheel in house, even steel
    rims with galvanzed spokes.
    --
    Andrew Muzi
    www.yellowjersey.org
    Open every day since 1 April, 1971

  6. A Muzi said:
    Quoted message said:
    Carl Fogel said:

    What do you predict will happen if two batches of stainless steel
    spokes, one "stretched", one not, are tested by boiling in a
    suitable pot of chemicals until the surface corrosion cracking
    associated with tensile stresses (internal in this case) leads to
    failure?

    Quoted message said:

    These stresses are relatively uninteresting until spoke tension is
    added to them to bring them up to the level that they can contribute
    to failure. I haven't given that much thought, but I suspect the
    highest stresses won't be close to half yield stress and therefore
    undetectable by this method.


    -snip-

    Quoted message said:

    The problem is that bending loads, especially at the elbows, are
    obscure because the length changes are so minute as to be immeasurable
    by reasonable means while the stresses are high. This is why this
    phenomenon escaped scrutiny previously and was believed to not exist.
    I find the criticism and disbelief of the information offered in
    "the
    Bicycle Wheel" to be what I anticipated and for which I was careful to
    include minutia that seemed to be insignificant... until the subject
    was attacked by the faithful of the status quo.

    I, for one, cannot 'prove' it. But it is true.

    Observation showed that even before The Book.

    Our mid-seventies wheelbuilding rate shows $5 for 'wheel build'* and
    $8 for 'pro build, oil nipples, stress wheel twice'.

    David Agger, our resident wheel master of the era, recommended
    bringing the oiled nipples to as high a tension as we could with a
    Surre spoke wrench, pressing the wheel over one's thigh and flexing
    the wheel as if to 'potato chip' it, then finishing the wheel by
    loosening nipples as much as possible. A second pass over one's thigh
    and we were effectively (the hard way) relieving the stresses and
    seating the spoke heads.

    A practical man's observation led to roughly the same prescription as
    Jobst's more thorough work and I'm sure others noticed these phenomena
    to some extent before he wrote.

    After The Book we had a more clear understanding of that. David
    empirically noticed that bringing high-tension spokes to a momentarily
    ultra-high tension and then backing off the tension slightly made a
    more durable wheel.

    * In those days we built every wheel in house, even steel rims with
    galvanzed spokes.

    This still does not address WHY the practice leads to a more durable
    wheel. Even Jim Beam agrees that it does, it is the mechanism that is
    questioned. As Carl Fogel has pointed out, there are a number of
    possible explanations.

  7. On Sat, 01 Jan 2005 19:55:46 -0600, A Muzi
    <[email hidden]> wrote:

    [snip]

    Quoted message said:

    I, for one, cannot 'prove' it. But it is true.

    Observation showed that even before The Book.

    Our mid-seventies wheelbuilding rate shows $5 for 'wheel
    build'* and $8 for 'pro build, oil nipples, stress wheel
    twice'.

    David Agger, our resident wheel master of the era,
    recommended bringing the oiled nipples to as high a tension
    as we could with a Surre spoke wrench, pressing the wheel
    over one's thigh and flexing the wheel as if to 'potato
    chip' it, then finishing the wheel by loosening nipples as
    much as possible. A second pass over one's thigh and we were
    effectively (the hard way) relieving the stresses and
    seating the spoke heads.

    A practical man's observation led to roughly the same
    prescription as Jobst's more thorough work and I'm sure
    others noticed these phenomena to some extent before he wrote.

    After The Book we had a more clear understanding of that.
    David empirically noticed that bringing high-tension spokes
    to a momentarily ultra-high tension and then backing off the
    tension slightly made a more durable wheel.

    * In those days we built every wheel in house, even steel
    rims with galvanzed spokes.

    Dear Andrew,

    I appreciate your comments, but step back for a moment and
    look at what you're saying.

    That you charged more for squeezing spokes does not show
    that it made spokes last longer.

    Nor does it show why the spokes lasted longer.

    It just shows that you charged more for squeezing spokes.

    (That Dave in good faith squeezed them twice illustrates the
    kind of problem involved. According to the modern theory,
    two squeezes are pointless--a single squeeze is supposed to
    be enough to make spokes immortal.)

