ANALYSIS OF MECHANICAL DISC BRAKE FOR ROAD

BICYCLE

A Design Output
Presented to the Faculty of Mechanical Engineering Department
College of Engineering, Architecture and Fine Arts
Batangas State University
Alangilan, Batangas City

In Partial Fulfillment
of the Requirements for the Degree in
Bachelor of Science in Mechanical Engineering

by

DIMAANO, MA. CECILIA S.

LEYNES, JOHN LEXMAR F.
MAGLINAO, MARTIN FONSY P.
MERCADO, DAN PHILIP Z.
NAVARRO, VON KENNETH, F.
RUBION, CHRISTIAN ANDREI G.

July 2021
 Abstract

Bicycle accidents have become the most prevalent road traffic dangers as the number of

bike riders has increased, resulting in mild or even serious injuries that can result in lasting medical

disability. Problematic braking systems are one of the reasons for these occurrences. This proposed

design and analysis of mechanical disc brakes for road bicycles has the machine components of

brake calipers, brake pad, brake cable connection, rear hub and disc brake. The obtained values in

theoretical calculation such as contact surface, final temperature, tangential force, and clamping

force were used in designing and simulating the mechanical disc brake rotor to evaluate the

strength of the disc brake rotor. The Von Mises Analysis in SolidWorks was used to conduct virtual

testing and analyze the design of the mechanical disc brake. The theoretical computation with

regards to simulation of the design of the disc brake has major similarities, specifically the pressure

that exists in the contact area during the braking process. It can be observed that the derived values

from theoretical analysis fall within the range of the simulated value, implying a limited margin

of error between the two. It deals with the principles regarding the stress strain analysis that is

basically used in the simulation via SolidWorks application.

ii
 TABLE OF CONTENTS

PAGE

TITLE PAGE i

ABSTRACT ii

TABLE OF CONTENTS iii

LIST OF TABLES iv

LIST OF FIGURES v

BODY OF REPORT

Introduction 1

Objectives 3

Design Strategy 4

Design Details 19

Design Verification 33

Cost Analysis 38

Conclusion 39

APPENDIX

Catalogue 40

Statement on the contribution of each member 45

References 45

iii
 LIST OF TABLES

Table No. Title Page No.

1 Parameters of the Bicycle 10

2 Properties of Grey Cast Iron 12

3 Summary of Results in Theoretical Computation 34

4 List of Total Machine Components Cost 38

iv
 LIST OF FIGURES

Figure No. Title Page No.

1 Brake Caliper and Brake Lining 20

2 Brake Pad 21

3 Rear Hub 23

4 Disc Brake 24

5 Assembly of Disc Brake 33

6 Stress Analysis 35

7 Strain 36

8 Displacement 37

v
Introduction
Cycling, often known as biking, is a popular recreational activity as well as a mode of

transportation in many situations. Around 12.4% of Americans cycled on a regular basis in 2016.

Over the last three years, the number of cyclists’/bike riders in the United States has risen from

about 43 million to 47.5 million in 2017. [1] Due to the increase in bike riders, bicycle accidents

became the most common road traffic hazards producing minor or even severe injuries that can

lead to permanent medical impairment. One of the reasons why these things happen is due to

problematic braking systems. Improving the safety for cyclists has been identified as a big

challenge in the road safety area. Sufficient amount of stopping power is required to adequately

stop a road bicycle.

Disc brakes offer greater stopping power, which can be helpful on long descents. Compared

to rim brakes, disc brakes don’t heat the rim which causes tires to blow on long descents. With

disc brakes, change in rotor sizes allows adjustment on how much braking power is needed. Lastly,

it is easier to use wider tires with disc brakes and work better than rim brakes in wet weather. To

summarize, disc brakes generally require less effort to stop a vehicle and it generates less heat

compared to rim brakes at the same amount of braking torque. The type of brake that will generate

the necessary stopping power will be disc brake since it allows the rider to apply less force to the

lever before the bike comes to a halt. In line with this, disc brakes are now overshadowing the

popularity of rim brakes. Disc brakes are designed for high velocity braking as well as in extreme

weather.

Keong, Leonn & Teoh, Choe Yung (2018), in their study entitled “Topology Analysis of

Bicycle Rim Brake Pad to Improve Braking Performance” asserted that a bicycle's braking

performance is critical since it is a critical device for stopping the bicycle in an emergency. To

1
produce a greater performance brake pad, brake pad materials made from various combinations of

high-end braking material are required, which raises the price of the brake pad.[2] As a result of the

high expense of high-performance brake pads, most users will choose not to acquire them. The

braking ability of traditional rim brakes (rubber brake pads) is inferior to that of a standard disc

brake system. They also added that rubber brake pads are widely available on the market and have

minimal friction and braking performance. Poor performance results in a lack of braking power,

and as a result, slippage and sliding may occur when braking.

Oertel et. al, stated that the most important mechanical difference between the rim and disc

brake is its acting radius, which is essential for the brake torque generated. Given a smaller acting

radius indicates that higher frictional force is needed to produce enough brake torque, which gives

the bicycle a stop. To achieve the same brake power, the friction force of a disc brake (rotor

diameter 160mm) produced by the friction of the brake pads and the brake disc is approximately

3.5 times greater than that of a rim brake. [3]

The operating principle of the design revolves around the principle of the single block or

shoe brake. Its main purpose is to apply enough frictional force on the disc which is connected to

the wheels of the bicycle. Its working principle involves applying external force to pull a string

attached to the braking system which moves the braking pad toward the disc. The contact between

the braking pad and the braking disc generates friction which stops the rotation of the wheel. The

important parameters for the design are the speed of the wheel, coefficient of friction between the

road and the wheel, and the force necessary to stop the wheel.

