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zh Manufacturing Process and Material Selection of Brake Calipers？
2024-12-24 16:49:59 hits：0
The manufacturing process of brake calipers is rather complex and mainly includes the following steps:
Model Making:
Based on the design drawings of the brake calipers, appropriate materials are used to create models. The traditional method is manual production of wooden models, but for the master molds with complex curved shapes, it has low efficiency and poor precision. Nowadays, CNC machining centers or the fused deposition manufacturing process in rapid prototyping technology are often adopted. For example, Beijing Yinhua Laser Rapid Prototyping and Mould Technology Co., Ltd. uses the MEM process to obtain the precision casting master molds of automotive brake calipers.
Material Selection of Brake Calipers:
Gray Cast Iron: It is the most common material. It has good casting properties and can be easily cast into complex shapes with relatively low cost. For instance, it is widely used in the brake calipers of many ordinary household cars and can meet the basic braking performance requirements.
Aluminum Alloy: The main advantage of this material is its light weight. For high-performance cars or new energy vehicles that pursue vehicle lightweight, aluminum alloy brake calipers are a good choice. It helps to reduce the unsprung mass of the vehicle and improve the handling and acceleration performance.
Stainless Steel: Stainless steel brake calipers have excellent corrosion resistance. If the vehicle often operates in harsh environments, such as high-humidity and high-salt seaside environments or needs to frequently wade through water, stainless steel brake calipers can effectively prevent rust and corrosion and ensure the service life and performance of the brake calipers.
Iron Melting:
First, batching is carried out. The raw material composition generally includes 20%-30% pig iron, 20%-30% low manganese steel, 50%-60% return material and the balance of vector adjustment alloys, etc. Then, the materials are charged and melted. After melting, stirring and slag skimming are carried out, and a pre-analysis sample is taken. Then, alloys are added to adjust the composition according to the results and stirred. Subsequently, nodularization treatment is carried out. The dosage, composition and reaction time of the nodularizer have strict requirements. Finally, it is left to stand and keep warm.
Casting:
The melted iron is poured into the model at an appropriate temperature to form a casting. The tapping temperature of the iron is generally controlled between 1560°C - 1580°C, and the pouring temperature is controlled between 1360°C - 1480°C. The casting process lasts no more than 12 minutes.
Shakeout, Cleaning and Inspection:
After the casting cools, shakeout is carried out to remove impurities such as sand grains on the surface. Then cleaning is carried out, including the removal of burrs and flash. After that, an inspection is carried out to check for defects such as blowholes, shrinkage cavities and cracks.
Finishing Machining:
Finishing machining such as milling, grooving, drilling and tapping is carried out on the inspected and qualified castings to meet the final size and precision requirements of the brake calipers.
Surface Treatment:
To improve the corrosion resistance and wear resistance of the brake calipers, surface treatments such as electroplating and spraying are usually carried out.
Assembly and Testing:
The processed various parts are assembled. After assembly, a comprehensive test is carried out, including braking performance and sealing tests to ensure that the quality and performance of the brake calipers meet the requirements.
Tiegu is a professional automotive parts supplier that provides high-quality brake calipers and other automotive components to users worldwide. Click to view brake caliper castings.
