Brakes and Pads
In contrast to standard stainless steel rotors, 2-piece rotors
combine a stainless steel rub area with an aluminium carrier (or
spider). The advantage of the alloy carrier are a cooler running disc as
aluminium has superior heat dissipation qualities to that of stainless
steel. This will also help to keep your pads, calliper and fluid cooler.
Aluminium is also lighter than stainless steel so a reduction in weight
can be expected.
CenterLock - The Shimano CenterLock system
eliminates the risk of stripping threads as there are no bolts to worry
about, just one centre locking ring. Installation and removal is also
simplified, although you will need a CenterLock tool. Lack of
mass-market adoption means that hub choices are limited and brake choice
may also be limited due to odd sized rotors. CenterLock rotors are also
generally slightly heavier and can come at a price premium.
Sintered brake pads are made up of hardened metallic ingredients
which are bound together with pressure and high temperature. The
advantages of this compound are better heat dissipation, a longer
lasting pad, better resistance to fading and superior performance in wet
conditions. The trade-offs are more noise, longer bed-in time and a
poor initial bite until the friction material has chance to warm.
Organic pads then are probably more suited to less aggressive riding in mostly dry conditions.
Hydraulic Brakes
Hydraulic brakes have transformed mountain bike disciplines ever
since their arrival. They enable us to go faster and stop harder. So
what is it about hydraulic brakes which make them the stoppers of choice
for professionals and trail riders alike? First a little bit about
hydraulics..
Hydraulics
The principle behind any hydraulic system is simple: forces that
are applied at
one point are transmitted to another point by means of an
incompressible fluid. In brakes we call this brake fluid of which there
are a few different varieties, but more on that later.
As is common in hydraulics the initial force which is applied to
operate the system is multiplied in the process. The amount of
multiplication can be found by comparing the sizes of the pistons at
either end. In braking systems for example, the piston driving the fluid
is smaller than the pistons operating the brake pads therefore the
force is multiplied helping you to brake easily and more efficiently.
Another convenient characteristic of hydraulics is that the pipes
containing the fluid can be any size, length or shape allowing the
lines to be fed almost anywhere. They can also be split to enable one
master cylinder to operate two or more slave cylinders if needed.
Components
Now that we understand hydraulics let's take a look at the
different parts which make up the hydraulic brake. The entire braking
system can be broken down into the following main parts:
- Master cylinder (Lever)
- Lines
- Fluid
- Slave cylinder (Caliper)
- Pads
- Rotor
Next we will explain these components in more detail.
Master Cylinder/Lever
The master cylinder, mounted to the handlebar, houses the brake
lever and together they produce the input force needed to push hydraulic
brake fluid to the slave cylinder (or caliper) and cause the brake pads
to clamp the rotor.
The lever stroke can be divided into 3 categories:
1.
Dead-stroke - This is the initial part of the
lever stroke when the primary seal pushes fluid toward the reservoir
before it goes on to push fluid on to the caliper via the brake lines.
2.
Pad Gap Stroke - This is the part between the
caliper beginning to push the pistons out of their housings and the pads
contacting the disc (as the dead space between the pads and rotor is
taken up).
3.
Contact & Modulation - The pads are now
clamping the rotor and by stroking the lever further, additional brake
power will be generated. Modulation is rider controlled and not
necessarily a characteristic of the braking system, however some brakes
may allow the rider to better modulate or control the braking forces
than others.
Open or Closed?
Master cylinder systems can be categorised into two groups - open and closed.
An open system includes a reservoir and bladder which allow for
fluid to be added or removed from the braking system automatically
during use. Reservoirs are the overflow for fluid which has expanded due
to heat produced by braking. The bladder has the ability to expand and
contract therefore as the fluid expands the bladder will compensate
without any adverse effects on the 'feel' of the brake. Reservoirs also
provide the additional fluid needed as the pads begin to wear resulting
in the need for the pistons to protrude further to compensate for the
reduced pad material.
A closed system also utilises a reservoir of brake fluid, however
the lack of an internal bladder to compensate for the expansion in brake
fluid and also to compensate for pad wear means that any adjustments to
the levels of brake fluid within the working system need to be made
manually.
Brake Lines
Hydraulic brake lines or hoses play the important role of
connecting the two main working parts of the brake, i.e. the master
cylinder and slave cylinder. We've already mentioned that hydraulic
systems can be very versatile in that their lines or hoses can be routed
almost anywhere so let's take a closer look.
Hose Construction
Hydraulic hoses are multi-layered in their construction and usually consist of 3 layers:
1.