2
Objectives
The study aims to design and analyze a mechanical disc brake of a bicycle. Generally, disc

brakes are becoming a popular means of braking system for most bicycles. The parts of the

assembly to be considered are brake calipers, braking pads, brake lining, rear hub and the disc

brake. The design as well as the type of machine components are based on certain references and

standard measurements. The use of different sources will be a great help to understand more about

the analysis of disc brakes.

Specifically, this study aims to:

1. Identify the requirements conditions for the analysis of the mechanical disc brake such as:

1.1. System Component

1.2. Material Specifications

1.3. Dimension

2. Present the theoretical calculations for the evaluation of the mechanical disc brake for road

bicycle taking into consideration the following input parameters:

2.1. Braking Torque

2.2 Angular Velocity

2.3. Clamping Force

2.4. Final Temperature

3. Evaluate and compare the calculated pressure between the braking pad and the contact area

of the disc rotor with respect to:

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 3.1 Simulation Results

3.2 Allowable pressure on the disc rotor

Design Strategy
The working principle of a mechanical disc brake is based on the principle of the single

block brake where it uses a lever and only has one contact area in the disc brake rotor, unlike the

double block brake where it has a contact area in top and bottom or left and right of the disc brake

rotor. The brake lever from the handle of the bicycle, when pressed, produces force which is

transferred to the lever of the caliper by means of a cable. The force transmitted to the lever of the

caliper actuates the lever which pushes the piston inside the caliper which also makes the piston

pad move towards the disc brake rotor. The contact between disc brake rotor and piston pad

produces friction which makes the braking possible.[4]

A. Comparison of Rim Brake and Disc Brake

The recent inclusion of mechanical disc brakes has been considered and recommended over

the rim brakes due to the presence of brake pad against a surface on a wheel where disc brakes

apply a particular force on the rotor that acts towards the wheel to engage the braking process.

Compared to rim brakes, the force exerted is in the outer rim of the wheel which implies an indirect

contact of brake application causing a delay time of stopping power. Consistent braking using disc

brakes are determined by generating more braking power than the standard rim brakes in which

the riders will press less pressure to the levers. Additionally, the bike riders will be able to apply

force accurately to get the desired amount of braking. On the other hand, rim brakes are most

commonly used by the riders to engage because of its lighter usage, easier to repair and cheaper

prices.[5]

4
 Based on the Global Cycling Network (2017), wearing of wheels is one of the major

disadvantages of using the rim brakes. When the rims and wheels have worn out, the braking

performance is going to be compromised in which the bicycle would have a more risk of wheel

falling entirely. Since 2011, rim brakes started to fade in a way that the disc brakes have been

introduced into the public wherein most bike riders have also turned in using these mechanical

disc brakes due to its advantages and more reliable factors in braking. People used to adapt the

affordability as well as the essential mechanism and function of the disc brakes.

However, over time, the wear out becomes the factor of fading off the use of rim brakes.

From the director of BMC (Bicycling Manufacturer’s Company) of North America, the study

stated that the safer riding condition compared to rim brakes is very prone to the wearing out of

rims and wheels that leads to accidents and failure in the whole braking system. Rim brakes are

known for their inevitably wear causing defects on the surface of the rim. This continuously

developed usually when there happens to be exposure of rim into another mechanical component

which is mainly wheels of the bikes. Chemical reactions have also been identified to be one major

cause of worn out of the rim brakes due to the simultaneous contact between different materials

made of the bicycle’s mechanical component. The factors mentioned lead to the failure of the

braking performance of the bicycles. With these, the demand and supply of using mechanical disc

brakes rises over the rim brakes regardless of their cost.[6]

Generally, the statement of one of the owner and co-founders of Shimano company, Ben

Hillson, has stated that whatever type of brakes used, their life span will all be dependent on the

force applied and the proper cleaning of the braking system of the bikes. The introduction of disc

brakes legitimately conquers the bicycle brakes category in which rim brakes demand has fallen.

5
The consistent cleaning of the rims as well as its braking system is a must to be able to last its

braking capability and maintain the efficient performance. [7]

B. Input parameters
In designing the proposed mechanical disc brake for road bicycle, the preliminary

parameters must be considered to determine the desired dimension of the disc brake. The

parameters of the bicycle and the properties of the gray cast iron which is the material to be used

in designing the disc brake is stated below:

Table 1.0
Parameters of the Bicycle
PARAMETER Values

Weight of the bike 12 kg

Top Speed 18 km/hr

Wheel Diameter 559 mm, 27.5 in

Wheelbase 1080 mm

Rim Diameter 584.2 mm, 23 inches

Caliper Piston Diameter 17 mm

Body length, breadth, height 1639, 63.5, 1070 (mm)

Outer diameter of the rotor disc 180 mm

Inner diameter of rotor disc 146 mm

Most of the parameters of the bicycle are based on catalogs and standard sizes since the

other parts of the bicycle are designed based on standard sizes and if the sizes are to be customized,

it would be hard to find other parts that would be suitable for the custom sized parameters. The

commonly used standard sizes for a road bicycle are 26, 27.5, and 29, 26 being the smallest among

the three and 29 being the biggest. The 27.5 sized bikes favor the average sized bikers while the

29er favors taller riders. Thus, the bike size used for analysis is the 27.5 since it is the generally

6
used size for average bikers.[8] The 27.5 sized bikes have a wheel diameter of 27.5 inch or 559mm,

a rim diameter of 23 inches, or 584.2mm, a suitable wheelbase of 1080mm and a body length,

breadth, and height of 1639mm, 63.5mm, and 1070mm, respectively. These parameters were

measured using the dimensions of an actual bike that is personally owned. The weight of the bike

depends on the material used. The lightest material and strongest is carbon fiber but it is also the

most expensive which is not commonly used by average bikers because of the expensive price.

