CAD DESIGN PROJECT
MOUNTAIN BIKE DISC
BRAKING SYSTEMS
DARYN MEGAW
DAVID GORDON
GARETH EDWARDS
DAVID BELLINI
STANDARD CALIPER DESIGN
POOR - MODERATE BRAKING PERFORMANCE
POOR IN WET CONDITIONS
USES STANDARD LEVERAGE RATIO
VEE BRAKE SYSTEM
 MODERATE - GOOD BRAKING PERFORMANCE
 APPLY PADS TO THE WHEEL RIM
 POOR PERFORMANCE IN WET CONDITIONS
 USES VEE BRAKE SPECIFIC LEVERS
DISC BRAKE SYSTEMS
 STRONG, EFFECTIVE BRAKING PERFORMANCE
 GOOD PERFORMANCE IN WET CONDITIONS
 CONSISTENT, SMOOTH APPLICATION OF BRAKING
 SLIGHTLY HEAVIER THAN CALIPER OR VEE BRAKE SYSTEMS
TYPES OF DISC BRAKES
Mechanical Design
Hydraulic Design
LESS EXPENSIVE THAN
COSTLY
SELF ADJUSTING
PRECISE AND POWERFUL
HYDRAULIC DISC BRAKE
SYSTEMS
WORKS WITH STANDARD RIM
BRAKE LEVERS
BRAKING
SIMPLE ADJUSTMENT AND
HIGHER MAINTENANCE
MAINTENANCE
REQUIRED
NOT AS SMOOTH OR
REQUIRES HYDRAULIC
POWERFUL AS HYDRAULIC DISC
SYSTEMS
LEVERS
IMPROVEMENT GOALS
INTERCHANGABLE HYDRAULIC / MECHANICAL UNIT
VARIATIONS IN BRAKE ROTOR OPTIONS
IMPROVED BRAKING SURFACES
EASE OF ADJUSTABILITY
BETTER MODULATION
LOW UNIT COST
OVERALL DESIGN ASPECTS
RECOGNIZE INTERNATIONAL STANDARDS
MANUFACTURING CONSIDERATIONS
EASE OF SERVICABILITY
WEIGHT FACTORS
AESTHETICS
COSTS
COMPONENT BREAKDOWN
COMPLETE SYSTEM
Rotors
& Hubs
Mechanic Hydraulic
Caliper
Lever
Hydraulic
Caliper
HUB & ROTOR Design
specification
USE OF SEALED BEARINGS THROUGHOUT FOR
MAINTENANCE PURPOSES
COMPATABLE WITH STANDARD QUICK RELEASES AND
20mm THROUGH AXLE STANDARDS
TOOLESS DISSASSEMBLY OF THROUGH
AXLE FOR WHEEL CHANGES
MUST USE HAYES ROTOR
MOUNTING STANDARD
HOPE 20mm FRONT HUB
MECHANICAL CALIPER DESIGN SPECIFICATION
LEVERAGE RATIO SUITED TO STANDARD VEE BRAKE
LEVERS
PROVIDE ADEQUATE BREAKING FORCE
REMOVABLE MECHANISM
GIVE ZERO PAD DRAG
PERFORM RELIABLY
HAYES MECHANICAL
CALIPER + ROTOR
HYDRAULIC LEVERS
 ERGONOMICAL DESIGN
 OPEN BATH DESIGN
 ROBUST DESIGN
HOPE HYDRAULIC
LEVER
HYDRAULIC DISC
MUST USE OPEN BATH SYSTEM
PROVIDE ADEQUATE
BRAKING FORCE
USE READILY
AVAILABLE
SEALS
HAYES HYDRAULIC
UNITS
MATERIALS SELECTION
THE HUBS - 6061 Al Alloy
 LIGHT WEIGHT
 HIGH STRENGTH
 WEAR RESISTANCE
 MACHINABILITY
HYDRAULIC FITTINGS
Barrel inserts- Mild Steel
WEAR RESISTANCE
RIGIDITY
THE ROTORS - Carbon Fibre
 THERMAL PROPERTIES
 CORROSION RESISTANCE
 COEFFICIENT OF FRICTION
 WEIGHT
CALIPER HOUSING - 6061 Al Alloy
LIGHT WEIGHT
HIGH QUALITY SURFACE FINISH
HIGH RIGIDITY
MECHANICAL FITTINGS - Mild Steel
Pistons - Brass
GOOD BEARING QUALITY
HIGH STRENGTH
HIGH WEAR RESISTANCE
Rear hub assembly
Rear hub section
Rear hub explosion
Rear hub explosion
Rotor center
Rotor assembly
Rotor explosion
Bearing explosion
Front hub assembly
Front hub section
Front hub /
through axle
Front hub section
Lever front view
Lever rear view
Wireframe view
Wireframe view
Hydraulic Lever
Lever explosion
Lever section
How a hydraulic
lever works
Caliper assembly
Wireframe
views
interchangeable insert
Hydraulic insert
Mechanical insert
Caliper explosion
Caliper assembly
Full assembly
Full assembly
Full assembly
Full assembly