Inner Tube - this layer of tubing is designed
to hold the fluid. Teflon is usually the material of choice here as it
does not react or corrode with brake fluid.
2.
Aramid (Kevlar) Layer - provides the strength
and structure of the hose. This woven layer is flexible and handles the
high pressures of the hydraulic system efficiently in that it should not
expand. Kevlar is also very light, which is a desirable attribute for
any cycle component, and also it can be cut easily and re-assembled
using standard hose fittings.
3.
Outer Casing - Serves as a protection layer for both the Kevlar layer and the bike frame to reduce abrasions.
The layers that make up an average hydraulic brake line
Steel Braided Brake Lines
Steel braided hoses can provide some advantages over standard
hydraulic hoses. Steel braided hoses are also usually a 3-layer
construction, the inner most layer contains the brake fluid and there is
an outer most layer which provides protection against abrasions. The
key difference is in the middle layer which is made up of a stainless
steel braid.
This stainless steel layer is designed to be more resistant
against expansion than that of standard lines. This can be an advantage
because when the brake lever is applied we want all of the force we put
in to be transferred to the caliper to cause braking. Any expansion in
the hydraulic line due to the pressures within will mean that some of
that pressure will not be transferred to the caliper. This will be
wasted effort and will require additional lever input by the rider to
compensate.
Steel braided lines may also be more appealing aesthetically. Many
riders believe that they look better than the standard, boring black
hoses that are supplied with the vast majority of brakes on the market.
2011 Formula R1 brake with braided brake lines
Brake Fluid
Hydraulic braking systems typically use one of two types of brake fluid -
DOT fluid or mineral oil.
An important thing to note before we get into the properties of each is
that the two fluids should never be mixed. They are made up of very
different chemicals and the seals within the braking system are suited
to either fluid and not both; therefor mixing or replacing one fluid
with the other is likely to corrode the internals of your brake.
On the other hand, mixing fluid from the same family is allowed
but not generally advised. For example you may mix DOT 4 fluid with DOT
5.1 without harming your braking system.
DOT Brake Fluid
DOT brake fluid is approved and controlled by the Department of
Transportation. It has to meet certain performance criteria to be used
within braking systems and is classified by its performance properties -
mainly its boiling points.
DOT 3, 4 and 5.1 brake fluid are glycol-ether based and are made
up of various solvents and chemicals. Glycol-ether brake fluids are
hygroscopic, which means they absorb water from the environment even at
normal atmospheric pressure levels. The typical absorption rate is
quoted to be around 3% per year. This water content within the brake
fluid will affect the performance by reducing its boiling point. Which
is why it is recommended to change brake fluid every 1-2 years at most.
The table below shows DOT brake fluid in its various derivatives
with its corresponding boiling temperatures. Wet boiling point refers to
fluid with water content after 1 years' service.
DOT Fluid |
Dry Boiling Point |
Wet Boiling Point |
DOT 3 |
205 °C (401 °F) |
140 °C (284 °F) |
DOT 4 |
230 °C (446 °F) |
155 °C (311 °F) |
DOT 5 |
260 °C (500 °F) |
180 °C (356 °F) |
DOT 5.1 |
270 °C (518 °F) |
190 °C (374 °F) | | |
DOT brake fluid is commonly used in Avid, Formula, Hayes and Hope brakes.
DOT 5 Brake Fluid
DOT 5 brake fluid (not to be mistaken for DOT 5.1) is very
different from other DOT fluids as it is silicone based and not
glycol-ether based. This silicone based brake fluid is hydrophobic (non
water absorbing) and must never be mixed with any other DOT brake fluid.
DOT 5 can maintain an acceptable boiling point throughout its
service life although the way in which it repels water can cause any
water content to pool and freeze/boil in the system over time - the main
reason that hygroscopic fluids are more commonly used.
Mineral Oil
Mineral oil is less controlled as a brake fluid, unlike DOT fluid
which is required to meet a specific criteria, therefore less is known
regarding its performance and boiling points from brand to brand.
Manufacturers such as Shimano and Magura design their brakes
around their own brand of mineral oil and should never be introduced to
DOT brake fluid as this will likely have an adverse effect on the
brake's seals.
An advantage of mineral oil is that, unlike most DOT fluids, it
does not absorb water. This means that the brake will not need to be
serviced as often, but any water content within the braking system could
pool and freeze/boil adversely affecting the performance of the brake.
Mineral oil is also non-corrosive meaning handling of the fluid and spillages are less of a concern.