Another material used for bike frames is aluminum. Aluminum bike frames may be heavier than

carbon fiber but the price is lower significantly. Aluminum is known for being corrosion resistant,

fairly light (though typically not as light as carbon fiber), and having a high strength-to-weight

ratio. It’s also reasonably affordable, making it a popular choice for riders and racers on a budget.

For that reason, aluminum bike frame is considered in the design which commonly weighs 12kg

for the given size.[9]

The decision on rotor size comes down to stopping power and heat dissipation.

Commercially available disc brake rotors have standard size which ranges in 140 mm, 160 mm,

180 mm, and 203 mm. The larger the size of the rotor, the higher its price. Essentially a bigger

rider or those regularly descending big hills need more power to slow them down, so a bigger rotor

is required to dissipate the heat generated during braking. A larger rotor disc displays higher

stopping power and greater mass which allows for greater storage of heat. [10] It is beneficial to

have a greater capacity of heat since the kinetic energy absorbed was converted into heat when

braking occurs. Through this, brake pads can stay at operating temperatures. Considering the cost

and performance, a disc brake rotor with a diameter of 180 mm has been set as its dimension for

our theoretical and simulation analysis.

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 The only benefit from a functional perspective of the smaller rotor is a slight weight

reduction. The final size of the rotor is determined by considering the standard recommended sizes

and their respective costs for road bicycles which are always used on long descents, the bigger

rotor is recommended, thus for this type of application, a disc brake rotor with a diameter of 180

mm has been set as its dimension for our theoretical and simulation analysis.

The material that will be used for the disc brake is grey cast iron. Due to its outstanding

thermal handling capacity, damping qualities, wear and cost advantages, gray cast iron is the most

extensively utilized brake rotor material in the industry. Noise damping, resistance to abrasion,

thermal fatigue resistance, compactness, and other performance attributes are all found in gray cast

iron.[11] Basically, gray cast iron offers a variety of superior properties and cheap prices making it

the first choice of material to be used in disc brakes.

Table 2.0
Properties of Grey Cast Iron
Properties of disc brake Grey cast iron

Density 7000 Kg m3

Yield tensile strength 142 MPa

Compression-to-Tensile Strength Ratio 4.05

Young modulus, E 100 GPa

Thermal conductivity, K 54 W⁄m. K

Specific heat, 𝐶𝑝 586 J⁄Kg. K

Table 2.0 shows the properties of gray cast iron and overall, the values given in tables 1.0

and 2.0 will be utilized in calculating the theoretical computation for the design and analysis of

the mechanical disc brake of the road bicycle.

8
C. Design Equation

The design equations that will be utilized in theoretical computation of the design and

analysis of the mechanical disc brake for the road bicycle are stated below;

Kinetic Energy

The kinetic energy is a form of energy that an object or a particle has by reason of its

motion and depends not only on its motion but also on its mass. For the analysis of mechanical

disc brakes for road bicycles the mass of the rider and bicycle must be determined and also the

velocity that will be generated by the bicycle. The formula for the kinetic energy is given below:

1
𝐾. 𝐸 = 𝑚𝑣 2
2

𝑊ℎ𝑒𝑟𝑒: 𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑖𝑑𝑒𝑟 𝑎𝑛𝑑 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

𝑣 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

Maximum Friction Force

The friction force is a force generated by two surfaces that contact and slide against each

other. To obtain the maximum amount of friction force the normal force and coefficient of friction

must be determined. The normal force must be applied with the mass of the bicycle and

acceleration due to the gravity of the surrounding while the coefficient of friction will be

determined depending on the bicycle and the specific situation. Maximum Friction Force is given

by the formula:

𝐹𝑓 = 𝑓𝑁

𝑊ℎ𝑒𝑟𝑒 : 𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

9
 𝑁 = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ; 𝑚 𝑥 𝑔

Deceleration

The decrease in speed as the bicycle moves away from the starting point is described as

deceleration. Upon knowing the value of the maximum friction force and mass of the rider and

bicycle the deceleration can be calculated by dividing the maximum friction force to mass of the

rider and bicycle.

Deceleration is given by the formula:

𝐹
𝑎=
𝑚

𝑊ℎ𝑒𝑟𝑒 : 𝐹 = 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐹𝑜𝑟𝑐𝑒

𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑖𝑑𝑒𝑟 𝑎𝑛𝑑 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

Time taken to stop the bicycle

The time taken to stop the bicycle is given with the formula of velocity of the bicycle over

the computed value of the deceleration. The obtained value for the time taken to stop the bicycle

will be used to determine the stopping distance.

Time taken to stop the bicycle is given by the formula:

𝑉
𝑡=
𝑎

𝑊ℎ𝑒𝑟𝑒 : 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑎 = 𝑑𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

10
Stopping distance

The stopping distance is the distance travelled between the time when the body decided to

stop a moving bicycle and the time when the bicycle stops completely utilizing the values that

were generated in the previous formulas. The stopping distance depends on the factors such as the

road surface and reflexes of the cyclist. Stopping distance is given by the formula:

𝐷 = 𝑣𝑥𝑡

𝑊ℎ𝑒𝑟𝑒 : 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑡 = 𝑡𝑖𝑚𝑒 𝑡𝑎𝑘𝑒 𝑡𝑜 𝑠𝑡𝑜𝑝 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒

Another formula for the stopping distance is given by:

𝑣2
𝐷 = (𝑣 𝑥 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒) +
2𝑓𝑔

𝑤ℎ𝑒𝑟𝑒: 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

𝑔 = 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑑𝑢𝑒 𝑡𝑜 𝑔𝑟𝑎𝑣𝑖𝑡𝑦

Tangential braking force

The tangential braking force is a frictional force acting at the contact surface of the road

and the wheel of the bicycle. The formula for the tangential braking force can be obtained using

the value of the kinetic energy of the system over the average stopping distance. Tangential

braking force is given by the formula:

