The Braking

System

James Aranda
Valeria Garcia
Justin Imel

Braking System
Overview

Braking System
Components

Master Cylinder
Piston
Caliper
Brake pad

Master Cylinder

Material: Zarmak 3, which is Zinc Alloy 3

Manufacturing Process:

Die Casting
Trimming scrap
Threaded holes by Milling
Deburring with grinder
Bathing in parts cleaner
Etch bath
Painting
Assemble

Primary piston assembly, Secondary Piston Assembly, Lock

Ring, and an Adjustment Screw

Piston

Material: 6061, Forged Aluminum

Manufacturing Process:

Closed die forging

Trimmed then cut with lathe
Debbured with grinder
Bathed in parts cleaner
Polished

Caliper

Material: Alumina
Manufacturing Process:
Mix materials
HIP
Machine to do finishing
processes like drill holes.

Laser etch

Brake Pad

Material: Aluminum Silicon

Manufacturing Process:
Permanent mold casting
Machining to get rid of excess material from
mold cavity and to create holes for bolts
Electrostatic Coating

End

References:

http://www.brakecylinder.com/oddsandends.htm
http://
www.autotrucktoys.com/ram/Mopar-Dodge-Ram-OE-Replacement-Brak
e-Pads-PRD35698.aspx
http://bmwe32.masscom.net/sean750/caliper/RebuildBrakeCaliper.htm
http://www.eliseparts.com/products/show/2/12/brake-master-cylinder/
http://www.carparts.com/brakes.htm
http://www.scooterparts4less.com/Moped_Web/Moped_YY250T_FrontRe
ar_BrakePad_logo.jpg
http://bmwe32.masscom.net/sean750/caliper/newBrakeCalipers.jpg
http://www.liveoffroad.com/product/1409/jeep-brakes-master-cylinderpower-boosters-parts-accessories-cj-wrangler
http://makinaparts.com/lang-en/ktm/1780-50313008200-hand-brake-cyl
inder-repair-kit-11mm-piston-ktm-sx-125-sx-250-sx-400-sx-450-sx-52
0-sx-525-racing-4t-.html
http://forums.nicoclub.com/clutch-master-cylinder-write-up-t346562.h