Front Brake Disc for Kia RIO

The workshop adopts a fully enclosed dust-free processing area reaching ISO Class 8 air cleanliness standard. It effectively prevents metal dust and oil particles from adhering to processed surfaces, avoiding negative impacts on measurement precision and processing quality.

• Dual-spindle Synchronous CNC Lathe: Imported German DMG MORI dual-spindle turning centers complete all machining of inner and outer circles, end faces and central holes in one clamping for Kia Front Brake Discs for Kia RIO (Part No. 517121R000), eliminating concentricity errors caused by repeated clamping. After processing, the concentricity of inner and outer circles is no more than 0.015mm, and the cylindricity of central holes is no more than 0.01mm, fully meeting Kia's original tolerance requirement of ±0.02mm.
• Dedicated Arc Cooling Fin Milling Unit: Custom multi-axis linkage milling machines are deployed to process 32 arc cooling fins of 517121R000. CNC programs precisely control radian, height and spacing of cooling fins with errors within 0.1mm, ensuring even heat dissipation airflow and preventing brake jitter and thermal fading caused by uneven heat dispersion.
• High-precision Surface Grinder: Japanese Okamoto CNC surface grinders conduct final surface finishing. For the standard 22mm thickness of 517121R000, thickness deviation of single disc is controlled within 0.04mm and end face runout below 0.025mm, far above industrial average standards. It fundamentally resolves nose-dive during low-speed braking and jitter in high-speed braking.

The workshop maintains a constant temperature of 22±2℃ and constant humidity of 50±5% all year round. It eliminates dimensional deviations induced by thermal deformation of machine tools and workpieces due to temperature fluctuation, guaranteeing stable performance of 517121R000 brake discs across different batches and production periods.

• Optimized Isothermal Normalizing Process: Custom isothermal normalizing curves are designed for G3000 high-carbon gray cast iron used in 517121R000. Heating temperature is accurately set at 920±10℃ with 2.5-hour heat preservation, followed by slow cooling in a 600℃ isothermal furnace. After treatment, the content of type A graphite reaches over 88% and pearlite exceeds 94% in metallographic structure. Hardness stays steadily between HB180 and HB220, securing satisfactory wear resistance and avoiding abnormal brake pad abrasion from excessive hardness.
• Accurate Surface Roughness Regulation: Grinded in progressive stages, rough grinding removes machining allowance, semi-finish grinding corrects geometric tolerances and finish grinding optimizes surface quality. The surface roughness Ra value of 517121R000 is controlled within the optimal range of 1.7-2.5μm, enabling uniform fitting with brake pads and reducing braking noise. Bench tests prove braking noise stays below 62 decibels at speeds under 60km/h.
• Exclusive Dynamic Balance Correction: Every 517121R000 brake disc is inspected and corrected by automatic dynamic balancing machines. Weight removal via drilling limits dynamic balance accuracy to no more than 11g·cm, superior to Kia's original standard of 16g·cm. It secures driving stability at high speeds and avoids steering wheel vibration.

An independent thermostatic inspection room is physically separated from production areas. It houses high-precision testing devices including coordinate measuring machines, spectrum analyzers and metallographic microscopes. All testing equipment undergoes regular calibration traceable to national measurement standards.

• Full Incoming Raw Material Inspection: Each batch of G3000 high-carbon gray cast iron blanks undergoes spectral composition analysis, hardness test and metallographic examination. Only qualified blanks complying with design specifications of 517121R000 are admitted into production.
• In-line Inter-process Inspection: Automatic detection stations are arranged in rough, semi-finish and finish machining procedures. Laser diameter gauges and displacement sensors monitor critical dimensions such as outer diameter, inner diameter and thickness in real time. Production halts immediately for adjustment once deviations are detected.
• 100% Finished Product Inspection: Before delivery, finished products are tested for position degree of central and mounting holes by coordinate measuring machines, coating corrosion resistance via salt spray test, and friction coefficient stability through brake performance bench tests. Additional 100% inspection on end face runout and thickness difference is implemented for 517121R000 to ensure all delivered products meet quality criteria.

Adopting lean production layout, the workshop is scientifically divided into blank, processing, inspection and finished product zones. AGV automated guided vehicles handle material transportation to realize single-piece flow production, drastically cutting work-in-progress inventory and idle production time.

• Dedicated Production Line Layout: A specialized production unit is established forFront Brake Disc for Kia RIO (Part No. 517121R000), equipped with 6 CNC lathes, 2 surface grinders and 1 dynamic balancing machine. The standard daily output reaches 800 pieces to fulfill steady bulk order demands.
• Quick Mold Change System: Standard fixtures and modular programming design shorten mold replacement time to under 30 minutes. The production line can flexibly switch between different brake disc models while prioritizing production of 517121R000.
• Urgent Order Response Mechanism: Exclusive equipment and staff are deployed for rush orders, shortening production cycle to 15-20 working days. Priority logistics arrangement ensures no disruption to clients' maintenance and manufacturing schedules.

• 5S On-site Management System: Strict implementation of sorting, set in order, sweeping, standardizing and sustaining. All tools, materials and equipment are clearly marked and fixedly placed. The floor remains free of oil stains, water accumulations and sundries with unobstructed passages.
• Environmental and Safety Compliance: Advanced cutting fluid recycling systems and centralized dust collectors achieve recyclable cutting fluid utilization and zero dust emission, conforming to national environmental protection regulations. Safety guards are installed on all production facilities. Regular safety checks and staff training maintain stable and secure production operations.
• Visualized Management: Electronic display boards in the workshop real-timely present production progress, equipment status, quality data and environmental parameters, achieving transparent production management.

Our manufacturing processes and finished products comply with EU REACH Regulation and RoHS Directive, supporting export business worldwide. Continuous optimization of energy consumption and waste disposal contributes to building an eco-friendly and low-carbon modern manufacturing plant.