𝐾𝐸
𝐵𝐹𝑡 =
𝐷

11
 𝑤ℎ𝑒𝑟𝑒 : 𝐾𝐸 = 𝑘𝑖𝑛𝑒𝑡𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

𝐷 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑡𝑜𝑝𝑝𝑖𝑛𝑔 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒

Tangential force on each wheel
The force on an object in contact with a surface can be resolved into a component

perpendicular to the road surface at the given point and the component parallel to the surface. The

computed tangential braking force and the number of the wheel must be considered to calculate

the tangential force on each wheel with the formula of:

𝐵𝐹𝑡
𝐹𝑡 =
𝑛

𝑤ℎ𝑒𝑟𝑒 : 𝐵𝐹 = 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒

𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤ℎ𝑒𝑒𝑙

Braking torque on wheel

The brake torque is the force applied at the brake wheel to stop the motion of the bicycle.

Brake torque is essentially the power of the braking system. The brake caliper acts on the disc at

a certain distance from the hub center where it is also known as the effective radius. The braking

torque is given by the formula;

𝑇𝑤 = 𝐹𝑡 𝑥 𝑅

𝑤ℎ𝑒𝑟𝑒 : 𝐹𝑡 = 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑒𝑎𝑐ℎ 𝑤ℎ𝑒𝑒𝑙

𝑅 = 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑤ℎ𝑒𝑒𝑙

12
Effective rotor radius:

Effective rotor radius for a brake disc is calculated as the Mean radius of rotor. And it is

the meaning of rotor's outer diameter and inner diameter. Outer diameter of the rotor is the

greatest point at which brake-pads touch the rotor and vice versa.

Effective rotor radius is given by the formula;

𝑟𝑜𝑡𝑜𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑐𝑎𝑙𝑖𝑝𝑒𝑟 𝑝𝑖𝑠𝑡𝑜𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

𝑅𝑒 = ( )−( )
2 2

Braking torque on disc:

Braking Torque on Disc is given by the formula;

𝑅
𝑇𝑏 = 𝑇𝑤 𝑥
𝑟

𝑤ℎ𝑒𝑟𝑒 : 𝑇𝑤 = 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑤ℎ𝑒𝑒𝑙

𝑅 = 𝑤ℎ𝑒𝑒𝑙 𝑟𝑎𝑑𝑖𝑢𝑠

𝑟 = 𝑜𝑢𝑡𝑒𝑟 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟

Clamping force:

The force exerted by the braking pad on the contact area with the rotor disc of the braking

system. It is an important calculation because it allows clamps to have adequate capacity to resist

external force. The formulated values from the previous equation will be used to calculate the

clamping force which is the braking torque on disc over the quantity of coefficient of friction and

effective rotor radius.

13
 𝑇𝑏
𝐶=
2𝑥𝑓𝑥𝑅𝑒

𝑤ℎ𝑒𝑟𝑒 ; 𝑇𝑏 = 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑑𝑖𝑠𝑐

𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

𝑅𝑒 = 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑟𝑜𝑡𝑜𝑟 𝑟𝑎𝑑𝑖𝑢𝑠

Pressure at the contact area:

The pressure generated when the clamping force generated by the piston pads have

contacted the disc brake rotor during braking in the bicycle.

𝐶
𝑃=
2 𝑥 𝑤 𝑥 𝑟 𝑥 𝑠𝑖𝑛

𝑤ℎ𝑒𝑟𝑒 : 𝐶 = 𝑐𝑙𝑎𝑚𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒

𝑤 = 𝑤𝑖𝑑𝑡ℎ

𝑟 = 𝑟𝑜𝑡𝑜𝑟 𝑟𝑎𝑑𝑖𝑢𝑠

Angular velocity:

Angular velocity is given by the equation;

𝑊 =2𝜋𝑁

𝑤ℎ𝑒𝑟𝑒 : 𝑁 = 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒

Speed of the rotor:

Speed of the rotor can be calculated by:

𝑉 = (𝜋 𝑥 𝐷 𝑥 𝑁)

14
 𝑤ℎ𝑒𝑟𝑒 : 𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟

𝑉 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

Final temperature of the disc rotor:

The temperature generated by the disc brake rotor when kinetic energy was absorbed

during contact between the rotor and the braking pads.

𝐻𝑔 = 𝐾. 𝐸

where, Hg is also equal to;

𝐻𝑔 = 𝑚 𝑑 ∗ 𝐶𝑝 ∗ (𝑡2 − 𝑡1 )

Design Details
This section includes the machine components and also the theoretical computation which

is needed for the evaluation and analysis of the design.

A. Machine Components

The machine components that will be needed in the design and analysis of the mechanical

disc brake for the road bicycle are brake calipers, brake pads, brake cable connection, rear hub,

and disc brake. This section discusses the dimensions and material of each component.

Brake caliper and Brake Pads

Calipers in bikes are being connected from lever through lining into the brake system which

transport the pressure and force being exerted by the rider to apply braking. They are usually made

up of hard plastics. These are displayed with 2 hinged legs that are the primary constituents for

housing the brake pads and pistons. In addition, the caliper can be classified into a single symmetric

pivot or dual symmetric pivot, yet the proposed design uses a dual symmetric pivot that benefits

the efficiency of braking in the bike. It has better performance within the braking system and easier

15
to adjust if necessary. [12] Usually brake calipers are getting misaligned, which results in a metallic

grinding of noise during driving because of the loose caliper bolts during the spinning of the wheel.

Excess heat produced when driving bicycles is another factor of misaligning brake calipers.