    (That Dave in good faith believed that this merely improved
    spoke life is another kind of problem. According to modern
    theory often expressed here, the spokes should not merely
    have lasted longer--they should have lasted forever. No
    properly squeezed spoke should ever fail except in a crash,
    or so we're told, while all unsqueezed spokes should fail
    fairly soon--although how soon is never pinned down.)

    (That Dave began building more durable wheels is quite
    possible, but how do we tell what made them better? For one
    thing, the spokes themselves were improving in quality. Your
    good faith here is evident--you explain that Dave began to
    back off the tension slightly after the stress relief--which
    sounds like the overshoot-and-back-off method of avoiding
    spoke windup. It's demonstrable that wheels go to hell when
    spokes with windup unwind and lose tension, but because of
    our expectations stress relief is getting all the credit
    here.)

    (That yet another Dave has appeared in rec.bicycles.tech is
    just further confirmation of my darker and unrelated
    suspicions.)

    To put it another way, there was also probably a higher fee
    back then for tying and soldering, too.

    After all, people as experienced and sensible and practical
    as Dave honestly believed in the now-vanished habit of tying
    and soldering.

    Without a clear set of records that show wheels identical in
    build and use (except for the spoke squeezing), it's hard to
    convince anyone that it works, much less whether it works by
    relieving internal stresses or by improving the hub/spoke
    junction or by other means. And since everyone convinced of
    the value of spoke squeezing seems to squeeze all their
    spokes, there's no contemporary unsqueezed control group.

    It is in things that cannot be easily measured that we are
    most likely to fool ourselves. (We may not be fooling
    ourselves about spoke-squeezing having an effect--but how do
    we tell if there is no real testing or data? And how do we
    tell whether it works by relieving internal stress or by
    seating the spoke-head better or by simply encouraging us to
    be more careful and thorough with all the other steps?)

    When we do something that we believe beforehand will improve
    things, we usually notice a difference that seems quite
    empirical and obvious--whether it's there or not. The harder
    it is to verify, the more likely we are to believe in it.

    It's not a question of intelligence or honesty. Reasonably
    intelligent and well-trained doctors performing charity work
    are forever re-discovering how easy it is for us to see
    results that we expect to see.

    Is there really an effect?

    If so, is it the result of spoke squeezing, reducing spoke
    windup, better quality steel in the spokes, improved spoke
    design in terms of elbow angle and head formation, changes
    in how the spoke is whomped into shape, or what?

    If the result is due to spoke squeezing, how does it work?
    By relieving internal stress, by forming a better hub hole,
    or what?

    It's a fascinating question, if only because we are so prone
    to--well, if not jumping to conclusions, but often taking
    surprisingly large steps on faith.

    Carl Fogel

  8. Jim Smith said:
    Quoted message said:

    "It may help readers unfamiliar with such things to describe
    the difference in spokes. My road bicycle's 700c rear rim
    uses 2.0mm x 1.8mm x 2.0mm double-butted spokes, 295mmm long
    with a roughly 4mm hub-head and nipples about 3.5mm in a
    36-spoke cross-3 pattern."

    "My flimsy trials motorcycle's 18-inch rim rear wheel uses
    3.5mm x 3.5mm x 4.0mm hub-butted spokes, 165mm long with a
    roughly 7mm hub head and nipples about 6mm in a 36-spoke
    cross-2 pattern."

    "Here's a picture:

    http://home.comcast.net/~carlfogel/download/spokes.jpg

    Is the darker one the motorcycle spoke?

    Dear Jim,

    Yes, the motorcycle spoke is darker.

    Another clue is that it's twice as thick.

    In "Twins," Arnold Schwarzenegger is the twin with the
    accent, while Danny DeVito is the twin with the receding
    hairline. Otherwise, they're hard to tell apart.

    Roger Ebert

    (Drat! There goes another New Year's resolution about
    curbing my wicked tongue.)

    (To be fair, your are not the first poster to display a
    certain charming naivete about motorcycles on
    rec.bicycle.tech. For example, others have wondered in good
    faith whether motorcycles normally coast like bicycles.)

    (There is little excuse for my teasing. I often forget how
    my motorcycling expertise once led me to put the carburetor
    slides in backwards on a Yamaha 350 twin, a feat somewhat
    similar to putting a rear wheel into a bicycle frame with
    the derailleur on the wrong side.)

