CAD DESIGN PROJECT MOUNTAIN BIKE DISC BRAKING SYSTEMS

CAD DESIGN PROJECT MOUNTAIN BIKE DISC BRAKING SYSTEMS DARYN MEGAW DAVID GORDON GARETH EDWARDS DAVID BELLINI

STANDARD CALIPER DESIGN b. POOR - MODERATE BRAKING PERFORMANCE b. POOR IN WET CONDITIONS b. USES STANDARD LEVERAGE RATIO

VEE BRAKE SYSTEM b MODERATE - GOOD BRAKING PERFORMANCE b APPLY PADS TO THE WHEEL RIM b POOR PERFORMANCE IN WET CONDITIONS b USES VEE BRAKE SPECIFIC LEVERS

DISC BRAKE SYSTEMS b STRONG, EFFECTIVE BRAKING PERFORMANCE b GOOD PERFORMANCE IN WET CONDITIONS b CONSISTENT, SMOOTH APPLICATION OF BRAKING b SLIGHTLY HEAVIER THAN CALIPER OR VEE BRAKE SYSTEMS

TYPES OF DISC BRAKES Mechanical Design Hydraulic Design b. LESS EXPENSIVE THAN b. COSTLY b. SELF ADJUSTING b. PRECISE AND POWERFUL HYDRAULIC DISC BRAKE SYSTEMS b. WORKS WITH STANDARD RIM BRAKE LEVERS BRAKING b. SIMPLE ADJUSTMENT AND b. HIGHER MAINTENANCE REQUIRED b. NOT AS SMOOTH OR POWERFUL b. REQUIRES HYDRAULIC LEVERS AS HYDRAULIC DISC SYSTEMS

IMPROVEMENT GOALS b. INTERCHANGABLE HYDRAULIC / MECHANICAL UNIT b. VARIATIONS IN BRAKE ROTOR OPTIONS b. IMPROVED BRAKING SURFACES b. EASE OF ADJUSTABILITY b. BETTER MODULATION b. LOW UNIT COST

OVERALL DESIGN ASPECTS b. RECOGNIZE INTERNATIONAL STANDARDS b. MANUFACTURING CONSIDERATIONS b. EASE OF SERVICABILITY b. WEIGHT FACTORS b. AESTHETICS b. COSTS

COMPONENT BREAKDOWN COMPLETE SYSTEM Rotors & Hubs Mechanic Caliper Hydraulic Lever Hydraulic Caliper

HUB & ROTOR Design specification b. USE OF SEALED BEARINGS THROUGHOUT FOR MAINTENANCE PURPOSES b. COMPATABLE WITH STANDARD QUICK RELEASES AND 20 mm THROUGH AXLE STANDARDS b. TOOLESS DISSASSEMBLY OF THROUGH AXLE FOR WHEEL CHANGES b. MUST USE HAYES ROTOR MOUNTING STANDARD HOPE 20 mm FRONT HUB

MECHANICAL CALIPER DESIGN SPECIFICATION b. LEVERAGE RATIO SUITED TO STANDARD VEE BRAKE LEVERS b. PROVIDE ADEQUATE BREAKING FORCE b. REMOVABLE MECHANISM b. GIVE ZERO PAD DRAG b. PERFORM RELIABLY HAYES MECHANICAL CALIPER + ROTOR

HYDRAULIC LEVERS b ERGONOMICAL DESIGN b OPEN BATH DESIGN b ROBUST DESIGN HOPE HYDRAULIC LEVER

HYDRAULIC DISC b. MUST USE OPEN BATH SYSTEM b. PROVIDE ADEQUATE BRAKING FORCE b. USE READILY AVAILABLE SEALS HAYES HYDRAULIC UNITS

MATERIALS SELECTION THE HUBS - 6061 Al Alloy b LIGHT WEIGHT b HIGH STRENGTH b WEAR RESISTANCE b MACHINABILITY HYDRAULIC FITTINGS Barrel inserts- Mild Steel b. WEAR RESISTANCE b. RIGIDITY THE ROTORS - Carbon Fibre b THERMAL PROPERTIES b CORROSION RESISTANCE b COEFFICIENT OF FRICTION b WEIGHT CALIPER HOUSING - 6061 Al Alloy b. LIGHT WEIGHT b. HIGH QUALITY SURFACE FINISH b. HIGH RIGIDITY MECHANICAL FITTINGS - Mild Steel Pistons - Brass b. GOOD BEARING QUALITY b. HIGH STRENGTH b. HIGH WEAR RESISTANCE