Brake pads attached in the caliper helps to reduce friction level during contact and they are

made with rubber. It is located between the rotor and caliper that pushes a friction developed

against the braking surface on the revolving wheel by way of a hand-operated lever.[13] When

pressure is raised, the friction will also increase in the brake lever. The groove on the bike brake

caliper is proper to fit most road bike's tires, the brake caliper will quickly respond to the brake

handle, making the bike securely stop in a short time and the pads on the caliper will create little

harm to your tires, improving safety for your cycling trip.

Figure 1.0 Brake Caliper and Brake Lining

Resin and sintered materials are the commonly used type of piston pads in the bike industry.

Resin brake pads are made out of organic components such as glass, rubber, and fiber binders that

16
are glued together with resin. Metallic brake pads are metallic grains that are fused together under

high pressure. Resin pads are quieter and offer a stronger sense of bite when it comes to sensation.

They're better at controlling heat, but when the temperature rises, they may fade. They also wear

down faster, especially in muddy situations. For riders who primarily ride steep, lift-served

mountain riding, sintered pads are the best option.[14] Since road bikes are intended only for

traveling within roads and not suitable for trailing, we have considered the resin, which has

stronger bite as mentioned, specifically the rubber as the designated material for our braking pad

component.

Figure 2.0 Brake Pad

Brake Cable Connection

To transfer the force from the brake lever from the bike handlebar to the lever arm from

the caliper assembly, there must be some sort of connection. In this regard, a fluid may be used for

hydraulic connection and a cable may also be used for this purpose. The cable used for this purpose

is commonly made from stainless steel which is braided with each other. The purpose of this cable

17
is to transfer the force applied from the brake lever handle to the lever arm of the caliper assembly

in order to carry out the braking operation.

Rear Hub Bicycle

The primary function of the rear hub bicycle is to allow the wheel to rotate freely while

being linked to the frame. In addition, unlike the front hub, the rear hub plays a vital role in

transmitting pedaling effort to the back wheel, generally but not always through the chain and rear

sprocket.[15] It consists of an axle, bearings, and a body with connected wheel spokes. At least one

sprocket is used to transfer pedaling power to the back wheel. One geared (single speed, or even

fixed gear) hubs, internal gear hubs, and external derailleur hubs are the three fundamental hub

types with cassettes.

Bike shops offer rear bicycle hubs which are made up of steel, aluminum, or titanium

alloys. Steel is stronger compared to aluminum but the downside is that is more prone to

corrosion.[16] While titanium also displays high strength, its mass is 60% heavier than aluminum. [17]

Aluminum alloy is costly but a highly versatile metal that offers a lot of benefits, including being

lightweight, flexible, strong and resilient. Moreover, it is also corrosion resistant and also possesses

a high strength to weight ratio. [18] Considering all these, aluminum alloys will be utilized for the

rear hub bicycle in our design project.

Figure 3.0 Rear Hub

18
Disc brake

A disc brake is a kind of brake that creates friction by pressing pairs of pads against a rotor

or disc using calipers. [19] Disc brakes are located in the center of each wheel and work by pressing

a brake pad against a rotor fitted across the hub to stop the bike. Compared to rim brakes, disc

brakes have higher stopping power, which is especially useful in sloppy circumstances. Discs for

motorcycles, bicycles, and many cars often have holes or slots cut through the disc. This is done

for better heat dissipation, to aid surface-water dispersal, to reduce noise, to reduce mass, or for

marketing cosmetics. [20] Usually, disc brakes are made up of cast iron but it can also be made up

of composites. The diameter of the disc brake is 180 millimeters.

Figure 4.0 Disc Brake

B. Theoretical Computation

The design equations that will be utilized in theoretical computation of the design and

analysis of the mechanical disc brake for the road bicycle are stated below;

Computation for Kinetic Energy

Kinetic Energy is given by the formula:

19
 1
𝐾. 𝐸 = 𝑚𝑣 2
2

𝑊ℎ𝑒𝑟𝑒 : 𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑖𝑑𝑒𝑟 𝑎𝑛𝑑 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

𝑣 = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

The mass of the bicycle is 12kg while the mass of the rider is assumed to be 60kg.

Overall, the sum would be 82kg. The velocity of the bicycle is 50 km/hr. or 13.88889 m/s.

Substituting to the given equation:

1 𝑚 2
𝐾𝐾 . 𝐸 = (82 𝑘𝑔) (13.88888889 )
2 𝑠

𝐾. 𝐸 = 7908 .950617 𝐽

Computing for Maximum Friction Force:

Maximum Friction Force is given by the formula:

𝐹𝑓 = 𝑓𝑁

𝑊ℎ𝑒𝑟𝑒 : 𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

𝑁 = 𝑛𝑜𝑟𝑚𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 ; 𝑚 𝑥 𝑔

According to Jones and Childers, the coefficient of friction between tire and dry

road is 0.7.[21]

Substituting to the given equation:

𝑚
𝐹𝑓 = (0.7)(82𝑘𝑔) (9.81 )
𝑠2

𝐹𝑓 = 563.094 𝑁

20
Computing for Deceleration:

Deceleration is given by the formula:

𝐹
𝑎=
𝑚

𝑊ℎ𝑒𝑟𝑒 : 𝐹 = 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐹𝑜𝑟𝑐𝑒

𝑚 = 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑖𝑑𝑒𝑟 𝑎𝑛𝑑 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

Substituting to the given equation:

𝑚
563.094 𝑘𝑔 −
𝑠2
=
82 𝑘𝑔

𝑚
𝑎 = 6.867
𝑠2

Computing for the time taken to stop the bicycle:

Time taken to stop the vehicle is given by the formula:

𝑉
𝑡=
𝑎

𝑊ℎ𝑒𝑟𝑒 : 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑎 = 𝑑𝑒𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑖𝑐𝑦𝑐𝑙𝑒

