EMAG's New Double-Sided Grinding Machine Designed for Hard-Coated Brake Discs
The VLC 450 DG is designed for rigidity and durability to meet the high demands of batch production.
In March 2024, the European Parliament adopted the EURO 7 standard. For the first time, it sets limit values for brake particle emissions for cars and light trucks. Irrespective of the drive system used, a switch to new brake technology is necessary.
The most promising approach to reducing particulate matter in the braking system is currently the use of hard-coated brake discs. The friction layer consists of a soft matrix with carbides, e.g. titanium carbide. Due to the fundamentally different cutting behavior of the two materials, the design and development of suitable grinding tools and the design of the static and dynamic machine properties as well as the spindle drives is very complex.
VIDEO: VLC 450 DG: Grinding of hard coated Brake Discs
EMAG has introduced a solution: the VLC 450 DG -- a double-sided surface grinding machine for hard-coated brake discs. This machine was developed with a focus on rigidity and durability in order to meet the high requirements of batch production.
Both grinding spindles are arranged in parallel, the brake disk is machined in cross grinding.
The vertical design ensures optimum removal of the hard material particles without damaging the machine axes and excellent accessibility for set-up and maintenance work. Workpiece handling by means of a feed shuttle and pick-up spindle simplifies automation and offers short chip-to-chip times.
The machine concept is based on decades of experience in the manufacture of vertical turning and grinding machines. An intelligent sensor concept enables adaptive process control. This makes the VLC 450 DG a reliable solution for brake disc production that meets the highest productivity levels and workpiece quality requirements.
Brake disc after grinding
During three years of successful prototype testing, the first double-sided surface grinding machine has already processed thousands of brake discs with a wide range of geometries and coating systems. EMAG currently produces prototypes of various designs and with different coating systems on four VLC 450 DG machines, optimizing the grinding technology and the tools used.
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