Brake Caliper
描述
Forged Aluminum Bicycle Brake Caliper (Extended Barrel): Body and Barrel Forged Together
This extended-barrel forged aluminum bicycle brake caliper is a brake body forging with an angled cylindrical barrel. The box-shaped body carries bosses and mounting ears, and the barrel extends diagonally upward from it as a mounting section for a hose, hydraulic cylinder or linkage. Body and barrel are forged in one piece with no separately welded or threaded extension.
Where the barrel meets the body the section changes abruptly, and material must flow smoothly into the slender barrel during forging. Al Forge Tech (AFT) plans preform and finisher stages for closed-die hot forging so grain flow runs continuously from body into barrel. After heat treatment, the barrel bore, fluid passages and mounting holes are CNC-machined, and barrel angle and hole positions are verified on CMM.
主要功能
- Box-shaped body and angled barrel forged in one piece
- No welded or threaded extension interface
- Barrel bore, fluid passages and mounting holes CNC-machined
- Barrel angle and hole positions verified on CMM
Forged Aluminum Bicycle Brake Caliper (Extended Barrel) Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 產品類別 | Aluminum Forging Bicycle Parts |
| 申請 | Bicycle hydraulic brake bodies (to brand design) |
| 主要過程 | 閉式熱鍛造（熱鍛造壓機 600T–8,000T） |
| 材質 | Selected to customer specification; 2xxx, 5xxx, 6xxx and 7xxx series aluminum alloys available (e.g. 2014, 6061, 6082, 7075) |
| 熱處理 | 根據合金與強度要求而提供的內部 T4 處理方案（8 套）及 T6 人工老化處理方案（7 套） |
| 二次加工 | CNC 加工（52 台加工中心、30 台銑床）、銑削、振動磨削 |
| 表面處理 | 按要求進行陽極氧化（包括硬陽極氧化）、噴射粉碎、電子塗層或塗漆。 |
| 檢查 | Zeiss CMM (4 units), hardness testers, spectrometer, fluorescent penetrant inspection line |
| 尺寸與公差 | 按客戶提供2D/3D圖紙 |
| 品質管理系統 | IATF 16949:2016、ISO 14001:2015 |
Forged Aluminum Bicycle Brake Caliper (Extended Barrel) Manufacturing Process
- 繪圖評估與 DFM我們確認合金、載荷方向和關鍵尺寸，然後執行 QForm 模擬，以預測金屬流動和缺陷風險。.
- 設計與製造銑刀組數（例如，阻斷刀和完成刀）視零件的複雜程度而定，銑刀輪廓則使用便攜式3D掃描儀進行檢查。.
- 熱鍛造600T–8,000T 熱鍛造壓 Presses 的閉式成形技術創造出持續的晶粒流，並遵循零件的輪廓。.
- 熱處理T4 溶液處理和 T6 人工老化處理均在廠內進行，參數由合金和強度要求設定。.
- CNC加工 以及完成孔、螺紋和接合面均經過機械加工，然後根據需要進行拋光、振動拋光、噴丸或陽極氧化處理。.
- 檢查與運輸尺寸、硬度及化學成分均通過 CMM、硬度測試儀及分光光度儀進行驗證，且所有批次的產品均遵照 IATF 16949 的標準進行追蹤。.
常見問題
What is the benefit of forging the barrel in one piece with the body?
If the barrel were welded or threaded onto the body, the joint could become a hydraulic leak path or weak point and would add assembly steps. One-piece forging forms barrel and body from the same material with continuous grain flow and no joint, and fluid passages can be machined straight through one part, reducing leak risk.
How are forging defects avoided where the slender barrel meets the body?
Abrupt section changes can obstruct flow and cause underfill or laps. AFT uses QForm to simulate how material flows into the barrel, designs a preform so enough material reaches the barrel first, then completes the body detail in the finisher die, checking the junction on first, middle and last pieces.
How do you keep the Forged Aluminum Bicycle Brake Caliper (Extended Barrel) 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 (Extended Barrel) stable across lots.
Can Al Forge Tech supply the Forged Aluminum Bicycle Brake Caliper (Extended Barrel) 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 Bicycle Brake Caliper (Extended Barrel) can be delivered as a forged blank, semi-finished or fully machined part.
How are MOQ and lead time for the Forged Aluminum Bicycle Brake Caliper (Extended Barrel) 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 (Extended Barrel).
Request a Quote for the Forged Aluminum Bicycle Brake Caliper (Extended Barrel)
Developing a new Forged Aluminum Bicycle Brake Caliper (Extended Barrel) 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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若要比較相似的零件，請瀏覽 Aluminum Forging Bicycle Parts 以及我們的 汽車鋁合金鍛造應用, 或參觀 公司簡介 關於我們的設備與認證。.
