Brake Caliper
描述
Forged Aluminum Bicycle Brake Caliper (Single Boss): Compact Caliper Body Forging
This single-boss forged aluminum bicycle brake caliper is a compact disc caliper body forging: a shouldered body with a cylindrical boss on one side, which can be machined into a piston bore or hose-fitting seat, and an opening at the bottom that straddles the rotor. Compact calipers like this are used as halves of two-piece calipers or in mechanical and single-piston caliper designs.
The caliper body must stay dimensionally stable under braking. Forging keeps grain flow continuous between boss and body and gives a dense structure that is less prone to leaks after the piston bore is machined. After hot forging, Al Forge Tech (AFT) applies in-house T6 heat treatment, CNC-machines the bore, fluid passages and mounting holes, and inspects with fluorescent penetrant and CMM.
主要功能
- Compact body and cylindrical boss forged in one piece
- Suited to two-piece caliper halves or single-piston designs
- Dense forged structure reduces leak risk after bore machining
- Fluorescent penetrant and CMM inspection
Forged Aluminum Bicycle Brake Caliper (Single Boss) Specifications and Manufacturing Capability
| 商品 | 詳細 |
|---|---|
| 產品類別 | Aluminum Forging Bicycle Parts |
| 申請 | Bicycle disc brake calipers (two-piece halves, single-piston or mechanical designs) |
| 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 (Single Boss) 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
How do two-piece and monobloc calipers differ in forging?
A two-piece caliper is assembled from two halves, each simpler in shape, formed with fewer dies and easier to machine into bores and passages. A monobloc caliper is machined from a single forging, with a complex shape requiring multiple die sets but higher stiffness. AFT has production experience with both and can recommend based on the brand’s performance and cost targets.
How are piston bores kept leak-free?
Leaks usually come from internal porosity or surface defects on machined faces. Forged aluminum is dense, lowering the risk of internal porosity, and AFT inspects machined parts for surface defects on its fluorescent penetrant line and cleans fluid passages on its ultrasonic washing line. Bore size and surface roughness are measured with CMM and a surface roughness tester.
Can you assess forging feasibility while the Forged Aluminum Bicycle Brake Caliper (Single Boss) is still in design?
是的。Al Forge Tech 主要作為 OEM 供應商提供服務，我們的工程師可以在構思或繪圖階段就設計的可生產性（DFM）提供意見，例如調整薄邊緣、急切的切面變化或設計角度，以避免殘料和未填充區域。QForm 模擬能及早預測金屬流動，並與我們已有的模具設計經驗進行交叉核對。.
Can the Forged Aluminum Bicycle Brake Caliper (Single Boss) be anodized or given other surface finishes?
Yes. Al Forge Tech offers anodizing (including hard anodizing), shot blasting, vibratory finishing, e-coating and painting, plus pickling and ultrasonic washing lines to clean parts after machining. Please note the finish type and film thickness on the drawing so machining allowances and cosmetic standards for the Forged Aluminum Bicycle Brake Caliper (Single Boss) can be evaluated together.
Is heat treatment for the Forged Aluminum Bicycle Brake Caliper (Single Boss) 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 (Single Boss) 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.
Request a Quote for the Forged Aluminum Bicycle Brake Caliper (Single Boss)
Developing a new Forged Aluminum Bicycle Brake Caliper (Single Boss) 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.
- 線上查詢： 聯絡我們
- 電子郵件： [email protected]
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。.