Substituting to the given equation:

𝑚
13.88888889
𝑡= 𝑠
𝑚
6.867 2
𝑠

𝑡 = 2.022555539 𝑠

21
Computing for the stopping distance:

Stopping distance is given by the formula:

𝐷 = 𝑣𝑥𝑡

𝑊ℎ𝑒𝑟𝑒 : 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑡 = 𝑡𝑖𝑚𝑒 𝑡𝑎𝑘𝑒 𝑡𝑜 𝑠𝑡𝑜𝑝 𝑡ℎ𝑒 𝑣𝑒ℎ𝑖𝑐𝑙𝑒

Substituting to the given equation:

𝑚
𝐷 = (13.88888889 )(2.022555539 𝑠)
𝑠

𝐷 = 28.09104916 𝑚

Another formula for the stopping distance is given by:

𝑣2
𝐷 = (𝑣 𝑥 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒) +
2𝑓𝑔

𝑤ℎ𝑒𝑟𝑒: 𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

𝑔 = 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑑𝑢𝑒 𝑡𝑜 𝑔𝑟𝑎𝑣𝑖𝑡𝑦

An average rider might have a slower reaction time varying from 0.5 - 0.8 second or even

1 second.[22] So for the computation of reaction time, we used 1 second as the reaction time.

Substituting to the given equation:

𝑚 2
𝑚 (13.88888889 )
𝐷 = (13.88888889 𝑥 1 𝑠) + 𝑠
𝑠 𝑚
2 (0.7)(9.81 2 )
𝑠

22
 𝐷 = 27.93441347 𝑚

By considering the average stopping distance, we get;

28.09104916 𝑚 + 27.93441347𝑚
𝐷=
2

𝐷 = 28.01273131 𝑚

Now, to solve for the tangential braking force:

Tangential Braking Force is given by the formula:

𝐾𝐸
𝐵𝐹𝑡 =
𝐷

𝑤ℎ𝑒𝑟𝑒 : 𝐾𝐸 = 𝑘𝑖𝑛𝑒𝑡𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

𝐷 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑡𝑜𝑝𝑝𝑖𝑛𝑔 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒

Substituting to the given equation:

7908.950617 𝑁 − 𝑚
𝐵𝐵𝐹𝑡 =
28.01273131 𝑚

𝐵𝐹𝑡 = 282.3341476 𝑁

Solving for the tangential force on each wheel:

𝐵𝐹𝑡
𝐹𝑡 =
𝑛

𝑤ℎ𝑒𝑟𝑒 : 𝐵𝐹 = 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒

𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑤ℎ𝑒𝑒𝑙

Substituting to the given equation:

23
 282.3341476 𝑁
𝐹𝑡 =
2

𝐹𝑡 = 141.1670738 𝑁

Solving for braking torque on wheel:

𝑇𝑤 = 𝐹𝑡 𝑥 𝑅

𝑤ℎ𝑒𝑟𝑒 : 𝐹𝑡 = 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑒𝑎𝑐ℎ 𝑤ℎ𝑒𝑒𝑙

𝑅 = 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑤ℎ𝑒𝑒𝑙

As stated in table 1.0, the wheel diameter is 27.5 in or 0.559 m.

Substituting to the given equation:

0.559 𝑚
𝑇𝑤 = 141.1670738 𝑁 𝑥
2

𝑇𝑤 = 39.45619713 𝑁 − 𝑚

Solving for the effective rotor radius:

Effective rotor radius is given by the formula;

𝑟𝑜𝑡𝑜𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑐𝑎𝑙𝑖𝑝𝑒𝑟 𝑝𝑖𝑠𝑡𝑜𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

𝑅𝑒 = ( )−( )
2 2

The diameter of the rotor is 180 mm and the caliper piston diameter is 17 mm which

is both taken from table 1.0.

Substituting to the given equation:

. 18 𝑚 . 017 𝑚
𝑅𝑒 = ( )−( )
2 2

24
 𝑅𝑒 = 0.0815 𝑚

Solving for the braking torque on disc:

Braking Torque on Disc is given by the formula;

𝑅
𝑇𝑏 = 𝑇𝑤 𝑥
𝑟

𝑤ℎ𝑒𝑟𝑒 : 𝑇𝑤 = 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑤ℎ𝑒𝑒𝑙

𝑅 = 𝑤ℎ𝑒𝑒𝑙 𝑟𝑎𝑑𝑖𝑢𝑠

𝑟 = 𝑜𝑢𝑡𝑒𝑟 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟

Substituting to the given equation;

0.2795 𝑚
𝑇𝑏 = (39.45619713 𝑁 − 𝑚 ) ( )
0.09 𝑚

𝑇𝑏 = 122.5334122 𝑁 − 𝑚
Now, solving for the clamping force:

𝑇𝑏
𝐶=
2𝑥𝑓𝑥𝑅𝑒

𝑤ℎ𝑒𝑟𝑒 ; 𝑇𝑏 = 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 𝑜𝑛 𝑑𝑖𝑠𝑐

𝑓 = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛

𝑅𝑒 = 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑟𝑜𝑡𝑜𝑟 𝑟𝑎𝑑𝑖𝑢𝑠

Substituting to the given equation;

122.5334122 𝑁 − 𝑚
𝐶=
2 𝑥 0.7 𝑥 0.0815 𝑚

25
 𝐶 = 1073 .912464 𝑁

Now, solving for the pressure at the contact area:

𝐶
𝑃𝑃 =
2 𝑥 𝑤 𝑥 𝑟 𝑥 𝑠𝑖𝑛

𝑤ℎ𝑒𝑟𝑒 ; 𝐶 = 𝑐𝑙𝑎𝑚𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒

𝑤 = 𝑤𝑖𝑑𝑡ℎ

𝑟 = 𝑟𝑜𝑡𝑜𝑟 𝑟𝑎𝑑𝑖𝑢𝑠

Substituting to the given equation;

