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

制动钳

制动钳是车辆中安全相关部件，承受高热应力和机械应力。当踩下制动踏板时，制动液被 引导至制动钳的活塞，将刹车片压靠向制动盘上。根据车辆类型和电机的不同，结构形式 和活塞的数量也有所不同。
Brake caliper made of aluminium with labeling

Highlight aluminum machining

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

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

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

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