ブレーキキャリパー
説明
Forged Aluminum Bicycle Brake Caliper (Twin Bore): Disc Brake Caliper Body Forging
This forged aluminum bicycle brake caliper is the caliper body forging of a bicycle hydraulic disc brake. A central body spans the rotor, with piston bore bosses on both sides and mounting ears extending at each end to fix the caliper to the frame or fork mount. The body carries piston force and rotor torque under braking, and its stiffness directly affects brake feel.
With a three-dimensional body, thick bore bosses and slender mounting ears, the caliper requires blocker and finisher forging stages. Al Forge Tech (AFT) closed-die hot forges it so bores and ears fill completely with continuous grain flow, then raises strength by in-house T6 heat treatment. Piston bores, fluid passages and mounting holes are machined on 4.5-axis CNC and inspected by CMM and fluorescent penetrant inspection.
主な機能
- Caliper body, twin bore bosses and mounting ears forged in one piece
- Blocker and finisher stages ensure complete fill of the bore bosses
- Piston bores, fluid passages and mounting holes on 4.5-axis CNC
- Fluorescent penetrant and CMM inspection
Forged Aluminum Bicycle Brake Caliper (Twin Bore) Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 製品カテゴリー | Aluminum Forging Bicycle Parts |
| 申請 | Hydraulic disc brake calipers for bicycles and e-bikes |
| 主なプロセス | 閉型熱間鍛造（熱間鍛造プレス：600T～8,000T） |
| 素材 | お客様の仕様に合わせて選択可能。2xxx、5xxx、6xxx、7xxx シリーズのアルミニウム合金（例：2014、6061、6082、7075） |
| 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 | ザイツCMM（4台）、硬度計、分光計、蛍光透過検査ライン |
| 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 Bicycle Brake Caliper (Twin Bore) 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 is forging well suited to bicycle disc brake calipers?
The caliper carries piston force and rotor torque under braking, and a stiffer body gives a more direct brake feel. Forged aluminum is dense and free of the porosity common in castings, so leaks are less likely after machining piston bores and fluid passages. Continuous grain flow also gives higher strength at the same weight, suiting light, high-performance bicycle disc brakes.
What brake caliper experience does AFT have?
AFT produces forged and machined brake calipers for two-, three- and four-wheeled vehicles, including bicycle disc brake calipers, motorcycle and powersport calipers, and automotive monobloc caliper forgings. This experience helps evaluate die sets, alloy and machining approach for a new caliper.
Is heat treatment for the Forged Aluminum Bicycle Brake Caliper (Twin Bore) 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 Bicycle Brake Caliper (Twin Bore) 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 Bicycle Brake Caliper (Twin Bore) 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 Bicycle Brake Caliper (Twin Bore) stable across lots.
How does a forged aluminum Forged Aluminum Bicycle Brake Caliper (Twin Bore) compare with casting or machining from billet?
Forged Aluminum Bicycle Brake Caliper (Lightweight): Compact Disc Brake Caliper Forging
This lightweight forged aluminum bicycle brake caliper is a disc brake caliper body forging with a more compact shape: a smaller central body, mounting ears extending outward and bosses for the hose fitting and bleed valve. The compact body reduces caliper weight and suits weight-focused road and cross-country mountain bikes.
The more compact the body, the more precisely material must be distributed between bosses and ears. Al Forge Tech (AFT) closed-die hot forges the body and bosses and confirms fill of the small bosses with QForm simulation. After heat treatment, piston bores, fluid passages, fitting threads and mounting holes are CNC-machined, and mounting-hole spacing and bore positions are verified on CMM.
主な機能
- Compact body reduces caliper weight
- Hose-fitting and bleed-valve bosses forged in
- Piston bores, fluid passages and fitting threads CNC-machined
- Mounting-hole spacing and bore positions measured on CMM
Forged Aluminum Bicycle Brake Caliper (Lightweight) Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 製品カテゴリー | Aluminum Forging Bicycle Parts |
| 申請 | Hydraulic disc brake calipers for road and cross-country mountain bikes |
| 主なプロセス | 閉型熱間鍛造（熱間鍛造プレス：600T～8,000T） |
| 素材 | お客様の仕様に合わせて選択可能。2xxx、5xxx、6xxx、7xxx シリーズのアルミニウム合金（例：2014、6061、6082、7075） |
| 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 | ザイツCMM（4台）、硬度計、分光計、蛍光透過検査ライン |
| 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 Bicycle Brake Caliper (Lightweight) 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
How does a lightweight caliper balance weight and stiffness?
Weight is usually removed from lightly loaded areas while keeping section around the bore bosses and at the roots of the mounting ears. Forging gives the remaining material continuous grain flow and a dense structure, maintaining strength in a smaller section. The actual sections and lightening layout must be confirmed by the brand’s structural analysis and brake testing, and AFT can advise on forging features at the DFM stage.
Which standards must the caliper mounting holes match?
Common bicycle disc caliper mounts include post mount and flat mount, each with its own hole spacing and mounting-face specification. AFT machines the mounting holes and faces to the brand’s drawing and measures spacing, diameter and flatness on CMM to ensure correct fit with the frame or fork mount.
How does a forged aluminum Forged Aluminum Bicycle Brake Caliper (Lightweight) compare with casting or machining from billet?
Forging shapes aluminum in the solid state under pressure, so the grain flow follows the part contour and the porosity and shrinkage common in castings are avoided. Compared with machining from solid billet, a near-net-shape forging removes less material and shortens machining time. For a Forged Aluminum Bicycle Brake Caliper (Lightweight) under repeated loads, forging balances strength and weight; the final choice still depends on design loads and volume.
How are MOQ and lead time for the Forged Aluminum Bicycle Brake Caliper (Lightweight) determined?
MOQ and lead time depend on part size, number of die sets, alloy and machining scope, and are confirmed in the quotation after drawing review. The typical sequence is die development, forged samples, sample approval and then mass production. Sharing your annual volume and call-off schedule helps us plan dies and capacity for the Forged Aluminum Bicycle Brake Caliper (Lightweight).
Can you assess forging feasibility while the Forged Aluminum Bicycle Brake Caliper (Lightweight) 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。.
Request a Quote for the Forged Aluminum Bicycle Brake Caliper (Lightweight)
Developing a new Forged Aluminum Bicycle Brake Caliper (Lightweight) 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.
Forging shapes aluminum in the solid state under pressure, so the grain flow follows the part contour and the porosity and shrinkage common in castings are avoided. Compared with machining from solid billet, a near-net-shape forging removes less material and shortens machining time. For a Forged Aluminum Bicycle Brake Caliper (Twin Bore) under repeated loads, forging balances strength and weight; the final choice still depends on design loads and volume.
Request a Quote for the Forged Aluminum Bicycle Brake Caliper (Twin Bore)
Developing a new Forged Aluminum Bicycle Brake Caliper (Twin Bore) 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。 Aluminum Forging Bicycle Parts 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。.
