KR20200112556A - Method of manufacturing caliper piston - Google Patents

Abstract

The present invention relates to a method for manufacturing a caliper piston, which can quickly and precisely forge a caliper piston at low fabrication costs. To this end, the method for manufacturing a caliper piston according to the present invention comprises: a round bar preparing step of preparing a round bar; a cutting step of cutting the round bar to process the same into a cylindrical material having a height shorter than the outer diameter thereof; a material supplying step of supplying the cylindrical material to a parts former of a forging facility by means of the material supplying device of the forging facility; a shaping step of shaping the cylindrical material supplied to the parts former into a caliper piston through a single forging operation; and an ejection step of ejecting the shaped caliper piston from the forging facility.

Description

Manufacturing method of caliper piston {METHOD OF MANUFACTURING CALIPER PISTON}

The present invention relates to a caliper piston, and more particularly, to a method of manufacturing a caliper piston capable of forging a caliper piston quickly and precisely at a low manufacturing cost.

As is widely known, a disk brake caliper is a device that holds a front wheel brake by pressing a pad of an automobile in close contact with the disk brake, and is operated by hydraulic pressure.

As illustrated in FIG. 1, the disc brake caliper is a caliper having brake pads 130 that slide on both sides of the disc installed to rotate synchronously with the wheel while being fixed to the inner knuckle arm of the wheel. It consists of a caliper bracket 120 and a caliper body 110 that slides through the caliper bracket 120 so as to contact the brake pad 130 with the disk by the action of the piston 113 according to hydraulic pressure. have.

In addition, a wheel cylinder 111 is opened in the sliding direction of the brake pad 130 in the center of the caliper body 110, and a piston 113 is installed in the wheel cylinder 111 to provide the wheel cylinder 111 The brake pad 130 located inside the disk is slid toward the disk by hydraulic pressure injected into the disk.

At the lower end of the caliper body 110, a fork part 140 brakes the brake pad 130 located on the outer side of the disc in contact with the outer surface of the disc in reaction to the piston 113 when the piston 113 operates. It extends toward the pad 130 to support the rear surface thereof.

When the caliper brake configured as described above is used, the pressure of the vacuum boosting device acting as the brake pedal is depressed causes the brake oil of the master cylinder to flow into the wheel cylinder 111 of the caliper body 110. Inject.

At this time, the piston 113 moves forward by the injected brake oil and closes the brake pad 130 located inside the disk. While the brake pad 130 is in close contact with the disk, the caliper body 110 reacts backward to the forward action of the piston 113 by the pressure of the brake oil.

At this time, the caliper body 110 slides and moves backward. The fork portion 140 formed under the caliper body 110 that moves backward makes the brake pad 130 located on the outside in close contact with the outer surface of the disk.

Through the above-described process, the contact of the brake pad 130 to the disk stops the rotational motion of the disk or decreases the rotational speed through frictional force.

In addition, a seal 114 is installed between the end of the piston 113 and the inner surface of the wheel cylinder 111, and this seal 114 prevents leakage of brake oil from the wheel cylinder 111 to the outside. In addition, when the injection of the brace oil is released, the original position of the piston 113 can be restored.

In this way, in the disc brake caliper, the piston 113 (hereinafter referred to as a'caliper piston') that closely contacts the brake pad 130 to the disc is a component requiring a lot of precision for precise braking.

According to the prior art, a method of manufacturing a caliper piston includes a press forging method using a round bar cutting material and a former forging method using a coil material.

First, in the conventional press forging method using a round bar cutting material, after cutting a round bar material such as S10C to a certain standard, pretreatment such as annealing, shot blast, and bonderizing is performed, and then press It is a method of molding into a desired shape by putting it into a forging machine.

This conventional press forging method using a round bar cutting material enables precise molding of the product, and it is also possible to form large products with an outer diameter of 60 mm or more, and has the advantage of not only low cost of round bar, but also low cost of press mold, but round bar A process of cutting the ash is required, and there is a disadvantage that scrap is severely generated in the round bar by the saw blade during general sawing cutting.

In addition, the conventional forging method using a coil material is a method of continuously processing from cutting to molding by directly inserting the coil material wound in a coil shape that has been annealed and surface coated to a multistage forging machine called a parts former. The part former is forged in multiple stages, such as 4~6 stages, and molded into the desired shape.

On the other hand, the material supplied to the partformer is made in a method of supplying'coil material' wound in a coil form for improvement of supply efficiency and continuous manufacturing, and such coil material is straightened by the calibration roller of the uncoiler. The coil material thus calibrated is cut in a shearing method by a shear-type cutter and then transferred to a part former (refer to Registration Patent No. 10-0280894).

