• A collage of different tools for machining brake calipers for vehicles.

Brake Caliper

The brake caliper is a safety-relevant component in the vehicle that is exposed to high thermal and mechanical loads. When the brake pedal is operated, brake fluid is sent to the piston of the brake caliper, which presses the brake pads onto the disc. Designs and the number of pistons vary depending on the vehicle type and motorisation.
Brake caliper made of aluminium with labeling

Component expertise Aluminium

  1. Brake Caliper Connection
  2. Oil Bores
  3. Brake Pad Surface
  4. Piston Bore
  5. Seal and Protection Gap Groove

Features and Machining Requirements

Solid aluminium brake calipers are used for weight reduction. They are ideal for high performance vehicles and heavy models that require a rapid brake response.

  • Safety-relevant component
  • High demand on quality
  • High quantities

  • High chip volume depending on casting situation
  • Tight tolerance fields due to process and machine capability in series production
  • High process reliability and dimensional accuracy
  • Multi-spindle machining or custom machine
  • Cast iron: Higher machining force

Brake Caliper Connection

Drilling tool with chuck

PCD Bore Milling Tool

  • Pre-machining and fine machining on one tool
  • Reverse circular milling of chamfer

Brake Pad Surface

A disc cutter for machining the brake caliper

PDC circular milling tool

  • High number of teeth for low cutting force
  • Burr-free milling due to perfect cutting-edge preparation

3. Piston bore

Drilling tool for machining a brake caliper

PCD boring tool

  • Fine machining of close diameter tolerances

4. Seal and protection cap groove

PCD circular milling tool for machining sealing and protective cap grooves

PCD circular milling tool

  • High form and dimensional accuracy due to laser-machined cutting edge

Oil Bores

Solid carbide drill bits for oil hole drilling

Solid Carbide Deep Drill

  • Process-reliable chip removal for bore depths 20xD
  • High cutting data due to optimal choice of coating

Brake caliper made of cast iron with labeling

Highlight cast iron machining

  1. Flange surface (contact surface)
  2. Main bore
  3. Seal and protection cap groove
  4. U-face

Features and machining requirements

Cast iron is frequently used in mass production as it is inexpensive and can be used irrespective of the machine concept.

  • Safety-relevant component
  • High demand on quality
  • High quantities

  • High chip volume depending on casting situation
  • Tight tolerance fields due to process and machine capability in series production
  • High process reliability and dimensional accuracy
  • Multi-spindle machining or custom machine
  • Higher machining forces

1. Superfície do flange (superfície de apoio)

Tools for drilling and milling

Combinação de fresamentode furações ISO
  • Redução do tempo de ciclo por meio de usinagem de duas características com uma ferramenta
  • Fresamento circular econômico da superfície do flange em um só corte com pastilhas intercambiáveis SPGN
  • Furação do furo de conexão com uma broca de metal duro integral revestida para dado de corte Elevado com uma longa vida

2. Furo principal

High performance reamer

HPR400 escareadores de alto desempenho
  • Arestas de corte intercambiáveis para a usinagemde acabamento do furo principal
  • Cabeça intercambiável HPR frontal para facilitar a troca de ferramentas em caso de desgaste
  • Máxima produtividade com baixos custos de ferramentas
  • Não é necessário ajustar as arestas de corte

3. Ranhura da tampa de vedação e proteção

Circular milling tool

Ferramenta de fresamento circular iso
  • Tecnologia tangencial
  • Usinagem de ranhuras radiais em filigrana com requisitos de tolerância estreitos
  • Máxima precisão de concentricidade das arestas de corte para resultados de fresamento ideais
  • Usinagem com segurança de processo graças às pastilhas intercambiáveis com tecnologia tangencial

4. U-face

Boring tool with indexable inserts

Ferramenta de furação com pastilhas intercambiáveis
  • Pré-usinagem do furo principal no lado frontal
  • Corte de controle da superfície em forma de U
  • Usinagem econômica de duas características com uma ferramenta