  9. Quoted message said:
    Jim Smith said:
    Quoted message said:

    "It may help readers unfamiliar with such things to describe
    the difference in spokes. My road bicycle's 700c rear rim
    uses 2.0mm x 1.8mm x 2.0mm double-butted spokes, 295mmm long
    with a roughly 4mm hub-head and nipples about 3.5mm in a
    36-spoke cross-3 pattern."

    "My flimsy trials motorcycle's 18-inch rim rear wheel uses
    3.5mm x 3.5mm x 4.0mm hub-butted spokes, 165mm long with a
    roughly 7mm hub head and nipples about 6mm in a 36-spoke
    cross-2 pattern."

    "Here's a picture:

    http://home.comcast.net/~carlfogel/download/spokes.jpg

    Is the darker one the motorcycle spoke?

    Dear Jim,

    Yes, the motorcycle spoke is darker.

    Another clue is that it's twice as thick.

    OK, thanks. I hadn't noticed the size difference.

  10. Peter Cole said:

    "jim beam" <[email hidden]> wrote in message
    news:[email hidden]...

    Quoted message said:
    Peter Cole said:

    I'm (again) not sure exactly what you're claiming.

    1) That the spoke forming operations would not create residual stress?
    2) That the manufacturer must have mitigated them?
    3) The manufacturer didn't, but they're too small to cause problems?
    4) That, if they exist, the "stretching" method won't mitigate them?

    An article that describes internal residual stresses in cold-formed

    springs

    Quoted message said:
    Quoted message said:

    and the use of mechanical stress relieving, complete with neutron

    (deep)

    Quoted message said:
    Quoted message said:

    scans.
    <http://www.ncnr.nist.gov/AnnualReport/FY1999/residual.pdf>

    peter, let's cut to the chase.

    first, neither you nor jobst have taken the trouble to quantify the
    effects of "stress relief".

    The amount of residual stress before and after stress relief could only be
    measured by the kind of technique described above. It's well known that
    bending introduces these residual stresses and that either mechanical
    (stretching/compressing, vibrating) or thermal (annealing, temp cycling)
    are the only ways to remove them (again, ref. article above).

    didn't i cite this article some time ago? i've had a copy on my hard
    drive for some time. i even read it too. don't suppose you care to
    comment on the fact that an auto spring is ferritic wire that relies on
    heat treatment for its strength rather than a bike spoke which is
    austenitic and relies on cold work? you care to reconcile apples to
    oranges?

    Quoted message said:
    Quoted message said:

    second, if residual stress is tensile on the inside of a spoke elbow &
    compressive on the outside of a spoke elbow, why do i have a collection
    of broken spokes, some showing fatigue initiation from the _outside_ of
    the elbow as well as some initiating from the inside?

    Residual stress is not the only factor in spoke breakage. If the spoke
    angle is wrong, the spoke will be loaded to near yield as it is tensioned,
    and then will load cycle around yield, causing fatigue. Jobst has explained
    all this.

    finally you [partially] respond to a specific issue. finally you admit
    that residual stress is not the only prairie oyster in the bucket. this
    is what i've been saying all along. the simplistic approach of "it must
    be stress relief!" is just plain inadequate. /still/ you do not
    acknowledge inclusion levels or surface finish and their significance in
    this equation. there's a reason the literature focuses on mechanical
    design, material quality & surface finish - they are found to be easily
    controlled factors that quantifiably mitigate fatigue! in the absence
    of data from you or anyone else to the effect that residual stress is
    both present & measured to be at a level to be an issue for this
    application, then you're just trying to make friction fit the facts.
    and yes, i do know a little about residual stress thanks - that's why i
    suggested the stress corrosion testing elsewhere in this thread - not
    something you've seen fit to comment on.

    and if you're trying to tell me that the guy that doesn't understand the
    difference between a material exhibiting strain aging and one that
    doesn't, the guy that doesn't understand hooke's law, is the guy to
    lecture me about residual stress, well peter, you've shown yourself to
    be willfully blinding yourself just for the sake of arguing.

    Quoted message said:
    Quoted message said:

    third, why would a manufacturer reveal their trade secrets? mavic
    aren't exactly forthcoming about their rim welding techniques, but that
    doesn't seem to be a problem.

