• 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

关键特征 铝

  1. 制动钳连接
  2. 刹车片表面
  3.  活塞孔
  4. 密封槽和防护帽槽
  5. 油孔

特性和加工要求

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

1. Brake caliper connection

Drilling tool with chuck

PCD Bore Milling Tool

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

2. 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

5. 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

Key Features Cast Iron

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

Features and Machining Requirements

El hierro fundido se utiliza generalmente en la producción en serie porque es rentable y puede utilizarse independientemente del concepto de máquina.

  • Componente relevante para la seguridad
  • Altos niveles de calidad
  • Gran cantidad de piezas

  • Alto volumen de virutas en función de la situación de la fundición
  • Márgenes de tolerancia estrechos debido a la capacidad del proceso y de la máquina en la producción en serie
  • Gran seguridad de proceso y precisión dimensional
  • Mecanizado multihusillo o máquina especial
  • Hierro fundido: Mayores fuerzas de mecanizado

1. Superficie de la brida (superficie de contacto)

Tools for drilling and milling

Combinación de taladrado y fresado ISO
  • Reduccion del tiempo de ciclo mediante el mecanizado de dos caracteristicas con una herramienta
  • Fresado circular economico de la superficie de la brida en un corte con insertos de corte intercambiables SPGN
  • Taladrado del orificio de conexion con broca de metal duro revestida para obtener altos valores de corte con una elevada vida util de la herramienta

2. Barreno principal

High performance reamer

HPR400 高性能铰刀
  • 用于精加工主孔的可互换切削刃
  • 端面的HPR可换头用于在磨损情况下 方便更换刀具
  • 以较低的刀具成本实现最高的生产率
  • 无需设置切削刃

3. 密封槽和防护帽槽

Circular milling tool

PCD圆盘铣削刀具
  • 立装技术
  • 加工具有严格公差要求的精密径向沟槽
  • 切削刃的最高径向跳动精度可实现最佳的 铣削结果
  • 采用切向技术的可转位刀片实现工艺可靠的 切削加工

4. U型面

Boring tool with indexable inserts

装刀片组合刀具
  • 主孔端面的预加工
  • U面控制切削
  • 用一把刀具经济地加工两个特征