Brake Caliper
描述
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.
主要功能
- 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 |
|---|---|
| 產品類別 | Aluminum Forging Bicycle Parts |
| 申請 | Hydraulic disc brake calipers for bicycles and e-bikes |
| 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 (Twin Bore) 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
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.
主要功能
- 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 |
|---|---|
| 產品類別 | Aluminum Forging Bicycle Parts |
| 申請 | Hydraulic disc brake calipers for road and cross-country mountain bikes |
| 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 (Lightweight) 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 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?
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。.
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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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。.