1073.912464 𝑁
𝑃=
2 𝑥 0.0025 𝑥 .09 𝑥 𝑠𝑖𝑛 15

P = 9.220620307 MPa

Now, to solve for angular velocity:

Angular velocity is given by the equation;

𝑊 =2𝜋𝑁

𝑤ℎ𝑒𝑟𝑒 : 𝑁 = 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒

Computing first for the speed of the rotor;

Speed of the rotor can be calculated by:

𝑉 = (𝜋 𝑥 𝐷 𝑥 𝑁)

𝑤ℎ𝑒𝑟𝑒 : 𝐷 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟

26
 𝑉 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦

Substituting the known values to the equation to solve for the speed of the rotor;

𝑚
13.88888889 = (𝜋 𝑥 0.559 𝑚 𝑥 𝑁)
𝑠

𝑁 = 7.908713133 𝑟𝑝𝑠

Now, we can compute for the angular velocity;

180
𝑤 =2𝜋𝑁𝑥( )
𝜋

180
𝑤 = 2 𝜋 (7.908713133 𝑟𝑝𝑠)( )
𝜋

𝑟𝑎𝑑
𝑤 = 49.69191016
𝑠

Solving for the final temperature of the disc rotor,

𝑔 = 𝐾. 𝐸

Also, heat generation, Hg is also equal to;

𝐻𝑔 = 𝑚 𝑑 ∗ 𝐶𝑝 ∗ (𝑡2 − 𝑡1 )

Therefore,

𝐻𝑔
(𝑡2 − 𝑡1 ) = ( )
𝑚 𝑑 ∗ 𝐶𝑝

𝐻𝑔
𝑡2 = ( ) + 𝑡1
𝑚 𝑑 ∗ 𝐶𝑝

The specific heat used is 586 J / kg - K which was stated in table 2.0.

Substituting the values from the solved parameters and assuming that initial temperature is

25°C,

27
 7908.950617 𝐽𝑜𝑢𝑙𝑒
𝑡2 = + 25°𝐶
𝐽𝑜𝑢𝑙𝑒
0.27995 𝑘𝑔 (586 )
𝑘𝑔 − 𝐾

𝑡2 = 73.21040457 °𝐶

C. Design Assembly

Brakes used in bicycles are mechanical single disc brakes which consist of major

components such as brake caliper, brake pad, piston, brake cable connection and the rear hub

portion of the braking system of the bicycle. The design parameters involved for simulation are

clamping force, pressure on the contact surface, temperature, angular speed, and braking torque.

The theoretical computation with regards to simulation of the design of the disc brake has major

similarities, specifically the pressure that exists in the contact area during the braking process. It

deals with the principles regarding the stress strain analysis that is basically used in the simulation

via SolidWorks application.

Figure 5.0 Assembly of Disc Brake

28
 Braking systems of the bicycles are designed with specific measurements to be able to

withstand its braking principles and proper assembly considering the material specifications and

dimensions. The assembly of components of disc brakes are working along with the other

components of the braking system.

Design Verification
This section included the summary of results in the theoretical computation, results in the

stress strain analysis from SolidWorks. The obtained values from the theoretical computation and

results in the simulation are needed for the evaluation of the design and analysis of the mechanical

disc brake for the road bicycle.

The table below shows the variety of parameters regarding the results in theoretical

computations that were involved in the disc brake of a bike.

Table 3.0
Summary of results in theoretical computation
Kinetic Energy 7908.950617 J

Maximum Friction Force 563.094 𝑁

Deceleration 6.867 m / s2

Time taken to stop the bicycle 2.022555539 𝑠

Stopping distance 28.01273131 𝑚

Tangential braking force 282.3341476 𝑁

Tangential force on each wheel 141.1670738 𝑁

Braking torque on wheel 39.45619713 𝑁 − 𝑚

Effective rotor radius 0.0815 𝑚

Braking torque on disc 122.5334122 𝑁 − 𝑚

Clamping force 1073.912464 𝑁

29
 Pressure in the contact area of the rotor 9.220620307 MPa

Speed of the rotor 7.908713133 𝑟𝑝𝑠

Angular velocity 𝑟𝑎𝑑

49.69191016
𝑠

Stress Strain Analysis

The simulation performed to analyze the design of mechanical disc brakes is Von Mises

Stress Analysis in SolidWorks. Stress is a fundamental quantity that is commonly used to

determine the strength of a design when subjected to load or pressure. Stress may manifest itself

in a variety of ways, making it difficult to assess stress in a straightforward manner when it

manifests itself in several ways. All of these pressures have a role in determining failure utilizing

Solid Works simulation findings.

30
 Figure 6.0 Stress Analysis
Figure 6 represents the stress distribution within the disc brake after its contact to the

braking pad. Different colors were used to define various values of the pressure applied in the disc

brake. The values of braking torque, clamping force, final temperature and angular velocity (see

Table 3) were used as input parameters to evaluate the material in the SolidWorks Simulation.

Frictional coefficient of 0.7 and grey cast iron material were also considered. Referring to the

figure, the contact area of the braking pad and the disc brake almost has a bluish light color.

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Figure 7.0 Strain

32
 Figure 8.0 Displacement
Figures 6 & 7 shows the displacement and strain across the disc brake as it receives pressure

from the braking pads as shown in Figure 7.

