ブレーキキャリパー
説明
Forged Aluminum Automotive Multi-Piston Brake Caliper: Arc-Shaped Caliper Body Forging
The forged aluminum automotive multi-piston brake caliper is a caliper body forging for performance cars. Its arc-shaped body follows the outer edge of the brake disc, with several piston-bore bosses arranged along the arc and radial mounting ears at both ends. The arc shape fits large-diameter discs, and the multi-piston layout spreads clamping pressure so the pads load evenly.
With several bore bosses along a slender arc, material must fill both the body and every boss during forging. Al Forge Tech (AFT) plans multiple forging stages and die sets for the shape (a monobloc caliper typically needs three die sets), confirms fill with QForm simulation, closed-die hot forges the body and completes T6 heat treatment in-house, then machines piston bores, fluid passages and mounting holes on 4.5-axis CNC. AFT has production experience with forged calipers for two-, three- and four-wheeled vehicles.
主な機能
- Arc-shaped body fits large discs, with piston bores along the arc
- Formed progressively over multiple forging stages and die sets
- Piston bores, fluid passages and radial mounting holes on 4.5-axis CNC
- Fluorescent penetrant, CMM and hardness inspection
Forged Aluminum Automotive Multi-Piston Brake Caliper Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 製品カテゴリー | 自動車部品 |
| 申請 | Multi-piston disc 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; 6061-T6 or high-strength 7xxx alloys are typically evaluated for performance calipers |
| 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 Multi-Piston 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
What makes the arc-shaped body of a multi-piston caliper difficult to forge?
The arc body is slender, with several bore bosses along its length, so material must be distributed evenly along the arc during forging. Otherwise the body ends or bosses can underfill, or laps can form at the boss roots. AFT plans billet shape and preforms with QForm simulation, forms the part progressively with blocker, intermediate and finisher dies, and checks the form on first, middle and last pieces.
Which aluminum alloys are used for forged calipers?
Caliper material must balance strength, stiffness and sealing integrity after machining. 6061-T6 offers balanced machinability and corrosion resistance and is widely used; 7xxx alloys provide higher strength for high-load racing or performance calipers but need anodizing for corrosion resistance. AFT works with 2xxx, 6xxx and 7xxx alloys, and the final choice follows the customer’s performance targets and test standards.
Can you assess forging feasibility while the Forged Aluminum Automotive Multi-Piston Brake Caliper is still in design?
はい。Al Forge Techは主にOEMサプライヤーとして活動しており、エンジニアはコンセプトまたは図面段階で設計適合性評価(DFM)のフィードバックを提供できます。これには、薄い肋骨の調整、急な断面変更、およびラップやアンダーフィルを回避するために設計された角度の調整などが含まれます。QFormシミュレーションは金属流動を早期に予測し、その結果は当社による金型設計経験と比較されます。.
How do you keep the Forged Aluminum Automotive Multi-Piston 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 Multi-Piston Brake Caliper stable across lots.
Can Al Forge Tech supply the Forged Aluminum Automotive Multi-Piston 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 Multi-Piston Brake Caliper can be delivered as a forged blank, semi-finished or fully machined part.
Request a Quote for the Forged Aluminum Automotive Multi-Piston Brake Caliper
Developing a new Forged Aluminum Automotive Multi-Piston 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。.
