Bicycle brakes undergo extreme heating during descents and emergency stops, especially in high altitude or temperature conditions. This study aims to improve brake cooling using modular ducting systems designed via computer-aided design and evaluated with computational fluid dynamics and downhill testing. Five ducts combined into 13 configurations were tested for cooling performance. Laser scanning and 3D printing enabled the creation of easily installable and customizable ducts. CFD simulations and downhill tests showed that the best duct increased heat transfer rates from the disk and caliper by 5% and 20%, respectively, compared to no ducts. Crosswind CFD simulations indicated performance decline for the disk outside a negative 6° to positive 7.5° angle range (the caliper was enhanced above negative 6°). Downhill testing of duct D on a 1.2 km course, using multiple thermocouple measurements, showed approximately a 33 K (17%), 26 K (18%), and 5 K (23%) reduction in peak temperatures of the disk, pads, and caliper, respectively. The findings suggest that strategically designed ducts can enhance brake cooling, though real-world variability like crosswinds must be considered. This work contributes to improving braking efficiency and safety for competitive and recreational cyclists.
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