Amazing factory tour: manufacturing process of car disc brake by iron casting method

Witness amazing heavy-duty engineering in this exclusive factory tour showing how car disc brakes are made from scratch! The industrial workflow begins on the raw factory floor with the breakdown of massive scrap iron parts using a manual sledgehammer. This process is a prime example of industrial recycling and sustainability, giving old, discarded metal a second life as a vital safety feature instead of letting it rot in landfills. The broken chunks are then fed into a powerful induction furnace that burns at extreme temperatures between 1,150°C and 1,300°C. Once the metal turns into a glowing liquid, workers use a long rod for continuous stirring and slag skimming to remove surface impurities, ensuring the structural integrity of the final product. This is highly educational because it demonstrates traditional sand casting methods mixed with strict factory specifications. The workers prepare green sand molds (silica sand mixed with clay and water) using a cope-and-drag flask, compacting the sand manually with their feet to perfectly capture the disc brake pattern. The molten Grey Cast Iron (specifically grade GG20 or GG25 following SAE J431 standards) is then poured at a blazing 1,200°C into the mold using a heavy ladle. This specific material is chosen globally for its superior ability to dampen brake vibrations and handle extreme friction heat. After a natural cooling and shakeout stage, the rough, sandy casting is cleaned and immediately sent to the precision machining bay. The ultimate goal of this process is absolute reliability. The rough casting is mounted onto a massive conventional lathe machine for precise facing and turning, where sharp carbide cutting tools shave the outer, inner, and central ventilation ribs to achieve a standardized thickness. The disc then goes to a vertical drilling machine equipped with a specialized jig fixture to drill identical wheel bolt holes with a microscopic tolerance of 0.05 mm to 0.1 mm, followed by chamfering to smooth out sharp edges. The result is a gorgeous, shiny silver-finish disc brake that provides premium stopping power. If you love machines and engineering, please subscribe, like, share, and watch our other fascinating industrial videos! All footage is 100% original, filmed on-site, and produced by icit real process and team. #factorytour #amazing #discbrake #ironcasting #car #manufacturing #asmr #satisfying #fyp #viral #engineering #industrial #howitsmade #globalindustry #machine #icitrealprocess #heavyindustry #heavyduty #steel #incredible #metalworking #foundry #massproduction #recycling #metalcasting #vehicles #tech #sains #technique #iron #scrapmetal #process #howtomake ##cncmachine #machining #sandcasting #moltenmetal #automotive #spareparts #components #lathemachine #drilling #mrbeast #production #unbelievable #industry #craftsmanship #expert #skills