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Machining braking systems

1. Electronic braking system

Controls functions such as ABS, TCS and ESC

2. Brake calliper

Deceleration of the vehicle during the braking process

         

1. Electronic braking system machining
ABS, TCS and ESC: on the cutting edge

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 somewhat of a challenge for machine operators and tools, and complex contours often have to be produced with absolute precision.

To prevent jams on the production lines, state-of-the-art tool concepts from the CERATIZIT Group release the brakes and guarantee a clear run for efficient production.

1. PCD stepped drill for the solenoid valve bore

Drilling the solenoid valve bore with maximum precision

  • Carbide base body with centring 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 cutter

Face milling the 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)
To product

3. PCD stepped drill for the pump interface

Drilling complex bore contour of the pump interface in a single operation

  • Carbide base body with centring 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

         

2. Brake calliper machining
Get a grip on service life and performance with cast iron and aluminium

Machining brake callipers 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. On top of that, the machine concepts also have an effect on the tool design in question. But no matter 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 callipers worldwide is what enables the CERATIZIT Group to surpass all requirements, from the simplest of carbide drills to a high-end solution with mechatronic tools.

1. Side and face milling cutter

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 stabilise 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 CERATIZIT cutting material CTCP325 guarantees maximum service life despite high cutting speed
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