Cycling / Bicycle
🛑 Bicycle Braking System Components
Thin disc rotors with vented/spider webs, precision-machined piston inserts, hollow banjo bolts with sealing washers, multi-position adapters
What is Bicycle Braking System Components?
🛑 Bicycle Braking System Components represents a complete system of precision titanium components engineered for Cycling / Bicycle applications. Thin disc rotors with vented/spider webs, precision-machined piston inserts, hollow banjo bolts with sealing washers, multi-position adapters The system integrates 9 distinct component types manufactured through 3 specialized processes.
Key manufacturing processes for this system include CNC turning Swiss-type for brake caliper hardware geometry, Thread rolling DIN 13-1 6g at 200W fiber laser, Vibratory deburring at 200W fiber laser, Go/No-Go ring gauging at 200W fiber laser, Thread rolling DIN 13-1 6g for net-shape tolerance, each selected and qualified to meet component-specific requirements.
Engineering & Design Principles
Material: Grade 5 (Ti-6Al-4V) offers high shear strength for rotor bolts, ultra-low thermal conductivity (7 W/mK vs 105 for Al) to insulate brake fluid — critical for preventing brake fade on long descents. Cal
Form: Plate stock for rotor machining. Bar stock for bolts, piston inserts, banjo fittings, and bleed screws. SLM 3D printing for flat-mount brake adapters with optimized topology. All bolts: forged + threa
Standards & Material Specifications
Standards: ASTM B348 Grade 5, rolled threads (DIN 13-1 / ISO 965-2, 6g), T25 Torx, 100% MPI + 6g ring gauge + pressure tested, PVD coated per ISO 27874 (1.5um), ASTM F86 passivated
Engineering Solution Blueprint
Bicycle Braking System Components
Cycling · Automotive · Aerospace
1 Part Feature Analysis
Precision-machined caliper bodies with opposed pistons, thin disc rotors (160-203mm) with floating mount interface, banjo fittings, bleed port screws, lever blades with pivot bushings
- ⚠️ Weight reduction for rotational/unsprung mass
- ⚠️ Brake fade from heat buildup during long descents
- ⚠️ Pad material compatibility with Ti rotor surfaces
- ⚠️ Lever blade stiffness under heavy braking force
- ⚠️ Corrosion from brake fluid and road salt
2 Material Selection Rationale
Grade 5 Ti-6Al-4V — General alpha-beta alloy, high strength
Grade 5 (Ti-6Al-4V) provides the optimal balance of strength, heat dissipation (thermal conductivity 6.7 W/m·K), and weight for brake calipers and levers. Grade 23 ELI for master cylinder pistons requiring surface hardness. Grade 5 is anodized black for corrosion resistance against DOT fluid.
3 Form Selection Rationale
Round Bar / Rod — for turning, fasteners
CNC machining from billet for caliper bodies and lever blades. Bar stock for banjo bolts and bleed screws. Plate cutting + CNC profiling for disc rotors. Swiss-turning for master cylinder pistons.
4 Manufacturing Process & Services
Core Processes:
Toll Processing Services:
Process Pitfalls:
- ⚠️ Disc rotor thickness variation must be <0.05mm to prevent brake pulsation at high speed
- ⚠️ Caliper bore surface finish Ra<0.2um required for seal integrity without stiction
- ⚠️ Ti disc rotors require sintered metal pads — organic pads glaze over at high temperature
5 Procurement Specifications
ASTM B348 Grade 5, annealed + anodized, 100% pressure tested + CMM inspected, brake dyno certified per batch
Manufacturing Process Flow
5-axis CNC milling centers provide simultaneous multi-axis interpolation for complex titanium components. The ability to tilt the tool relative to the
Thread rolling cold-forms threads by displacing material between two reciprocating or rotary dies, rather than cutting it away. Compressive residual s
Swiss-type automatic lathes use a sliding headstock and fixed guide bushing to machine slender titanium components. The guide bushing supports the bar
Components in This System
| Component | Material |
|---|---|
| Titanium Brake Caliper Mounting Bolt | Grade 5 Ti-6Al-4V |
| Titanium Brake Bleed Port Screw | Grade 5 Ti-6Al-4V |
| Titanium Brake Lever Pivot Pin | Grade 5 Ti-6Al-4V |
| Titanium Brake Caliper Piston Insert | Grade 5 Ti-6Al-4V |
| Titanium Brake Rotor (Disc) | Grade 5 Ti-6Al-4V |
| Titanium Brake Pad Retaining Pin | Grade 5 Ti-6Al-4V |
Frequently Asked Questions
What titanium grades are used in Bicycle Braking System Components systems?
What manufacturing processes are used for Bicycle Braking System Components?
What quality standards apply to Bicycle Braking System Components components?
What industries use Bicycle Braking System Components?
Can you provide DFM feedback for Bicycle Braking System Components designs?
Engineering Trends
- ▸ Process: CNC machining of rotor profile/brake track
- ▸ Process: Precision turning of caliper piston Ti-inserts
- ▸ Process: Hot forging + thread rolling of all rotor & caliper bolts
Related Manufacturing Capabilities
These specialized processes support Bicycle Braking System Components component manufacturing.
One Metal. One Focus. Infinite Precision.
Founded in 2011 in Baoji's Titanium Valley, BOZE Metal is dedicated exclusively to titanium — from raw material to precision engineering. AS9100D, ISO 13485 & ISO 9001 certified with 500+ clients across Aerospace, Medical & Motorsport industries, we deliver end-to-end precision titanium CNC machining with full material traceability from source to component.
Boze CNC Ti is the dedicated titanium manufacturing center of Baoji Boze Metal Products Co., Ltd.