33
Results of the Simulation

Throughout the simulation, in Figure 7.0, the bluish light color is approximately 9.671 MPa

as seen in the stress plot. It can be compared to the computed value of the pressure of 9.220620307

MPa obtained from the theoretical calculation. In relation, it can be concluded that the obtained

values from both simulation and theoretical calculation have a small margin of error. Both these

values are in range of the typical brake line pressures during a braking which ranges from less than

800psi, approximately 5.5 MPa, under "normal" conditions, to as much as 2000psi, approximately

13.8 MPa, in a maximum effort, therefore it serve as our point of termination in our simulation. [23]

In figures 8 & 9, the generated values from the simulation are small and somehow can be neglected.

Therefore, we can conclude that the disc brake has the capability to withstand the pressure and

force applied by the braking and piston pads as the braking occurs within the braking system.

Cost Analysis
The cost analysis of the design is essential in selecting the appropriate machine components

which are commercially available in the market. This section includes the machine components,

brand name, model number and their corresponding cost for the design and analysis of the

mechanical disc brake for road bicycle.

Table 4.0
List of Total Machine Components Cost

Component Brand Model No. Cost (Php)

Rear hub Shimano FH-MT200-B 1500.00

Rotor Disc Brake Shimano Deore RT 64 1450.00

Caliper Shimano R561 Rear Short 1850.00

Total 4800.00

34
 The table above shows the appropriate machine component for the design of the

mechanical disc brake. The rear hub, rotor disc brake and caliper are selected from the Shimano

brand with a total cost of Php 4800.00.

Conclusion

The following conclusions stated below are based from the process of analyzing the results.

1. Upon the completion of the study, the mechanical disc brake has been successfully

modelled based on its material specification, system components and its dimension with

the aid of SolidWorks software. Throughout the process, it is established that thorough

analysis between each system component, dimension and its material specification must

be ensured to successfully conduct the analysis.

2. The obtained values in the theoretical calculations for the analysis of the mechanical disc

brake were utilized as the parameters for the simulation of the design project, specifically

braking torque, angular velocity, clamping force, and final temperature using SolidWorks.

These are necessary to determine the accurate value of allowable pressure needed in the

contact area.

3. Comparing the theoretical value of the pressure to the simulated and allowable value, it

can be seen that the obtained values from theoretical analysis lies between the range of the

simulated value, therefore it has a small margin of error between the two. The values

generated from the simulation and the theoretical computations are within the range of the

allowable pressure for bikes. In which we conclude that the disc brake has the capability

to withstand the pressure applied.

35
Appendix
Catalogue
1. Rear Hub

36
37
2. Disc brake rotor

38
3. Caliper

39
40
Statement on the Contribution of each team member
As we are given a design project that is needed to be accomplished, we conduct a google

meeting everyday wherein we use the service of google docs. In google docs, we both utilize

documents which are used for writing down the manuscript and also the spreadsheet which was

used for writing the formula and its computation. In that particular meeting, any changes to the

proposal are seen in real time. Through that, it is ensured that everyone in the group comprehends

every part of the design project. Each in the group do it simultaneously to ensure that each and

every part of our paper is understood, also its flow. So, we can give our opinions and corrections

on each part and for every contribution of the members.

Dimaano, Ma. Cecilia S. Leynes, John Lexmar F. Maglinao, Martin Fonsy P.

Group Member Group Member Group Member

Mercado, Dan Philip Z. Navarro, Von Kenneth F. Rubion, Christian Andrei G.

Group Member Group Member Group Member

41
References
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[2] Keong, Leonn & Teoh, Choe Yung. (2018). Topology Analysis of Bicycle Rim Brake Pad to

Improve Braking Performance. MATEC Web of Conferences. 217. 04004.

10.1051/matecconf/201821704004.

[3] Peter Barzel, et al. Die neue Fahrradtechnik: Material, Konstruktion, Fertigung. Bielefeld,

Germany : BVA Bielefelder Verlag, 2008. ISBN: 978-3-87073-322-3

[4] https://havefunbiking.com/disc-brakes-function-maintenance/

[5] https://www.realbuzz.com/articles-interests/cycling/article/the-pros-and-cons-of-using-disc-

brakes-on-a-road-bike/

[6] https://www.bicycling.com/bikes-gear/a33318651/should-we-mourn-the-death-of-rim-brakes/

[7] https://road.cc/content/feature/how-tell-when-your-wheel-rims-have-worn-out-and- how-

make-them-last-longer-238960

[8] https://www.rei.com/learn/expert-advice/mountain-bike-wheel-size.html

[9] https://www.bicycling.com/bikes-gear/a21784287/bike-frame-materials-explained/

[10] https://www.cyclingweekly.com/news/product-news/everything-you-need-to-know-about-

disc-brakes-202130

[11]https://www.researchgate.net/publication/339992540_Comprehensive_Analysis_on_the_Per

formance_and_Material_of_Automobile_Brake_Discs

[12] https://www.bicycling.com/bikes-gear/a20023166/the-beginners-guide-to-disc-brakes/

[13] https://www.cyclingweekly.com/news/product-news/everything-you-need-to-know-about-

disc-brakes-202130

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[14] https://www.bicycling.com/bikes-gear/a20023166/the-beginners-guide-to-disc-brakes/

[15] https://bit.ly/3eGk6MX

[16] https://www.wenzelmetalspinning.com/steel-vs-aluminum.html

[17] https://material-properties.org/aluminium-alloys-vs-titanium-alloys-comparison-pros-and-

cons

[18] https://www.azom.com/article.aspx?ArticleID=4192

[19] https://www.purposeof.com.au/purpose-of-industrial-disc-brakes/

[20] https://www.irjet.net/archives/V6/i8/IRJET-V6I854.pdf

[21] http://hyperphysics.phyastr.gsu.edu/hbase/Mechanics/frictire.html.

[22] https://drivesafety.com/managing-a-slow-reaction-time

[23] https://www.brakes-shop.com/brakepedia/general/brake-systems-and-upgrade-selection

43