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Machining braking systems

1. Brake caliper

Deceleration of the vehicle during the braking process

2. Electronic braking system

Controls functions such as ABS, TCS and ESC

3. Brake disc

Converts kinetic energy into heat

1. Brake calliper machining – exceptionally challenging milling

Machining brake calipers comes with a range of challenges. If nodular cast iron is used, then the service life of the tools is what counts, whereas if aluminium is used, it is the performance. What's more, the machine concepts also have an effect on the respective tool design. But regardless of whether a machining centre, a lathe or a special-purpose machine is used, our customers always receive the perfect solution for their particular application. 
A wide range of tools coupled with many years of experience in machining brake calipers worldwide is what enables us to surpass all requirements, from the simplest of carbide drills to a high-end solution with mechatronic tools.

1. Side and face milling cutters

Milling of pad face, disc clearance and dust cap face in one cut

  • Cycle time savings of approx. 50%
  • Tangential inserts for maximum performance
  • Surface completion in a single step or rough/finish machining is possible with a two-part milling disc with adjustable width
  • Cross-pitching of the inserts eliminates vibrations
  • Left and right-hand cutting can be used

2. Roughing boring bar

Roughing and chamfering the piston bore in a single operation

  • TOHT indexable inserts with POWER support chamfer technology enable high feeds and quiet running despite long overhang lengths
  • Additional solid carbide support elements at 90° to the indexable insert axis also stabilize the tool when countersinking the base of the piston bore
  • Additional tangential inserts for the control cut

3. Sealing ring groove milling cutter

Simultaneous machining of the sealing ring groove and clamping ring groove

  • Maximum precision thanks to ground cutter body and eroded adapter chambers 
  • Tool accuracy of +/-0.025 mm in diameter
  • No complicated adjustment
  • Wear-resistant CTCP325 carbide grade guarantees maximum service life despite high cutting speed

2. Drilling and milling - electronic braking systems

Electrification has been on trend for decades. Assistance technology such as antilock braking systems, traction control systems or electronic stability control all play a huge role in vehicle safety and are now included as standard in modern cars. In terms of quality, the holes in the control housing pose something of a challenge for machine operators and tools, and complex contours often have to be produced with absolute precision. 
To prevent traffic jams on the production lines, our state-of-the-art tool concepts release the brakes and guarantee a clear run for efficient production.

1. PCD stepped drills

Drilling the solenoid valve bore with maximum precision

  • Carbide base body with centering tip and brazed-in 5-step PCD blanks
  • Complex drilling contour
  • A cutting speed of up to 400 m/min can be achieved
  • Surface quality < Ra 0.8

2. HPC PCD milling cutters

Face milling exterior

  • Significant reduction in the primary processing time of up to 72%
  • 3D-printed milling ring for maximum number of cutting edges and perfect coolant supply
  • Maximum cutting speeds and service life for efficient production
  • Reduced burr formation and quieter running than conventional PCD milling cutters
  • PCD cutting edges can be re-lasered
  • Available as face mills, screw-in cutters or monoblock milling cutters from stock (dia. 10 – 100 mm)

3. PCD stepped drills

Drilling complex contour of the pump interface in a single operation

  • Carbide base body with centering tip and brazed-in PCD blanks
  • Highly wear-resistant PCD grade for maximum service life and performance
  • Lasered PCD contour for optimum surface results and contour accuracy

3. Turning and grooving brake discs with the most wear-resistant claw on the market

There is huge competition when it comes to machining brake discs and brake drums. And yet both components need to provide ever greater levels of performance at increasingly lower prices. High volume production in particular places high demands on application data and process security, in order to keep the unit costs as low as possible. In the car and commercial vehicle sector, grey cast iron is still predominantly used to manufacture brake discs. However, despite supposedly being easy to work with, the material has its challenges: In particular, the extremely fine, but just as abrasive, chip flow is a real test for clamping devices. At cutting speeds in excess of 1,000 m/min and with feeds of over 0.5 mm, normal steel clamping fingers do not last much longer than a single cutting edge. 
We counteract wear through the use of innovative solid carbide solutions with an unbeatable service life.

1. C-CLAMP 2.0 – double tool

Turning the braking surface and mounting surface in a single operation

  • All the advantages of the C-Clamp 2.0 clamping system
  • Cycle time savings thanks to simultaneous machining
  • Simultaneous machining of the braking surface and mounting surface reduces cycle time and magazine positions
  • Specially for "W" indexable inserts

2. Ceramic CX24 grooving system

Grooving the thermal groove

  • Efficient, process-secure, flexible
  • Cutting force is distributed into two components due to installation at an angle
  • Profiling can be carried out with side feed f=0.6 through 110° prism
  • Wedge shape as pull-out protection during reverse profiling
  • Secure attachment even with profile grooving inserts

3. C-CLAMP 2.0 – clamping system with solid carbide claw

Turning the braking surface

  • Virtually no wear on the claws
  • Maximum feeds and cutting speeds can be achieved
  • Solid hexagon head screw > no more contamination of the TORX® or hexagon socket screw key profiles
  • Larger contact surface > optimized surface pressure
  • 20 Nm tightening torque!

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