PA AVTOREAL – About Company

AVTOREAL Production Association is a South-Ural company founded in 1999 which soon has become a leading producer of car brake system components.

In the first year, we produced front brake disks for VAZ-2101 and other classical VAZ models, and also for front-drive model VAZ-2108. In a year we started a serial production of brake disks for VAZ-2121 Niva.

In 2001, AVTOREAL got a patent and started the production of our original disks named Euro. These disks became an improved alternative to ordinary disks for classical models and VAZ-2108.

In the same year, our company was the first to produce ventilated disks for the new VAZ family which were VAZ-2110, VAZ-2112 and their modifications. As ventilated disks had quite a new design, we had to make a number of innovations in our technological process. And we were successful in this process!

Year 2002 saw new achievements: we started producing disks for VAZ-1111 Oka. And we also worked in other new directions of making car components. We began making brace arms for VAZ-2108.

In 2003 the production of crankshaft pulleys for VAZ-2101 was started.

That was year 2005 when our company began making brake disks for GAZ-3302 GAZelle.

In 2006 the company produced brake drums for VAZ-2108, and also for Daewoo-Nexia, Daewoo-Lanos, Chevrolet-Lanos cars.

Our designers developed a new model of rear brake drum 1118-3501070 for VAZ Kalina. This model was approved by OAO AvtoVAZ technical service to be used in all front-drive VAZ cars.

AVTOREAL has constantly been increasing a range of products; in 2009 the production of wheel hubs for VAZ family: 2101, 2108, LADA Kalina, 2121 Niva, Chevrolet Niva was started.

PA AVTOREAL uses the latest automatic equipment for making our products. It is turning centers made by DOOSAN corporation. Automatic machine-tools allow optimizing the machining process regardless of the operator’s experience and aligning the AVTOREAL products with such brands as Brembo and Lucas.

Machining is made by precise turning at high cutting speed (about 1000m/min), at such speed the disk has no time to be heated so there is no inner distortion.

For machining we use tools made by leading world manufacturers. The application of such cutters made of ultra-hard materials (borazon (cubic boron nitride) and mineraloceramics) guarantees the high quality of product machining.

During the machining the products are also completely tested. One of the tests is ventilated disk balancing. For this, an automatic machine-tool R300 made in Korea is used.

According to AvtoVAZ requirements, the ventilated disk imbalance is not to exceed 30g/sm. AVTOREAL makes 100% disk balancing and precise milling operation makes the disk imbalance two times lower than it is recommended by VAZ specialists.

AVTOREAL Production Association invites all concerned enterprises to cooperation in machining and making spare parts and components of various complexities.

Send a letter concerning machining operation

All AVTOREAL products are certified.

AVTOREAL also has patents and utility certificates for many of our engineering developments, some of them are:

In 2007 AVTOREAL Production Association got a diploma “100 Best Russian Products” for front brake disks for VAZ cars.

Consumer Properties, Advantages, Competitiveness

The whole range of front brake disks for VAZ cars produced by AVTOREAL OOO has the following advantages:0

  1. While manufacturing, actual disk sizes and parameters influencing its operating characteristics shown in Table 1 are made 1.5-2 times more accurate than it is required. It is made because of our desire for minimizing all drawbacks which can appear during the disk operation, for increasing disk reliability and competitiveness. For example, the inner flange end beating against the inner hub end (see item 1 Table 1) results in the brake disk and pad wear unevenness; causes the vibration of the brake pedal and the steering wheel; leads to brake fading and increasing brake pedal travel. Making this parameter 1.5 times tougher we eliminate the above defects almost completely.

  1. Due to a new method of machining, the working area roughness is higher than it is required. It improves the braking effectiveness as reducing the disk working area micro-asperities and deformation (see item 2 Table 1) results in increasing the contact area between the shoe and the disk. These characteristics are especially important when you only start using the disk (the first 300-500km).

  1. Our break disks are made of high quality castings delivered to AVTOREAL by our certified suppliers. The casting material and its parameters have great influence on the disk operating characteristics. For example, the casting hardness lower than 190HB reduces the disk resistance to distortion, and distortion, in its turn, increases end beating and working area deformation.

  2. If the temperature is low during the casting process, higher-carbon areas with hardness less than 50HRC may appear. This defect results in brake fading and increased brake pad wear.

Advantages of brake disks with face grooving on working areas (Utility Certificate No 21228)

  1. Disks with face grooving guarantee effective braking in any weather conditions as grooves improve disk ventilation at great temperature difference in the contact area of the disk and the pad.

  2. Disks with face grooving provide a more effective braking as due to the grooves the brake pad working areas always remain clean and there is a 100% contact between the pad and the disk which results in even disk wear.

  3. Disks with face grooving exclude brake release effect as high-temperature gases are vented through grooves out of disks.

  4. Face grooving also indicates the disk wear.

  5. Face grooving provides better ventilation and prevents the heating of working areas, calipers, pads and brake fluid.

Table 1

No

Parameter

Manufacturer’s limit value, mm

AVTOREAL

Other Russian manufacturers

Foreign manufacturers

1

The inner flange end beating against the inner hub end

0,03

0,05

0,04

2

Flange working area non-flatness

0,02

0,05

0,04

3

Outer flange end misalignment against its inner end

0,03

0,04

0,04

4

Outer hub end misalignment against its inner end

0,03

0,05

0,05

5

Inner hub end non-flatness

0,03

0,05

0,05

6

Flange working area roughness, Ra

0,8 µm

1,6 µm

1,6 µm