    Jobst has seen the DT process anyway. The spokes are bent then put into a
    box. As he also points out, spokes frequently have threads rolled at the
    shop, no post-treatment there, either.

    hmm. can't say i care to rely on jobst's observations. he's still in
    denial about brinelled headsets, so i really doubt he's going to see
    anything other than what he wants to see.

    Quoted message said:
    Quoted message said:

    if you have access to neutron diffraction equipment, you should arrange
    some testing of different spoke manufacturer's product to quantify this
    stuff.

    Yeah, sure, I have it in my basement. The principles are the same in the
    article referenced above, and they had the neutron scanning equipment.
    Believe it or don't.

    as above, that article's relevant for that application - they do have
    reliability problems after all. what's not mentioned in this article
    however is the real objective; trying to make springs as cheap as
    possible, hence researching what they can do to cut costs with cheaper
    wire feedstock. if it's possible to get away without the vacuum
    degassed option by better heat treatment and a lower stress profile, you
    can bet that's what's going to happen.

  11. On Sat, 01 Jan 2005 20:47:24 -0600, Jim Smith
    <[email hidden]> wrote:

    [snip]

    Quoted message said:

    This still does not address WHY the practice leads to a more durable
    wheel. Even Jim Beam agrees that it does, it is the mechanism that is
    questioned. As Carl Fogel has pointed out, there are a number of
    possible explanations.

    Dear Jim,

    Jim Beam is known for his gentle and credulous nature.

    I'm not yet convinced that spoke squeezing does improve
    durability.

    There's widespread agreement that it does, but there was
    equally widespread agreement that tying and soldering did
    the same thing.

    As I point out nearby in a far-too-long reply to Andrew, his
    good-faith description of how Dave (I scorn last names)
    began making better wheels seems to include not just spoke
    squeezing, but reducing spoke windup.

    I'm damned if I can find a clear example of spoke squeezing
    improves things that doesn't raise the question of whether
    the credit is due to other simultaneous improvements in the
    quality of the stainless steel, the subtle design of the
    spoke head and elbow, manufacturing process variations,
    wheelbuilders gaining experience (windup), double-butted
    spokes, and other candidates.

    If anyone knows of actual testing that compares squeezed and
    unsqueezed spokes, it would be wonderful.

    Since the topic is so often infuriating, I should add that I
    believe that everyone who says that spoke squeezing makes
    their wheels last longer is perfectly sincere and that I
    think that it's quite likely that their more recent wheels
    do indeed last longer.

    I'm just wondering if they are honestly but mistakenly
    crediting the spoke squeezing with an improvement due to
    other factors.

    Ten years after the first edition of his book, Jobst
    mentioned that spokes had improved so much that it would
    have been difficult for him to write the same book:

    "It appears that the better spokes now available would have
    made the discovery of many of the concepts of this book more
    difficult for lack of failure data. I am grateful in
    retrospect for the poor durability of earlier spokes. They
    operated so near their limits that durability was
    significantly altered by the techniques that I have
    outlined."

    --Jobst Brandt, "The Bicycle Wheel," 3rd Edition, 1993,
    p.124

    Now it's 2005. Yet people are still saying that they are
    squeezing spokes to avoid failure rates that Jobst felt had
    become almost invisible twelve years ago.

    It's possible that spoke squeezing once had a marked effect,
    but that it's largely vanished during twenty-two years of
    steady improvements. People who squeeze spokes would find it
    hard to notice this, since they aren't about to stop
    squeezing spokes.

    Carl Fogel

  12. Quoted message said:

    It's a fascinating question, if only because we are so prone
    to--well, if not jumping to conclusions, but often taking
    surprisingly large steps on faith.

    Agreed.

    In summary, I believe all the factors you metion affect
    wheel (spoke) longevity. And yes, I agree it is dificult if
    not impossible to structure a valid test. (In my research
    here for old commentary on wheels I found only a 1975 rate
    sheet as quoted).

    For example, momentarily high tension will deform an
    aluminum hub shell under the spoke and I think we agree that
    alone is a positive factor. That necesarily occurs when
    spokes are pulled tightly.

    So I for one am sated. I know that my wheels are suitably
    stable and durable. Yesterday afternoon I built a
    while-you-wait track wheel for a gentleman from Chicgao in
    about 35 minutes while he watched and I have very confidence
    it will give years of service. Just like Peter. No different
    from the many consumers here on r.b.t. who do their own
    wheelbuilding.

