Two-piece brake discs - Maintenance tips - forvia hella

Heavy-duty or more powerful vehicles require a larger-dimensioned brake system. For this reason, the diameter of the brake discs for vehicles of this kind is bigger and so is the thickness of the brake disc chamber. When subjected to a high thermal load, such brake discs are susceptible to deviations like variations in thickness, axial misalignment and in shielding. In these cases, two-piece brake discs, also known as "composite brake discs", offer distinct advantages. Thanks to the diverse materials and special binding processes used in their manufacturing, these discs allow a decoupling of the heat flow to the wheel hub.

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Depending on the vehicle type and the area of application, brake discs made of flake graphite (e.g. grey cast iron GG15) are, for the most part, set as a standard in series production. The properties of grey cast iron can be improved by adding the most diverse kinds of alloying elements to this metal. Molybdenum and chrome enhance the hot crack behaviour and the abrasion resistance of the alloy. Thermal absorption is improved by raising the alloy's carbon content. Two-piece HELLA brake discs consist of a brake disc chamber made of aluminum and a friction ring out of grey cast iron that has a high carbon content. Both components are secured at the joint with stainless steel rivets in order to guarantee the transferability of relatively high torques and also to ensure that, as the temperature rises, the friction ring can axially expand independently of the disc chamber. This minimizes thermal stress while reducing any heat cracks appearing at the point of transition from the friction ring to the disc chamber.

And as a result of using aluminium in the makeup of the brake disc chamber, the weight of the brake disc is additionally reduced by up to 20%.

During the braking action, kinetic energy is converted into thermal energy by means of the friction created. Up to 90% of this converted energy is absorbed by the brake disc and then emitted into the ambient air. Thus, under extreme conditions, temperatures reaching as high as 700°C can prevail at the wheel brakes.

As well as being affected by physical stresses and strains, brake discs are also exposed to environmental influences, to dirt, water and salt. All these issues have to be factored into the equation when structural design is being planned by the manufacturers of brake discs.

The two-piece brake discs are internally ventilated and, therefore, because of their greater mass they possess better heat storage capacity and they also cool down more quickly through the air flow in the channels. These radial channels are located between the two friction rings. The rotation of the brake disc brings about a fan effect, which then creates a permanent air flow throughout the brake disc. An added feature is that two-piece brake discs can also have slits or grooves or they can be axially perforated. Brake debris, water and dirt gather in the slits or grooves and such material is propelled outwards by the rotary movement. The axial bores increase heat dissipation, but they are only slightly self-cleaning as brake debris can accumulate in the holes.

Two-piece brake discs in BMW and Mercedes

Depending on the vehicle manufacturer, two-piece brake discs can be quite different in design, in their material composition and when it comes to the binding processes used in their production. The connection between the aluminium disc chamber and the grey, cast iron friction ring can also vary according to the manufacturer. Here it is possible for special casting, bonding or pressing procedures to be used and mechanical connections with rivets, clips, pins or screws can also feature.

On some of its vehicle models, Mercedes Benz uses composite brake discs with a disc chamber made out of sheet steel and a friction ring of cast iron. By means of a special construction, i.e. toothed design, both components are joined together in a press fit assembly. The toothed profile of the brake disc chamber's outer casing half engages the matching toothed profile on the friction ring in order to bring about torque transmission. The brake disc chamber made of sheet steel is only 2.5 mm thick. A classic brake disc chamber usually has a wall thickness of 7.5 to 9 mm.

Check composite brake disc condition

On account of the high mechanical and thermal load on such components, the state of the composite brake disc - just as is the case with conventional one-piece brake discs - should be checked at regular intervals as stipulated by the manufacturer. The wear limit of the brake disc is also an issue that is fixed by the manufacturer on the basis of the minimum thickness of the friction ring. This value in millimeters is stated or stamped on the brake disc's outer edge or on the disc chamber.

