Automotive – Brake Caliper

Tooling concepts

• Ensures stability and accuracy
• Improved production efficiency by selecting the optimum tool for large and unstable D.O.C in cast iron machining
• Selection of tools and machining methods that maximize machine performance
• Use of head changeable tools to reduce tool replacement and tool management tasks

Process 1: Plunge milling

Benefits

• Economical 4-corner insert reduces insert cost
• Uses tough tangential inserts to minimize the risk of insert breakage, provides outstanding reliability
• One insert has both left and right cutting edges, and the type of inserts to be used can be aggregated
• Low-cutting force inclination cutting edge prevents chattering even with the low-rigidity component
• Prevents chatter with the special insert layout design that is optimal for brake caliper machining, extends tool life and improves productivity

• 4 corner tangential insert
• Right＆Left hand cutting edges on insert
• High rake angle with inclination edge

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Process 2: Gang milling

Feature＆Benefits

• Economical 6-corner insert reduces insert cost
• One insert has both left and right cutting edges, and the number of inserts to be used can be reduced
• Low-cutting force inclination cutting edge prevents chattering even with the low-rigidity component
• Apply gang milling strategy. Achieves stable machining in low-rigidity machining sections by canceling out cutting resistance in the axial direction.

• 6 corner double sided insert
• Right＆Left hand cutting edges on a insert
• High rake angle with inclination edge

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Process 3: Combination drilling with long overhang

Benefits

• Combination drill with counter boring using a DrillMesiter head
• Shorten processing time by performing drilling and counterboring at the same time.
• DMC provides high self centering capability for extremely reliable drilling even in long overhang operations
• DMC head provides stable hole diameter and hole drilling straightness

DMC head

• Innovative self-centering geometry
• No pre-drilling required in 12xD drilling operations
• Double margins provides superior surface finish and hole drilling straightness

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Process 4: Combination drilling with face and back side chamfering

Benefits

• Combination drilling with face and back side chamfering using a DrillMesiter head
• Shorten processing time by performing drilling and face and back side chamfering processes at the same time.
• DMP head with low cutting force latest grade AH9130  ensures long tool life in cast iron drilling

DMP head

• Smooth radius edge honing provides low cutting force
• latest grade AH9130 ensures long tool life in cast iron drilling

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