Hard-coated brake discs become a hot topic

JUNKER develops innovative and unique process for hard-coated brake disc production.

Alongside tire wear and the combustion of fossil fuels, brake abrasion contributes to the high particulate pollution caused by vehicles with combustion engines and electric or hybrid drives. The automotive industry needs innovative technical solutions to reduce this contamination.

A series process, in which laser cladding provides brake discs with high-quality corrosion protection and a wear-resistant hard coating, is now available to reduce brake-related particulate emissions is available. This innovative hard coating process leads to high-quality anti-corrosion and wear-resistance. 

Coating and grinding process

JUNKER offers brake disc coating and grinding innovations, allowing optimum friction pairing and reduced particulate emissions. During the grinding process, the brake disc is simultaneously ground on its parallel sides with two opposing grinding wheels. This state-of-the-art manufacturing process achieves perfect flatness and precise axial runout, and the coating thickness deviation is significantly reduced.

Highlights

• Shortest cycle time compared to competitive processes

• Optimal turnkey solution for coating and grinding

• Highly productive grinding process

• Tooling costs per brake disk at benchmark level

• Exact parallelism and axial runout Minimum thickness deviation (DTV)

• Lowest media consumption costs compared to competitive processes

• Reduced heat due to innovative grinding process leads to minimal distortion 

• Closed loop between coating system and grinding machine

Technical data JUDISC machine

• X-axis travel: 200 mm

• Z-axis travel: 650 mm

• Grinding wheel diameter: 500 mm

• Grinding wheel width: 90 mm

Technical data brake disc

• Friction lining outer diameter: min. 220 mm, max. 500 mm

• Total width: max. 150 mm

• Weight: max. 30 kg

Workpieces

• brake disc