    If you fel the need to separate and test the individual
    components of our current wheelbuilding method I think
    you'll have a difficult time of it.

    --
    Andrew Muzi
    www.yellowjersey.org
    Open every day since 1 April, 1971

  13. A Muzi said:
    Quoted message said:

    It's a fascinating question, if only because we are so prone
    to--well, if not jumping to conclusions, but often taking
    surprisingly large steps on faith.

    Agreed.

    In summary, I believe all the factors you metion affect
    wheel (spoke) longevity. And yes, I agree it is dificult if
    not impossible to structure a valid test. (In my research
    here for old commentary on wheels I found only a 1975 rate
    sheet as quoted).

    For example, momentarily high tension will deform an
    aluminum hub shell under the spoke and I think we agree that
    alone is a positive factor. That necesarily occurs when
    spokes are pulled tightly.

    So I for one am sated. I know that my wheels are suitably
    stable and durable. Yesterday afternoon I built a
    while-you-wait track wheel for a gentleman from Chicgao in
    about 35 minutes while he watched and I have very confidence
    it will give years of service. Just like Peter. No different
    from the many consumers here on r.b.t. who do their own
    wheelbuilding.

    If you fel the need to separate and test the individual
    components of our current wheelbuilding method I think
    you'll have a difficult time of it.

    Dear Andrew,

    Agreed.

    I expect that you--and Jobst and others--build darned good
    wheels.

    It's the irritatingly hard-to-frame-and-hard-to-answer
    questions that are most intriguing.

    And thanks again for that wonderful not-embalming-a-pharaoh
    comment about the amazing tubular preparation article that
    Dianne gave us.

    Happy New Year!

    Carl Fogel

  14. Andrew Muzi said:
    Quoted message said:
    Quoted message said:

    What do you predict will happen if two batches of stainless steel
    spokes, one "stretched", one not, are tested by boiling in a
    suitable pot of chemicals until the surface corrosion cracking
    associated with tensile stresses (internal in this case) leads to
    failure?

    Quoted message said:
    Quoted message said:

    These stresses are relatively uninteresting until spoke tension is
    added to them to bring them up to the level that they can
    contribute to failure. I haven't given that much thought, but I
    suspect the highest stresses won't be close to half yield stress
    and therefore undetectable by this method.

    ....

    Quoted message said:
    Quoted message said:

    The problem is that bending loads, especially at the elbows, are
    obscure because the length changes are so minute as to be
    immeasurable by reasonable means while the stresses are high. This
    is why this phenomenon escaped scrutiny previously and was believed
    to not exist.

    Quoted message said:
    Quoted message said:

    I find the criticism and disbelief of the information offered in
    "the Bicycle Wheel" to be what I anticipated and for which I was
    careful to include minutia that seemed to be insignificant... until
    the subject was attacked by the faithful of the status quo.

    Quoted message said:

    I, for one, cannot 'prove' it. But it is true.

    Quoted message said:

    Observation showed that even before The Book.

    Quoted message said:

    Our mid-seventies wheelbuilding rate shows $5 for 'wheel build'* and
    $8 for 'pro build, oil nipples, stress wheel twice'.

    Quoted message said:

    David Agger, our resident wheel master of the era, recommended
    bringing the oiled nipples to as high a tension as we could with a
    Surre spoke wrench, pressing the wheel over one's thigh and flexing
    the wheel as if to 'potato chip' it, then finishing the wheel by
    loosening nipples as much as possible. A second pass over one's
    thigh and we were effectively (the hard way) relieving the stresses
    and seating the spoke heads.

    As I have mentioned and explained in the book, bending the wheel does
    not significantly increase tension in spokes. This was an old method
    cued to release windup but it did nothing for residual stress. The
    wheel stressing to relax twisted spokes was common in most better
    wheel shops and it did some good for retaining wheel trueness, but it
    did nothing for durability.

    Quoted message said:

    A practical man's observation led to roughly the same prescription
    as Jobst's more thorough work and I'm sure others noticed these
    phenomena to some extent before he wrote.

    Quoted message said:

    After The Book we had a more clear understanding of that.
    David empirically noticed that bringing high-tension spokes
    to a momentarily ultra-high tension and then backing off the
    tension slightly made a more durable wheel.

