Brake Caliper
描述
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.
主要功能
- 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 |
|---|---|
| 產品類別 | 汽車零配件 |
| 申請 | Multi-piston disc brake systems for performance and modified cars |
| 主要過程 | 閉式熱鍛造（熱鍛造壓機 600T–8,000T） |
| 材質 | Per customer specification; 6061-T6 or high-strength 7xxx alloys are typically evaluated for performance calipers |
| 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 | 蔡司 CMM（4 臺）、硬度測試儀、分光光譜儀、熒光穿透線；可提供抗拉強度測試和疲勞測試 |
| 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 Automotive Multi-Piston Brake Caliper 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 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?
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。.
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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- 電子郵件： [email protected]
