In the traditional manufacturing process of brake discs, manpower is almost always used for loading and unloading of processing machine tools. This primitive operation method has disadvantages such as high labor intensity and difficulty in balancing output and quality. In the general environment of "replacing people with machines", more and more auto parts manufacturers have launched automatic robot production lines, which has reduced labor costs, increased production and quality, and enhanced the competitiveness of enterprises.

The vertical lathe production line of the machine tool production line for processing brake discs

The vertical processing production line is composed of 2 vertical lathes and 1 vertical machining center. One of the lathes is an ordinary lathe equipped with a double turning tool holder, and the other vertical machining center is the basic equipment for deep processing. , together form a production line. The manipulator is the feeding equipment of the vertical lathe, which can effectively place the brake disc on the chuck of the vertical lathe, and effectively transfer the material to the circuit through the unloading device, and the frame manipulator sends the processed brake disc to the loop. It is transported to the vertical machining center. After the drilling and tapping production process is completed, the material is unloaded by the frame manipulator, and the processing of the entire device is finally completed. The advantage of the vertical lathe processing production line is that the processing flow direction is the same as the gravity direction, and the fixture is relatively simple. Chip removal during dry machining.

The horizontal lathe processing line of the machine tool production line for processing brake discs

Horizontal machine tool processing production line is a scheme that is currently used more. It can effectively form a brake disc production line through two horizontal machine tools and a vertical machining center. Among them, the horizontal machine tool needs to be equipped with double turning tool holders, which together with the vertical machining center form an in-line arrangement. At the same time, the upper space of the machine tool also needs to be effectively developed and utilized. A frame-type manipulator is configured to unload the machine tool. At the same time, combined with the function of the chuck position of the machine tool, it can achieve the effect of clamping the workpiece of the brake disc. The machining of the turned brake disc is positioned to the vertical machining center by the manipulator. After the drilling and tapping process is completed, the material is unloaded by the manipulator. The advantage of the horizontal machine tool is that the construction cost of the actual production line is relatively low. , but the disadvantage is that the basic requirements for three-dimensional space are relatively high. At the same time, the direction of processing flow is vertical to the direction of gravity, and the design of production line fixtures is complicated.

Although the application of the brake disc production line has improved production efficiency and reduced labor, it has also increased the requirements for supporting equipment and machine tool accessories, and cutting tools are one of them. Early brake discs were produced with alloy cutters and coated alloy cutters. Later, with the production line’s requirements for efficiency, cost and other factors, they were gradually replaced by CBN cutters. Valin Superhard, as a pioneer in the localization of superhard cutters, The developed BN-S300 and BNK30 grades are widely used in brake disc production lines and are well received by customers.

The material of BN-S300 is an integral polycrystalline CBN tool made of high-purity, high-purification rate raw materials sintered under high temperature and high pressure. The CBN content is as high as 97%. The density and uniformity of the blade are very high, and the hardness reaches HV3600 evenly. It has excellent wear resistance and edge strength, which makes it have a longer tool life in the field of continuous cutting and intermittent cutting.

   The BNK30 material adopts imported nano-scale binder and high-purity submicron + nanometer CBN particles in a mixed ratio, and is sintered at high temperature and high pressure without cemented carbide support (substrate) CBN polycrystal; its hardness is higher, and the CBN particle size is finer , especially suitable for high-speed finishing, and can obtain good and stable surface processing quality. At the same time, this CBN polycrystalline block can be fixed with any hard alloy substrate through a high-vacuum brazing process to form various shapes of CNC tools.