ブレーキキャリパー
説明
Forged Aluminum Automotive Brake Caliper: Monobloc Caliper Forging
The forged aluminum automotive brake caliper is a monobloc forging for an opposed-piston brake caliper. A bridge-shaped body spans the brake disc, with piston bores on both sides and reinforcing ribs and lightening pockets on its surface. A monobloc caliper has no bolted joint between halves, so it is stiffer and deflects less under braking, which is why it is common on performance cars and aftermarket brake systems.
With its three-dimensional shape and many pockets, a monobloc caliper cannot be formed in one hit in the solid state as a casting would be. Al Forge Tech (AFT) typically plans several forging stages and multiple die sets (for example, three sets) to form the part progressively and avoid laps and underfill. After in-house T6 heat treatment, piston bores, fluid passages and mounting holes are machined on 4.5-axis CNC, with CMM and fluorescent penetrant inspection.
主な機能
- Monobloc bridge body for high stiffness and low deflection under braking
- Formed progressively over multiple forging stages and die sets
- Piston bores, fluid passages and mounting holes on 4.5-axis CNC
- Fluorescent penetrant, CMM and hardness inspection
Forged Aluminum Automotive Brake Caliper Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 製品カテゴリー | 自動車部品 |
| 申請 | Opposed-piston brake systems for performance and modified cars |
| 主なプロセス | 閉型熱間鍛造（熱間鍛造プレス：600T～8,000T） |
| 素材 | Per customer specification; 6xxx alloys common for chassis and suspension parts (e.g. 6061, 6082, 6110), 7xxx evaluated for higher strength |
| 熱処理 | 合金および強度要件による社内T4処理（8ユニット）およびT6人工老化（7ユニット） |
| 二次加工 | CNC加工（52台の加工センター、30台の旋盤）、バリ取り、振動仕上げ |
| 表面仕上げ | 必要に応じて、陽極酸化（硬陽極酸化を含む）、ショットブラスト、電子コーティングまたは塗装 |
| 検査 | Zeiss CMM (4 units), hardness testers, spectrometer, fluorescent penetrant line; tensile and fatigue testing available |
| 寸法と公差 | 顧客ごとに2D/3D図面 |
| 品質システム | IATF 16949:2016、ISO 14001:2015 |
Forged Aluminum Automotive Brake Caliper Manufacturing Process
- ドローイングレビューとDFM合金、荷重方向、重要な寸法を確認し、その後 QForm シミュレーションを実行して金属流動と欠陥リスクを予測します。.
- デザインと製造ダイセットの数（例えば、ブロッカーダイとファイニッシャーダイ）は部品の複雑さに合わせて計画されており、ダイの形状は携帯型3Dスキャナーで確認されます。.
- 熱間鍛造600T～8,000Tの熱間鍛造プレスでの閉型成形により、部品の形状に沿った連続した粒状流が生成されます。.
- 熱処理T4溶液処理とT6人工老化は社内で実施され、合金および強度要件によって設定されたパラメータが使用されます。.
- CNC加工 そして仕上げ穴、スレッド、接合面は機械加工され、その後、必要に応じてバリ取り、振動仕上げ、ショットブラスト、または陽極酸化が行われます。.
- 検査と発送寸法、硬度、化学組成はCMM、硬度計、分光計を用いて確認され、ロットのトレーサビリティはIATF 16949に従って管理されています。.
よくある質問
Why does a monobloc brake caliper need multiple die sets?
The bridge body, piston bore bosses and lightening pockets of a monobloc caliper are complex, and solid metal can only flow a limited distance in the die. Forming it in one hit risks laps at pocket corners or underfill at the bore bosses. It is therefore formed progressively with blocker, intermediate and finisher dies, for example three die sets, so material is placed correctly before details are formed.
How does a monobloc caliper differ from a two-piece caliper?
A two-piece caliper bolts left and right halves together, which is easier to machine, but the joint can deflect slightly under high load. A monobloc caliper is machined from a single forging, giving a stiffer body, less deflection under braking and a more direct pedal feel, at the cost of more demanding forging and machining. AFT has production experience with forged calipers for two-, three- and four-wheeled vehicles.
Is heat treatment for the Forged Aluminum Automotive Brake Caliper done in-house?
Yes. Al Forge Tech operates 8 T4 solution treatment units and 7 T6 artificial aging units on site, so the Forged Aluminum Automotive Brake Caliper can be solution treated, quenched and aged in the same facility before machining and inspection. Keeping heat treatment in-house removes inter-plant transport, reduces lead-time risk and keeps lot traceability within one quality system. Parameters are set according to the alloy grade and your specification.
How do you keep the Forged Aluminum Automotive Brake Caliper consistent from lot to lot?
Al Forge Tech runs incoming (IQC), in-process (IPQC) and final (FQC) inspection under IATF 16949:2016, supported by 4 Zeiss CMMs, hardness testers, a spectrometer and a fluorescent penetrant inspection line. First, middle and last pieces of every lot are checked against the die; when wear causes dimensional drift, the die is reworked to keep the Forged Aluminum Automotive Brake Caliper stable across lots.
Can Al Forge Tech supply the Forged Aluminum Automotive Brake Caliper from forging through machining?
Yes. Forging, heat treatment, CNC machining, surface finishing and inspection are integrated in one facility: 52 CNC machining centers (40 four-axis and 12 4.5-axis), 30 lathes (14 with robotic loading), plus broaching, burnishing and centerless grinding. The Forged Aluminum Automotive Brake Caliper can be delivered as a forged blank, semi-finished or fully machined part.
Request a Quote for the Forged Aluminum Automotive Brake Caliper
Developing a new Forged Aluminum Automotive Brake Caliper or converting an existing part to aluminum forging? Send us your 3D/2D drawings, alloy and temper, annual volume and finishing requirements. Our engineering team will reply with a feasibility review, die plan and quotation.
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類似のパーツを比較するには、閲覧してください。 自動車部品 そして私たちの 自動車用アルミニウム鍛造用途, または、こちらをご覧ください 会社紹介 当社の設備および認証について。.
