Process of our
brake disc
production Casting The system of forming cold-box consists of a mixture
of sand with two resins, this mixture is added to a tool (negative
part), where she is forced to pass through a gas called a catalyst to
accelerate the solidification of this mixture, resulting Mold the
mixture solidified. After making the molds, they are referred to the
melting and casting industry.
Fusion
In the induction
furnace is added to steel, pig iron (Material noble), scrap iron (used
disc brakes, engine housings …), return (chip and channel) and some
alloying elements (carbon, silicon .. .) for the ideal composition of
the alloy to the established line of
brake rotors and drums.
When temperature reaches 1200 ° C, it begins the process of fusion of
materials, where they then pass into a liquid. When the metal reaches a
temperature of approximately 1450 ° C, is taken to analyze a sample in a
device called spectrometer, 14 chemical elements and verify that all
these are “within” the range of tolerance. Leak It is the process where
the liquid metal is removed from the oven and added within the sand
molds, and after this process is cooled down (goes to the solid state).
Deburing
After
solidification of the parts, there is the separation of these returns
to the sand molding process to start the cycle. The parts then go to
step Blasting, receiving a discharge of steel shot with high pressure
(the goal of this operation is the removal of burrs and surface
impurities), then the parts are separated by code and counted.
Definition
Technical
Machining Machining is a mechanical process where the whole piece is
the result of a process of removing material. It is a relationship
between rotation and advancement, thus causing a removal of material. In
practice this means submitting a raw material to the action of a
machine and / or tool to be worked out .
CNC Machining
In
the machining process, parts go through CNC lathes (Computerized
Numerical Control) machines, high precision and production. This process
is the removal of material and machining, where the piece reaches a
speed of 1500 rpm (revolutions per minute) and an insert carbide
“cutting” measures specified in the piece. Hurricane In the drilling
process is carried out drilling of parts where these holes will be
useful to set the piece in the vehicle. Grinding After completion of the
holes, the pieces go through a process of finishing the track brake,
called grinding, following the same method of work of the CNC. This
finish is to ensure that the ski
brake disks
are parallel to each other. Balancing The balancing process is to leave
the piece with its mass distributed as uniformly as possible. The parts
are trapped in a machine that spins at 1100rpm, where sensors measure
when the play is unbalanced. If the result is found above the tolerance,
the play suffers from a small cut, thereby removing some material,
either by making the balancing.
Packaging and Shipping
After
completion of the entire process of manufacturing the parts, they are
taken to the washing process. In this process the parts are hung on
hooks that take parts of a product to spray degreaser used to remove
possible traces of grease or oil the part. At the end of this line, the
pieces are still immersed in a solution of protective oil, in order to
protect the piece of oxidation. After this immersion, the parts are
removed from the hooks, put into individual plastic bags and placed
inside the packaging, which are then carried to the inventory of
finished product.