    Quoted message said:

    * In those days we built every wheel in house, even steel
    rims with galvanized spokes.

    I recall that time and it was part of what inspired me to get to the
    source of these rituals and how to make wheels that lasted longer than
    the ones we rode. Most riders in those days had spare spokes taped to
    their Silca tire pump or to one of the seat stays because failures
    were so common. Stretching the spoke made an significant improvement
    in spoke durability for Robergel and Stella spokes, common then.

    Jobst Brandt
    [email hidden]

  15. "jim beam" <[email hidden]> wrote in message
    news:[email hidden]...

    Quoted message said:
    Peter Cole said:
    Quoted message said:

    >An article that describes internal residual stresses in cold-formed
    >><http://www.ncnr.nist.gov/AnnualReport/FY1999/residual.pdf>

    Quoted message said:

    didn't i cite this article some time ago?

    I don't think so, I Google'd and didn't see it, perhaps you can?

    Quoted message said:

    i even read it too.

    Really? That is surprising given your naive comments about Jobst's
    explanation of the creation of residual stresses.

    Quoted message said:

    don't suppose you care to
    comment on the fact that an auto spring is ferritic wire that relies on
    heat treatment for its strength rather than a bike spoke which is
    austenitic and relies on cold work? you care to reconcile apples to
    oranges?

    No, I don't, because I don't see your point. Perhaps you'd care to explain
    how this case is different, either in the mechanism of the creation of
    residual stress or the available options for mitigating it?

    Quoted message said:
    Quoted message said:

    Residual stress is not the only factor in spoke breakage. If the spoke
    angle is wrong, the spoke will be loaded to near yield as it is


    tensioned,

    Quoted message said:
    Quoted message said:

    and then will load cycle around yield, causing fatigue. Jobst has


    explained

    Quoted message said:
    Quoted message said:

    all this.

    finally you [partially] respond to a specific issue. finally you admit
    that residual stress is not the only prairie oyster in the bucket. this
    is what i've been saying all along. the simplistic approach of "it must
    be stress relief!" is just plain inadequate.

    No one said that.

    Quoted message said:

    /still/ you do not
    acknowledge inclusion levels or surface finish and their significance in
    this equation. there's a reason the literature focuses on mechanical
    design, material quality & surface finish - they are found to be easily
    controlled factors that quantifiably mitigate fatigue!

    This is all well known and not controversial. Jobst comments on this in his
    book by saying essentially that spoke quality has improved so much that in
    recent years he might not have had enough failures to recognize the
    residual stress mechanism.

    Quoted message said:

    in the absence
    of data from you or anyone else to the effect that residual stress is
    both present & measured to be at a level to be an issue for this
    application, then you're just trying to make friction fit the facts.
    and yes, i do know a little about residual stress thanks - that's why i
    suggested the stress corrosion testing elsewhere in this thread - not
    something you've seen fit to comment on.

    Yes, but you tried to equate bending with pure tension to prove that
    residual stress didn't exist, which revealed a very spotty understanding of
    the underlying science. There *must* be residual stress from a cold forming
    operation like spoke elbow forming (and it must be high), yet you still
    argue that it either isn't present, or its presence is questionable. If you
    understood the science, you'd not make these claims.

    Quoted message said:

    and if you're trying to tell me that the guy that doesn't understand the
    difference between a material exhibiting strain aging and one that
    doesn't, the guy that doesn't understand hooke's law, is the guy to
    lecture me about residual stress, well peter, you've shown yourself to
    be willfully blinding yourself just for the sake of arguing.

    Straw man. Let's stay away from discussing your (distorted) assessment of
    Jobst and stick to the science, shall we?

    Quoted message said:
    Quoted message said:

    Jobst has seen the DT process anyway. The spokes are bent then put into


    a

    Quoted message said:
    Quoted message said:

    box. As he also points out, spokes frequently have threads rolled at


    the

    Quoted message said:
    Quoted message said:

    shop, no post-treatment there, either.

    hmm. can't say i care to rely on jobst's observations. he's still in
    denial about brinelled headsets, so i really doubt he's going to see
    anything other than what he wants to see.

    Well, I'll ask you again (3rd time, anyway): What do *you* think the spoke
    manufacturers are doing to eliminate residual stress?

