2019年11月06日

Brembo, the world leader in braking systems, and Cannon Ergos cooperate in a EU-Life innovation project to develop a brake caliper for car wheels using high pressure injection of semi-solid aluminium alloy

Brake calipers are essential to the car’s ability to stop and are one of the most important automobile parts. In a disc-braking system the car wheels are attached to metal discs that spin along them. Brake calipers squeeze the brake pads against the surface of the disc, which is made of cast iron in most commercial vehicles but can be of Carbon Composites in racing cars and motorbikes. The squeezing action creates a friction, sufficient to slow or stop the vehicle, producing instantly a lot of heat, that must be dissipated quickly to avoid problems to the whole braking system.

Brembo, the world leader and acknowledged innovator of the disc brake technology for automotive, based in Bergamo, Italy (www.brembo.com), features an impressive catalogue of disc brakes for cars, motorcycles, commercial vehicles and racing. Their R&D Division constantly looks for new records to beat, developing stronger, lighter and safer braking systems: the development of a brake caliper made of secondary Aluminium alloy, featuring a mechanical strength similar to that obtained with a primary alloy and very high homogeneous microstructure, combined with a production cycle time achieved with the die-casting method, is the final target of a EU-LIFE CRAL project started by Brembo in 2016.

Cannon Ergos, whose experience in vertical Aluminium Die-casting equipment dates back more than 50 years, gladly shared the execution of this 36-month project.

一種創新的方法,其特征在於這種具有挑戰性的任務:使用垂直注入技術使用噴射帶有層流的半固體鋁合金和非常高的比壓力。將液體合金直接攪拌到機器中,在嚴格控製的條件下,保持高粘性,並立即使用具有自下而上的注入路徑的液壓活塞在封閉的模具中轉移。

A special 10,000 kN Cannon Ergos vertical die-casting press has been built and installed in Brembo’s premises for this development.

The most innovative aspect characterising this new equipment is how the alloy is dosed, prepared and directly injected in one of the injection sleeves of the machine.

A special design characterises this press: a short-stroke design and a multiple container (a multi-injection sleeve) that allow to reduce the cycle time, thanks to the possibility to perform different operations in hidden time.

Significant advantages derive from this project:

更快的冷卻製動卡鉗,比以前的方式輕,提供superior mechanical characteristicswith alower weight impacton the car or motorbike wheel, and thelower environmental properties impact是最終產品的這個項目所需的改進。

Shape and geometry of the calipernot obtainable with the traditional moulding technology.

Faster cycle time, reduced investment在鑄造設備中,一個near-to-shape caliper, ready to be used with limited post-processing operations, are the industrial production and economic returns.

Cannon Ergos worked closely with Brembo, providing processing support and availability of die-casting equipment for trials, to reach the expected results defined by the European Community LIFE CRAL financing program: to implement a breakthrough先導半固體金屬(SSM)線生產高質量和light-w的能力eight automotive cast components from both recycled low-purity aluminium alloys and new ECO-magnesium alloys in a safe and clean manner.

For more information:www.cralproject.eu/en.eu/en.

Brembo Plant by Cannon