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Automotive – Brake Caliper

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Brake Caliper

Brake calipers are one of the main components of the disc brake system which houses the brake pads. They are a critical part of an automobiles braking system that squeezes the brake pads against the rotors to slow the spin of the wheels to stop the vehicle.
Brake calipers are commonly made of cast iron.
High machining quality is required to ensure safety, and it is essential to select the appropriate tool for each machining process.
Tungaloy offers stable and high-quality machining performance and comprehensive machining solutions with high production efficiency by utilizing the optimum cutting tools and machining know-how.

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

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full tooling solutionTechnical drawings with Tungaloy recommended solutions

Featured process

Plunge milling

Gang milling

Combination drilling with long overhang

Combination drilling with face and back side chamfering

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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Industries
Tungaloy’s tooling solutions for a wide variety of components

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