• 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

Key Features Aluminium

  1. Brake caliper connection
  2. Brake pad surface
  3. Piston bore
  4. Seal and protection cap 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

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

铸铁经常用于大规模生产，因为成本低廉， 并且不取决于机床方案都可以使用。

  • 安全相关部件
  • 高质量要求
  • 大批量

  • 高切除率取决于铸造情况
  • 由于批量生产的工艺流程和机床能力， 公差范围狭窄
  • 高工艺可靠性和尺寸精度
  • 多轴加工或专用机床
  • 铸铁：更高的切削加工力

1. 法兰面（接触面）

Tools for drilling and milling

ISO钻铣组合
  • 通过使用一把刀具加工两个特征以缩短 生产节拍时间
  • 使用SPGN可转位刀片一次切削对法兰表面 进行经济的圆盘铣削
  • 使用涂层整体硬质合金钻头钻削连接孔，可实现高切削值和长刀具使用寿命

2. 主孔

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