Design of a composite mountain bike hydraulic disc brake

A. H.M.E. Rahman, David Pugh

Research output: Chapter in Book/Report/Conference proceedingConference contribution


The primary goal of the project is to design a hydraulic disk brake system for mountain bikes made from reinforced plastics. Hydraulic brakes offer significantly better performance for a mountain bike over traditional cable rim break or cable disk break. Nevertheless, people are unable to appreciate advantage because of the price. The traditional hydraulic disk brake systems are made of aluminum alloy. With a proper design, it may be possible to create a lever assembly and a caliper that would be competitive on price and weight. Often bike parts are judged by how much they weight, the less they weight, the more they are desirable. This is only true to a certain extent because lighter parts come with a premium price tag. The current project proposed that the injection molded brakes would be lighter because of the material being used and cost-effective because the manufacturing process can be utilized. Commercial reinforced plastic composites have been identified as lighter materials compared to aluminum alloy. Through an iterative design process, the final designs of lever assembly and caliper have been achieved. The stopping force has been determined considering the abrupt stoppage with a standard weight person riding the bike. Based on the stopping force the stress analyses were obtained using FEA simulation for master cylinder, slave cylinder, and lever. At the end, the final designs were chosen based on the stress analyses and manufacturability.

Original languageEnglish (US)
Title of host publicationDesign, Systems, and Complexity
PublisherAmerican Society of Mechanical Engineers (ASME)
ISBN (Electronic)9780791883518
StatePublished - 2019
EventASME 2019 International Mechanical Engineering Congress and Exposition, IMECE 2019 - Salt Lake City, United States
Duration: Nov 11 2019Nov 14 2019

Publication series

NameASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)


ConferenceASME 2019 International Mechanical Engineering Congress and Exposition, IMECE 2019
Country/TerritoryUnited States
CitySalt Lake City

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering


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