In addition, the generally applicable testing procedures for brake discs can also be carried out on these occasions. This would include checking radial run-out and thickness deviation (differing disc thicknesses). The appropriate tolerance values are fixed by each individual vehicle manufacturer and are to be strictly observed.

Welcome to our article discussing an age-old debate: Are brake discs the same as rotors? If you've ever been unsure about the difference between these two essential components in your vehicle's braking system, you've come to the right place. Buckle up as we delve into the distinct features and functions of brake discs and rotors, uncovering the hidden nuances that automotive enthusiasts have pondered for years. Whether you're a passionate petrolhead or simply seeking to expand your knowledge, join us on this informative journey as we demystify the true essence of brake discs and rotors. Prepare to hit the brakes on any uncertainties and accelerate your understanding of these paramount elements in automotive engineering.

Are Brake Discs the Same as Rotors?

When it comes to automotive essentials, brake discs and rotors play a crucial role in ensuring vehicle safety. However, many people often confuse the terms "brake discs" and "rotors" and use them interchangeably. In this article, we will delve into the similarities and differences between brake discs and rotors to understand their functions and significance in the realm of automotive parts.

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1. Defining Brake Discs and Rotors:

Brake Discs: Brake discs, also known as brake rotors, are essential components in the braking system that provide friction to slow down or stop the rotation of the wheels. These discs are usually made of high-quality cast iron or composite materials, designed to withstand high temperatures and constant friction.

Rotors: Rotors, on the other hand, are an integral part of the braking system that work in tandem with brake discs. They are primarily referred to as rotating components that attach to the wheel hub. Rotors provide a surface for the brake pads to clamp against when the brakes are applied, generating the necessary friction to decelerate or halt the vehicle.

2. Similarities Between Brake Discs and Rotors:

Despite the apparent differences in terminology, brake discs and rotors are essentially the same component. Both terms refer to the metal discs that work together to facilitate friction and deceleration when the brakes are engaged. The distinction in terminology varies across regions, with "brake disc" being more commonly used in Europe, while "rotor" is the preferred term in North America.

3. Differences in Usage:

While brake discs and rotors serve the same primary function, their usage may differ depending on the type of vehicle and braking system. In general, the term "brake disc" is used in vehicles with a hydraulic braking system, where the brake caliper clamps the disc to generate the necessary friction force. On the other hand, "rotor" is a term predominantly used in vehicles with manual or mechanical braking systems.

4. Brand Spotlight: Frontech Auto Parts:

Frontech, a leading brand in the automotive industry, specializes in manufacturing high-quality brake discs and rotors. With a wide range of products designed to cater to various vehicle types and models, Frontech Auto Parts has earned a stellar reputation for reliability and performance.

5. Advancements in Brake Disc and Rotor Technology:

As technology continues to evolve, so does the automotive industry. Brake discs and rotors have seen significant advancements in design, materials, and technologies. Manufacturers like Frontech have introduced innovative features such as cross-drilling and slotting, which enhance the braking performance, heat dissipation, and overall longevity of the components. These advancements have not only improved the safety aspect but also contributed to a smoother and more efficient braking experience for drivers.

In conclusion, brake discs and rotors are indeed the same components, with variations in terminology depending on the geographic location and type of braking system used in vehicles. Understanding the significance and functionality of these parts is crucial for every vehicle owner. Frontech Auto Parts, known for its exceptional quality and performance, has leveraged these advancements to provide top-notch brake discs and rotors to ensure the safety and satisfaction of drivers worldwide.

Conclusion

In conclusion, while the terms "brake discs" and "rotors" are often used interchangeably, there are subtle differences between the two. Understanding these differences is crucial for car enthusiasts and professionals in the automotive industry. Whether you prefer the term "brake discs" or "rotors," what matters most is recognizing the importance of these vital components in ensuring the safety and performance of your vehicle's braking system. So, the next time you find yourself discussing brake discs or rotors, remember that it's not just a matter of terminology but rather an essential aspect of vehicle maintenance and safety.

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