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

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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.
Aluminium brake caliper for vehicles

Highlight aluminum machining

  1. Brake caliper connection
  2. Brake pad surface
  3. Piston bore
  4. Seal and protection gap groove
  5. Oil bores

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

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

Cast iron brake caliper for vehicles

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. Flange surface (contact surface)

Tools for drilling and milling

ISO bore milling combination

  • Reduced cycle times due to machining of two features with one tool
  • Cost-effective circular milling of the flange surface in one cut with SPGN indexable inserts
  • Drilling of the connection bore with coated solid carbide drill or high cutting data with high tool life

2. Main bore

High performance reamer

HPR400 high-performance reamer

  • Replaceable blades for fine machining the main bore
  • Face-side HPR replaceable head for easy tool change in case of wear and tear
  • Maximum productivity with low tool costs
  • No setting of cutting edges necessary

3. Seal and protection cap groove

Circular milling tool

ISO circular milling tool

  • Tangential technology
  • Machining delicate radial grooves with tight tolerance requirements
  • Maximum radial run-out accuracy of the cutting edges for optimal milling output
  • Process reliability in machining thanks to indexable inserts with tangential technology

4. U-face

Boring tool with indexable inserts

Drilling tool with indexable insert

  • Face-side pre-machining of the main bore
  • Control cut of U-surface
  • Cost-effective machining of two features with one tool