    Quoted message said:
    Quoted message said:
    Quoted message said:

    if you have access to neutron diffraction equipment, you should arrange
    some testing of different spoke manufacturer's product to quantify this
    stuff.

    Yeah, sure, I have it in my basement. The principles are the same in


    the

    Quoted message said:
    Quoted message said:

    article referenced above, and they had the neutron scanning equipment.
    Believe it or don't.

    as above, that article's relevant for that application - they do have
    reliability problems after all. what's not mentioned in this article
    however is the real objective; trying to make springs as cheap as
    possible, hence researching what they can do to cut costs with cheaper
    wire feedstock. if it's possible to get away without the vacuum
    degassed option by better heat treatment and a lower stress profile, you
    can bet that's what's going to happen.

    I think you need to reread the article. The whole point was to verify that
    a mechanical stress relieving process would be as effective as a thermal
    one (annealing) for a cold-formed part. The relevant part of that article
    (to the question of stress relieving spokes) was the actual (neutron) scan
    of the material cross section, showing the residual stress gradients, and
    the effect of momentarily high loading to bring the high stress locations
    into yield and a large reduction in residual stress. This is exactly the
    same process that Jobst is describing. The fact that Ford had to go to the
    trouble of actually doing a neutron beam stress profile before & after
    probably means that they must have some "jim beams" there, too.

  16. jim beam said:
    Quoted message said:

    Peter Cole wrote:

    Quoted message said:
    Quoted message said:

    This is all well known and not controversial. Jobst comments on this in his
    book by saying essentially that spoke quality has improved so much that in
    recent years he might not have had enough failures to recognize the
    residual stress mechanism.

    agreed, it's in the book, as a kind of footnote after the extensive
    missive incorrectly based on strain aging. but such qualifications are
    never repeated in all the king kong chest thumping that occurs on this
    forum or the "faq's". my point is that he's claiming, along with the
    invention of stress relief [sic] that he's the guy solely responsible
    for the ability to build reliable wheels. i'm saying that his relief
    "theory" is based on a number of fundamental misconceptions [which you
    consistently fail to address btw] which simply _don't stand relative to
    the work that precedes him in the spoke factory_.

    Dear Jim and Peter,

    Here's what Jobst said:

    "It appears that the better spokes now available would have
    made the discovery of many of the concepts of this book more
    difficult for lack of failure data. I am grateful in
    retrospect for the poor durability of earlier spokes. They
    operated so near their limits that durability was
    significantly altered by the techniques that I have
    outlined."

    --Jobst Brandt, "The Bicycle Wheel," 3rd Edition, 1993,
    p.124

    I'm beginning to wonder about something that should have
    occurred to me earlier. Could both sides be right, but
    looking at different eras?

    That is, in 1981 (I just looked at the copyright dates in my
    second edition, and that's the earliest) spoke-squeezing was
    applied to spokes so inferior to modern spokes that it
    worked in a blatantly obvious manner.

    By 1993 (third edition), spokes had improved so much that
    Jobst could say that the failure rate had dropped so much
    that the effect would be hard to see.

    And now in 2005, the spokes are so good that some people are
    wondering what the fuss was about.

    If this is even partly true, people who began squeezing
    spokes in 1981 would understandably believe that the process
    is valuable--it really worked back then, so why would they
    stop doing it?

    And new wheel-builders reading about the process would use
    it, find that their spokes lasted impressively, and assume
    that the squeezing was responsible, even when most of the
    improvement is due to better spoke manufacture.

    There are plenty of holes in this scenario, but it might
    explain some of the confusion.

    Carl Fogel

  17. Carl Fogel said:

    I'm beginning to wonder about something that should have occurred to
    me earlier. Could both sides be right, but looking at different
    eras?

    Quoted message said:

    That is, in 1981 (I just looked at the copyright dates in my second
    edition, and that's the earliest) spoke-squeezing was applied to
    spokes so inferior to modern spokes that it worked in a blatantly
    obvious manner.

    Quoted message said:

    By 1993 (third edition), spokes had improved so much that Jobst
    could say that the failure rate had dropped so much that the effect
    would be hard to see.

    Quoted message said:

    And now in 2005, the spokes are so good that some people are
    wondering what the fuss was about.