Slave Cylinder/Calliper
The brake callipers reside at each wheel and respond to the lever
input generated by the user. This lever input is converted to clamping
force as the pistons move the brake pads to contact the rotor. Callipers
can be fixed by a rigid mount to the frame or floating. Fixed callipers
are combined with a fixed rotor which offers the only way of achieving
zero free running drag, one drawback of this design is that it is much
less tolerant of rotor imperfections. Floating callipers slide axially
and self-centre with each braking application.
Construction
Calliper construction can fall into two categories - mono-block
and two piece. The difference here is the 'bridge' design, the bridge is
the part of the calliper above the pistons which connects the two
halves together and provides the strength to endure the clamping forces
generated by the pistons.
1.
Mono-block - A mono-block calliper is actually
a one piece design formed from one piece of material. This can offer a
unique design and usually a lighter calliper as there is no need for
steel bolts joining both halves as in a two piece design. Also the lack
of a transfer port seal means there is one less opportunity for fluid
leaks at the half way seam. Servicing a mono-block calliper can be
tricky however and manufacturing and assembly are usually more
difficult.
2.
Two piece - These two piece callipers are
constructed as two separate halves and are then held together with steel
bolts which can provide additional strength over a mono-block design.
Servicing, manufacturing and assembly are simplified. Steel bolts and
additional seals are a means of additional weight and can be problematic
during servicing.
Exploded view of an Avid two-piece calliper design
Pistons
The pistons are the cylindrical components housed within the
calliper body. Upon lever input they protrude to push the brake pads
which contact the rotor. The number of pistons within a calliper or
brake can differ. Many hydraulic mountain bike brakes have 2 piston
callipers, some may have 4 pistons. Whereas some automobile brake
callipers have 6 or even 8 pistons. It is an important note that brake
power is not determined by piston quantity. A more reliable indicator
would be total piston contact area, e.g. 4 smaller pistons can be just
as powerful as 2 larger pistons.
Pistons can be either opposed or single sided. Opposed pistons
both protrude with lever input to push the brake pads equal amounts to
meet the rotor at both sides. Whereas single sided calliper pistons
stroke on one side and float the rotor to the opposite pad.
Brake Pads
Choosing the right brake pads can mean the difference between a
great and a poor performing brake. With the sheer diversity of brake pad
materials out there it is quite easy to get it wrong when the time
comes to replace the pads.
Let's jump right in and take a look at the different pad materials available and their properties.
Organic
Organic brake pads contain no metal content. They are made up of a
variation of materials which used to include asbestos until its use was
banned. These days you will commonly find materials such as rubber,
Kevlar and even glass. These various materials are then bonded with a
high-heat-withstanding resin. An advantage of organic pads is that
they're made up of materials that don't pollute as they wear. They are
also softer than other brake pads and as a result quieter. Also they
inflict much less wear upon the brakes' rotor. However organic pads wear
down faster and they perform especially poorly in wet gritty conditions
(UK readers take note :).
Semi-metallic
The metallic content of semi-metallic pads can vary from anything
between 30% and 65%. The introduction of metal content into the friction
material changes things slightly. It can improve the lifespan of the
pad quite significantly as metal wears slower than organic materials.
Also heat dissipation is improved as it is transferred between the pad
material and the backing plate. Some disadvantages can include increased
noise during use and the harder compound means increased wear on the
rotor.
Sintered
Ceramic
Ceramic brake pads are now seen more and more as an
alternative/upgrade mountain bike brake pad. Traditionally ceramic brake
pads would only be seen on high performance racing cars with brakes
which need to perform under intense heat. Heat like that is not usually a
problem for the average mountain bike brake and therefor for most
people ceramic pads would be overkill, however they might have other
desirable properties. The advantages of a ceramic material then is one
which can cope with extreme heat and keep performing strongly; this is
in part down to its great dissipating abilities. They also last longer
than other pads and noise is less of an issue. They're also easier on
brake rotors and produce a lot less dust that other brake pad compounds.
Rotors
Rotor size has a direct effect on braking power. The larger the
brake rotor the more power will be produced for any given input. This
can be a concern with larger rotors as they tend to have more of a
'grabby' feel making the brake more difficult to modulate.
Mountain bike rotors tend to range in size from 160mm to 203mm,
with smaller rotors geared toward XC type riding and larger rotors
designed for downhill riding.
Rotor Design
Important specifications of rotor design include hardness, thickness and rub area.
The material used to manufacture rotors must be hard and durable
due to the aggressive forces inflicted upon them from the pad friction
material. This has a direct impact on rotor wear.
