Rear Brake Disc Of LEXUS RC

The workshop adopts a fully enclosed negative pressure design. Standardized management is implemented throughout air purification, temperature and humidity control, and material handling, completely eliminating the impact of environmental factors on machining precision.
Constant Temperature and Humidity Precision Machining Area
The core machining area maintains a constant temperature of 20±2℃ and relative humidity of 45±5% all year round. Equipped with independent central air conditioning and dehumidification systems, it effectively controls thermal deformation of machine tools and dimensional expansion of workpieces. In response to the high precision requirements of 424320W010, temperature fluctuation during machining is controlled within ±0.5℃, ensuring the dimensional consistency error of brake discs produced in different batches and periods is no more than 0.01mm.

ISO Class 7 Dust-Free Clean Area
The air cleanliness of finish machining and inspection zones meets ISO Class 7 standards, with no more than 35,200 particles larger than or equal to 0.5μm per cubic meter. A three-stage filtration system and central dust removal device prevent metal dust and oil particles from adhering to machining surfaces and measuring instruments, avoiding adverse effects on surface roughness and dimensional inspection accuracy.

Lean Zoned Layout
Physical isolation is applied in the workshop following the layout: rough blank pretreatment area - rough machining area - precision machining area - surface treatment area - constant temperature inspection area - finished product warehouse. AGV automated guided vehicles are used for material transportation to realize single-piece flow production, preventing cross contamination and collision damage. All equipment and tools are managed in fixed positions. The floor features anti-static and wear-resistant properties with no oil stains, water accumulation or sudries.

Tailored dedicated machining equipment and processes verified by thousands of tests are deployed to satisfy the requirements of , including 48 large-inclination spiral cooling fins, longitudinal surface grooves and strong deformation resistance.
Dual-spindle Synchronous Turning Center
German DMG MORI CTX beta 1250 TC dual-spindle turning centers are utilized. The whole machining of inner and outer circles, end faces, central holes and mounting holes of Rear Brake Disc of LEXUS 424320W010 can be completed in one clamping, thoroughly avoiding coaxiality errors caused by secondary clamping. After processing, the coaxiality of inner and outer circles is ≤0.01mm, cylindricity of central holes is ≤0.008mm, and position tolerance of mounting holes is ≤0.015mm, far exceeding the original Lexus factory tolerance standard of ±0.02mm.

Five-axis Linked Spiral Cooling Fin Milling Unit
German DMU 50 five-axis linkage machining centers are specially used to process 48 large-inclination spiral cooling fins of 424320W010. Custom cemented carbide coated cutters perform high-speed milling at 12,000 revolutions per minute. The errors of radian, height and spacing of cooling fins are controlled within 0.08mm, with surface roughness Ra no more than 3.2μm. The optimized geometric structure improves air circulation efficiency by 45% compared with ordinary brake discs, effectively lowering the temperature during continuous braking on tracks.

Special CNC Surface Grooving Machine
Special CNC grooving equipment conducts precision processing for 8 longitudinal flow guide grooves of Rear Brake Disc of LEXUS 424320W010. The grooves are 2mm deep and 3mm wide with tolerance limited within ±0.05mm, featuring burr-free and chipping-free edges. The grooving angle precisely matches the rotation direction of brake discs to achieve optimal chip removal, water drainage and thermal stress relief.

High-precision Double-ended Grinding Machine
Japanese OKAMOTO ACC-1224DX double-ended grinding machines conduct final surface finishing. For the standard thickness of 28mm of 424320W010, the thickness deviation of a single disc is ≤0.03mm and end face runout is ≤0.02mm. A staged grinding process is adopted: rough grinding removes 0.3mm allowance, semi-finish grinding corrects 0.1mm allowance, and finish grinding controls 0.05mm allowance. The final surface roughness Ra stably ranges from 1.2μm to 1.8μm.

Double High-temperature Tempering and Directional Sandblasting Process
After rough machining, brake discs undergo the first high-temperature tempering in a vacuum tempering furnace at 550±10℃ for 3 hours to eliminate casting stress. Secondary low-temperature tempering is carried out after finish machining to further release machining stress. Directional sandblasting is then performed with 120-mesh brown corundum abrasive under 0.6MPa pressure, forming a uniform micro rough structure on friction surfaces and boosting the initial friction coefficient by 30%.

Fully Automatic Dynamic Balance Correction
Every 424320W010 Rear Brake Disc is inspected and corrected by German Schenck CAB 950 fully automatic dynamic balancing machines. The drilling weight removal method keeps dynamic balance accuracy within 8g·cm, better than the original Lexus standard of 12g·cm, ensuring no steering wheel vibration at the maximum vehicle speed of 270km/h.

An independent constant temperature and humidity inspection center is completely separated from production areas and equipped with world-leading high-precision testing devices. All measuring instruments are calibrated annually and traceable to national measurement standards.
Full Inspection of Raw Materials on Arrival
Each batch of HT250 high-carbon alloy cast iron blanks undergoes spectral composition analysis to qualify the content of alloy elements such as molybdenum and nickel, hardness test ranging from HB200 to HB240, and metallographic examination requiring Type A graphite content ≥92% and pearlite content ≥96%. Unqualified blanks are rejected and prohibited from entering production.

In-process Online Inspection
Automatic inspection stations are set at critical procedures including rough machining, semi-finish machining and finish machining. Laser diameter gauges, displacement sensors and visual inspection systems monitor key parameters of 424320W010 in real time, such as outer diameter, inner diameter, thickness and cooling fin dimensions. Production halts for adjustment once deviations are detected, keeping defective product rate below 0.1%.

100% Full Inspection of Finished Products
All finished products pass seven inspection procedures before delivery: geometric tolerance detection via coordinate measuring machines, surface defect scanning, dynamic balance test, salt spray test (sampling), high-temperature thermal stability test (sampling), appearance inspection and packaging inspection. An additional 600℃ rapid cooling test is implemented for 424320W010 to guarantee no cracks or deformation under extreme working conditions.

Dedicated Production Unit
A dedicated production unit is established for Lexus F-series high-performance brake discs, equipped with 4 dual-spindle turning centers, 2 five-axis machining centers, 1 double-ended grinding machine and 1 dynamic balancing machine. The standard daily output of 424320W010 reaches 200 pieces, meeting steady bulk order demands of global distributors.

Quick Mold Change System
Standard hydraulic fixtures and modular CNC programs reduce the mold change time between different F-series brake disc models to no more than 45 minutes. Production schedules can be adjusted flexibly while priority production of 424320W010 is guaranteed.