Aerospace & Automotive Surface Grinding of Carbon Ceramic Brake Disc (CCB)

🕜 Material Removal Rate (MRR) - 3.3x higher | ⚙️ Tool Life - 3x longer
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes Carbon Ceramic Brake Disc (CCB) difficult to machine?



Carbon-ceramic brake discs (CCB) use ceramic matrix composites (CMCs, Ceramic Matrix Composites), which are a type of high-performance advanced composite material. This material combines the toughness of carbon fiber with the high-temperature resistance of silicon carbide ceramics, capable of withstanding temperatures above 1000°C; it is lightweight, which can reduce unsprung weight and improve handling stability; its service life is more durable than ordinary cast iron brake discs and exhibits almost no brake fade.

Despite the excellent performance, the manufacturing process of carbon-ceramic brake discs is extremely complicated, especially during the grinding stage, which is the most challenging part of the entire process. The carbon fiber ceramic composite material itself has high hardness and brittleness, which can cause severe tool wear; the heterogeneous structure composed of carbon fiber and ceramic results in unstable cutting force during processing, making product quality difficult to control; the processing time is long, and a single disc may take several days or even a week to complete.

 
 

☑️ Surface Grinding of Carbon Ceramic Brake Disc (CCB): Machining Information

 
    Surface Grinding of Carbon Ceramic Brake Disc (CCB): Machining Information
  Material   Carbon Ceramic Brake Disc (Carbon-SiC)
  Feature   Surface Grinding
  Parameters   S 5,952rpm _ F 1,200mm/min _ Ae 20mm _ Ap 0.020mm _ Ultrasonic Power Level 100%    
  Ultrasonic Tool Holder           HBT40-W01 Grinding Wheel Toolholder 
  Tool Selection   #80 Φ120mm Electroplated diamond grinding wheel   


 

【NEW PRODUCT - HBT-40 Ultrasonic Grinding Wheel Toolholder】For Surface Grinding of Carbon Ceramic Brake Disc (CCB)




--- As the Secret Weapon to Enter the Supply Chain of Semiconductor Industry ---

🔹 Best applied in the rough grinding of semiconductor advanced-material
🔹 Overall Machining Efficiency: 2 - 3x Higher
🔹 Material Removal Rate (MRR): More than 3x Higher
🔹 Great reduction in production costs and energy consumption

 

Product Specification

Model   HBT40-W01-2010          
Operating Frequency            20 ~ 32 kHz   
Max. Spindle Speed   24,000 rpm
Tool Interface   Thread Locking
CTS   70 bar



📣 Welcome to visit HIT's booth Q5344 at SEMICON Taiwan 2025 to learn more about ultrasonic machining products!


 

HIT's Goal in Surface Grinding of Carbon Ceramic Brake Disc (CCB)


For ultrasonic-assisted surface grinding of carbon-ceramic brake discs (CCB), the goal is to use HIT's developed Ultrasonic Grinding Wheel Toolholder (using a D80mm electroplated diamond grinding wheel) on CNC machines to perform surface grinding, and to improve material removal rate and extend tool life while maintaining workpiece quality.




 

Ultrasonic-Assisted Surface Grinding of Carbon Ceramic Brake Disc (CCB): Machining Results

 

Surface Grinding of Carbon Ceramic Brake Disc (CCB): Material Removal Rate (MRR)

using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, allows for improved feed rate
(Figure 1. using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, allows for improved feed rate)


using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, material removal rate can be increased by 3.3 times
(Figure 2. using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, material removal rate can be increased by 3.3 times)

 
  • Using HIT's ultrasonic module to assist in optimizing the surface grinding process of carbon-ceramic brake discs (CCB), ultrasonic provides high-frequency micro-vibrations to the grinding wheel, which intermittently impacts the workpiece during processing, creating space for cooling and chip removal, helping to reduce grinding force.
  • The reduction in grinding resistance allows for increased feed rate and depth of cut per pass, achieving an overall 3.3x improvement in material removal rate (MRR).



 

Surface Grinding of Carbon Ceramic Brake Disc (CCB): Tool Life

using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, tool life is extended by 3 times
(Figure 3. using HIT HBT-40 ultrasonic grinding wheel toolholder module in surface grinding of carbon-ceramic brake discs, compared to the original process, tool life is extended by 3 times)

 
  • Ultrasonic provides the grinding wheel with high-frequency micro-vibrations, which intermittently impact the workpiece, allowing the grinding wheel to achieve cooling and chip removal, helping to reduce grinding force.
  • The reduction in grinding force, along with effective cooling and improved chip removal of the grinding wheel, helps to extend the tool life. In this process, the tool life is effectively extended by 3x.




 

HIT Ultrasonic Machining Technology Achievements in Surface Grinding of Carbon Ceramic Brake Disc (CCB)


(with HIT HBT40 Ultrasonic Grinding Wheel Toolholder)


🕜 Material Removal Rate (MRR) - 3.3x higher
⚙️ Tool Life - 3x longer




📣 Welcome to visit HIT's booth Q5344 at SEMICON Taiwan 2025 to learn more about ultrasonic machining products!


 

Surface Grinding of Carbon Ceramic Brake Disc (CCB): Industry Application



Surface grinding of ceramic matrix composites (CMCs) is applied in the Automotive, EV, Motorsport Parts, and Aerospace industry, especially used for carbon-ceramic brake discs (CCB), engine blocks/piston components, etc.


Carbon-ceramic brake discs (CCB) use ceramic matrix composites (CMCs), which are a type of high-performance advanced composite material. They were initially used in the aerospace field and entered motorsports such as F1 in the 1980s, later expanding to high-performance civilian supercars such as Ferrari and Porsche. They are now widely used in high-performance automotive, EV, and aerospace fields.

This material combines the toughness of carbon fiber with the high-temperature resistance of silicon carbide ceramics, capable of withstanding temperatures above 1000°C; it is lightweight, which can reduce unsprung weight and improve handling stability; its service life is more durable than ordinary cast iron brake discs and exhibits almost no brake fade.

From aerospace technology to civilian vehicles, the application of CMC materials symbolizes the crystallization of advanced manufacturing technology, which also explains why such products are expensive but favored by high-performance car manufacturers and the motorsport industry.

The value of carbon-ceramic brake discs lies not only in their excellent braking performance but also in the extremely high difficulty and time-consuming nature of the manufacturing process.


That was when HIT's Ultrasonic Machining Module came to help!  HIT offers a comprehensive solution in machining advanced materials.  With the assistance of HIT's Ultrasonic Machining Technology and HIT Ultrasonic Grinding Wheel Toolholder, clients stopped worrying about poor workpiece quality while trying to speed up the process time.  The machining efficiency/material removal rate (MRR) can be enhanced while tool wear is greatly reduced.  HIT assures its clients of not only matching up with their requirements, but also achieving even better outcomes!




💡 Learn more about other HIT Ultrasonic Machining of Semiconductor Advanced Material case studies: 


📣 Welcome to visit HIT's booth Q5344 at SEMICON Taiwan 2025 to learn more about ultrasonic machining products!