Brake Disc Production Line

A brake disc is a large component of a braking system. The friction material on the disc surfaces is responsible for braking performance. When a vehicle applies braking force, the disc’s temperature rises. This causes friction material to ‘cone’ due to thermal stress. Disc axial deflection varies according to the outer and inner radius. A poorly corroded or contaminated abutment will decrease disc performance and cause noise.

A number of processes are used to manufacture the discs. In brake disc production, a “lost-core” technology is used to define the cooling channel geometry. This protects the carbon from high temperatures, which would otherwise destroy it. In the next step, the ring is molded using different fiber components and friction layers on its exterior surface. The final machining process requires high technology and diamond tools because of the material’s hardness.

The process of casting a brake disc involves several stages. First, the mold is mirrored and a runner placed in the top box connects it to a bottom box. Then, a central bore is formed in the brake disc. Once this is formed, the casting process takes place in the top box. A runner attached to the top box will rise to form the hub and friction ring. After the runner is formed, the brake disc will be cast.

The process involves preparing aluminum molds that are specific to the brake disc shape. Aluminum cores are inserted into these gaps. This is a cooling method that helps to prevent disc overheating. It also prevents the disc from wobbling. ASK Chemicals is working with a foundry to improve its INOTEC ™ inorganic core binder system to make a disc with the right properties.

A thorough inspection is required to determine whether friction materials are in contact with the rotor. Brake discs wear due to the friction material’s geometric constraints. The friction material can’t make complete contact with the brake disc due to these constraints. In order to accurately determine how much contact the brake discs have with the rotor, it is necessary to measure the amount of bedding and the percentage of friction between the disc and the rotor.

The friction material’s composition has a profound influence on the disc’s performance. Strong deviations from the desired A-graphite, or D-graphite, will result in poorer tribological behavior and increased thermal load. Both D-graphite and undercooled graphite are unacceptable. In addition, a disc with a large percentage of D-graphite is not suitable. The friction material must be made with great care and precision.

The friction-induced wear rate is a complex process. In addition to friction-induced wear, the temperature and working conditions contribute to the process. The higher the friction-inducing material, the more wear the brake pad will experience. During braking, the friction-inducing material produces third bodies (called “third bodies”) that plow the pad and rotor surfaces. These particles then form iron oxide. This wears down the brake pad and rotor surfaces.