Rotors must also have no thickness variations. Differences in
thickness around the circumference of the rotor can have undesired
effects on the braking system including pulsing as thicker and thinner
sections pass between the pads. Rotors also need to run true. Any
lateral wobble in the rotor during use can cause the brake to contact
the pads intermittently during riding.
Left to right: Formula Lightweight, Avid G3 Clean Sweep, Ashima AiRotor
A rotor's rub area can take the form of many different designs.
The three rotors above show this in detail. Rub area design can affect
the weight and strength of the rotor. It also has a direct effect on pad
lifetime.
Six Bolt or CenterLock?
The two types of rotor on the market today are ISO standard 6-bolt
rotors and CenterLock rotors. Both have their pros and cons.
6 Bolt - Readily available and interchangeable
between many brake models, this is the most common rotor fixing system
in use today and was adopted by all manufacturers in the late 1990's.
With no shortage of hub options, cross-compatibility with other products
is rarely a problem. However installation of six fixing bolts can be
cumbersome and there is always the risk of stripping a thread on fixing
bolts and hub mounting points.
Left to right: ISO standard 6-bolt, Shimano CenterLock
2-Piece Rotors
2-Piece rotors are supplied as standard with some higher priced
brake sets and can also be bought separately as a brake upgrade.
Formula 2-Piece Stainless Steel / Aluminium Rotor
Why Brakes Fail
Hydraulic brakes can fail or temporarily stop working for numerous
reasons such as a simple (but potentially catastrophic) fluid leak or
eventual brake fade after prolonged use. Knowing the causes of brake
failure can be valuable knowledge in curing the problem and preventing
future episodes.
As we know there are a couple of important principles behind
hydraulic brakes. Hydraulics rely on pressure within the system and
brakes rely on friction. Absence of either will result in failure of the
system. For example, a loss of brake fluid will decrease the pressure
within the system as the lever has nothing to transfer the input forces
to. On the other hand if brake fluid contacts the brake pads or rotor, a
loss of friction will occur due to the lubricating nature of brake
fluid.
The above examples should be obvious to most but what about the
less obvious causes of brake failure? Earlier we mentioned brake fade, a
term which I bet many of you have heard, however did you know that
there are multiple types of brake fade? Below is an overview of the
three different types.
Pad Fade
All friction material (the stuff your pads are made of) has a
coefficient of friction curve over temperature. Friction materials have
an optimal working temperature where the coefficient of friction is at
its highest. Further hard use of the brake will send the friction
material over the optimal working temperature causing the coefficient of
friction curve to decline.
This high temperature can cause certain elements within the
friction material to melt or smear causing a lubrication effect, this is
the classic glazed pad. Usually the binding resin starts to fail first,
then even the metallic particles of the friction material can melt. At
very high temperatures the friction material can start to vaporize
causing the pad to slide on a layer of vaporized material which acts as a
lubricant.
The characteristics of pad fade are a firm, non-spongy lever feel
in a brake that won't stop, even if you are squeezing as hard as you
can. Usually the onset is slow giving you time to compensate but some
friction materials have a sudden drop off of friction under high
temperatures resulting in sudden fade.
Green Fade
Green fade is perhaps the most dangerous type of fade which
manifests itself on brand new brake pads. Brake pads are made of
different types of heat resistant materials bound together with a resin
binder. On a new brake pad these resins will cure when used hard on
their first few heat cycles and the new pad can hydroplane on this layer
of excreted gas.
Green fade is considered the most dangerous as it can catch users
unaware given its quick onset. Many people would consider new brake pads
to be perfect and may be used hard from the word 'go'.
Correct
bedding-in of the brake pads
can prevent green fade. This process removes the top layer of the
friction material and keys the new pad and rotor together under
controlled conditions.
Fluid Fade
Fluid fade is caused by heat induced boiling of the brake fluid in
the callipers and brake lines. When used under extreme conditions heat
from the pads can transfer to the calliper and brake fluid causing it to
boil, producing bubbles in the braking system. Since bubbles are
compressible this results in a spongy lever feel and prevents the lever
input from being sent to the calliper.
The major cause of fluid fade is absorbed water from the air under
normal atmospheric conditions which reduces the boiling temperature of
the brake fluid. DOT brake fluid has an affinity for absorbing water
from the air around it, especially in hot humid conditions. This is the
main reason why we replace brake fluid on an annual basis.
Fortunately fluid fade has a gradual onset giving the user time to compensate for potential loss of braking.