    Let me recall for you that I am riding wheels with spoke from 30 years
    ago, ones that have served well for all this time and are still
    working after close to 300,000 miles and many tours over the Alps,
    trails, dirt roads and what have you.

    Quoted message said:

    If this is even partly true, people who began squeezing spokes in
    1981 would understandably believe that the process is valuable--it
    really worked back then, so why would they stop doing it?

    As i pointed out, we regularly have reports here about people with
    good quality components (spokes) breaking in short order and requiring
    rebuilds. It is not as though the problem is gone. It has gotten
    better.

    Quoted message said:

    And new wheel-builders reading about the process would use it, find
    that their spokes lasted impressively, and assume that the squeezing
    was responsible, even when most of the improvement is due to better
    spoke manufacture.

    They would do well to consider these procedures as warranted,
    considering that stress concentrations must occur in spokes while
    wheel building. Otherwise, used spokes would not have a different
    elbow shape than new ones.

    Quoted message said:

    There are plenty of holes in this scenario, but it might explain
    some of the confusion.

    I think blowing smoke all over the issue, as you are, does not lessen
    confusion. Your "But what if..." writings are not helping.

    Jobst Brandt
    [email hidden]

  18. Quoted message said:
    Carl Fogel said:

    I'm beginning to wonder about something that should have occurred to
    me earlier. Could both sides be right, but looking at different
    eras?

    Quoted message said:

    That is, in 1981 (I just looked at the copyright dates in my second
    edition, and that's the earliest) spoke-squeezing was applied to
    spokes so inferior to modern spokes that it worked in a blatantly
    obvious manner.

    Quoted message said:

    By 1993 (third edition), spokes had improved so much that Jobst
    could say that the failure rate had dropped so much that the effect
    would be hard to see.

    Quoted message said:

    And now in 2005, the spokes are so good that some people are
    wondering what the fuss was about.

    Let me recall for you that I am riding wheels with spoke from 30 years
    ago, ones that have served well for all this time and are still
    working after close to 300,000 miles and many tours over the Alps,
    trails, dirt roads and what have you.

    that's 300k, selectively discounting the failures.

    Quoted message said:
    Quoted message said:

    If this is even partly true, people who began squeezing spokes in
    1981 would understandably believe that the process is valuable--it
    really worked back then, so why would they stop doing it?

    As i pointed out, we regularly have reports here about people with
    good quality components (spokes) breaking in short order and requiring
    rebuilds. It is not as though the problem is gone. It has gotten
    better.

    good quality? when i ask the spoke brand, respondees return with
    unknown names.

    Quoted message said:
    Quoted message said:

    And new wheel-builders reading about the process would use it, find
    that their spokes lasted impressively, and assume that the squeezing
    was responsible, even when most of the improvement is due to better
    spoke manufacture.

    They would do well to consider these procedures as warranted,
    considering that stress concentrations must occur in spokes while
    wheel building. Otherwise, used spokes would not have a different
    elbow shape than new ones.

    they have a different shape because you recommend "correcting the spoke
    line" - a practice of unproven benefit & even specified by at least one
    manufacturer as unsound.

    Quoted message said:
    Quoted message said:

    There are plenty of holes in this scenario, but it might explain
    some of the confusion.

    I think blowing smoke all over the issue, as you are, does not lessen
    confusion. Your "But what if..." writings are not helping.

    now who's blowing smoke???

    Quoted message said:


    Jobst Brandt
    [email hidden]

  19. On Sun, 02 Jan 2005 23:07:17 GMT,
    [email hidden] wrote:

    [snip]

    Quoted message said:

    I think blowing smoke all over the issue, as you are, does not lessen
    confusion. Your "But what if..." writings are not helping.

    Jobst Brandt
    [email hidden]

    Dear Jobst,

    What I write may not be helping you, but that's not the
    point of the exercise.

    Carl Fogel

  20. Wow lots of info here, thanks! I want to make the spokes myself simply
    because I enjoy making things, now I could go to DT et al, and get them
    to make me some long spokes to fit my wheel. But I then feel slightly
    guilty putting my name to the finished machine.. This may sound odd but
    I want to make the whole bike.
    It was a tap that I wanted as well to make nipples, Hanro tools in
    India were making me some taps, took my money and then.....
    I cant seem to find anyone anywhere to supply these?
    Joff

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