An example of such a part former is illustrated in Korean Patent Registration No. 10-0599182, and the part former includes a plurality of dies juxtaposed on the front of the die block and a ram having a plurality of punches installed opposite the die block, and a plurality of The die and the plurality of punches are made of a corresponding number. The parts former constitutes a plurality of forging stations as dies and punches corresponding to each other form one forging station, and a transfer mechanism for sequentially transferring materials between the plurality of forging stations is installed. With this configuration, the forging process is sequentially performed in a plurality of forging stations, and the shape of the product is formed step by step.

In the conventional forming method using coil material, the product can be directly obtained by directly inputting the coil material into the wave-side former, so the process is reduced and the production time per piece is more efficient than the press.For example, in the case of the press forging method, 25 spm (per minute) 25 production), whereas in the case of the former method, about 40-50spm is possible. However, there is a limit to the diameter of the supplied coil material, for example, if the diameter of the product to be processed is 60 mm, the diameter of the wire material must also be increased correspondingly, but it is difficult to manufacture the coil material with a diameter of 40 mm or more. Even if it is possible to manufacture a coil material having a diameter of 40 mm or more, there is a disadvantage in that the cost of the material increases and the manufacturing cost can be relatively increased. In addition, due to the multi-stage process method of the parts former, there was a disadvantage that not only the cost such as mold cost and item replacement time increased, but also the precision of the product was lowered.

In addition, in the conventional forming method using coil materials, coil feeders, uncoilers, cutters, etc. must be arranged in a line on the supply side of the forging module, as the coil material must be straightened and then cut through a cutter, etc. There was a drawback of taking up a lot of space.

KR 10-0280894 B1 KR 10-0599182 B1

The present invention is to overcome the various disadvantages of the prior art as described above, and combines only the advantages of the press forging method using the conventional round bar cutting material and the foamer method using the conventional coil material, so that the piston for a more inexpensive and precise caliper A caliper piston that forge-forms a more precise caliper piston through a single forging process by applying a cylindrical material formed by cutting a circular bar material that can be manufactured and is particularly inexpensive. Its purpose is to provide a method of manufacturing.

The method of manufacturing a caliper piston according to the present invention for achieving the above object,

Round bar material preparation step of preparing a round bar material;

A cutting step of cutting the round bar to form a cylindrical material having a height shorter than the outer diameter;

A material supply step of supplying the cylindrical material to a part former of the forging facility by a material supply device of the forging facility;

A forming step of forming a cylindrical material supplied to a part former into a caliper piston through a single forging operation; And

It consists of; a take-out step of taking out the molded caliper piston from the forging facility.

In the step of preparing the round bar, the round bar is a hot-rolled material hot-rolled into a round bar by a pressure roll while being reheated in a heating furnace.

In the step of preparing the round bar, the round bar is characterized in that surface defects are removed by cold re-rolling the hot-rolled material or cutting the surface of the hot-rolled material.

In the cutting step, the round bar is cut to a predetermined length by using any one of a circular saw and a band saw blade.

Between the cutting step and the material supply step, a pre-treatment step of lowering the hardness of the cylindrical material and increasing the ductility, and forming a film on the surface of the cylindrical material may be further included.

In the supplying step, cylindrical materials are arranged in a line by a material supply device and a material alignment device, and are supplied to the parts former.

The material supply device includes a plurality of step members installed in a stepped structure in which the position of each upper end increases from the front to the rear, and a plurality of transfer members installed to be movable up and down between the plurality of step members,

It is characterized in that the bottom dead center of the vertical movement distance of each transfer member corresponds to the upper rear point of the stair member adjacent to the lower side, and the top dead center of the vertical movement distance corresponds to the upper front point of the stair member adjacent to the upper side. do.

The material alignment device includes an alignment injection unit disposed adjacent to the material supply unit, a guide transfer unit located below the alignment injection unit, and a pressure transfer unit for pressing and transferring the materials transferred by the guide transfer unit toward the forging mold. Characterized in that.

In the forming step, the cylindrical material is transferred to the forging stations of the part former for forging molding,

Among the forging stations, only one forging station selectively performs the forging operation, and the remaining forging stations control timing for the supply of the cylindrical material, the forging operation of the cylindrical material, and the ejection of the molded caliper piston. It is characterized in that the caliper piston is formed by a single forging process by idle operation.

According to the present invention, by combining only the advantages of the conventional press forging method using a round bar cutting material and the advantages of the conventional forming method using a coil material, there is an advantage in that the caliper piston can be formed inexpensively and precisely.

In particular, the present invention prepares an inexpensive round bar material, and cuts the round bar material to form a coin-shaped cylindrical material, so that the material cost can be significantly reduced. In particular, in the case of the conventional forming method using a coil material, the cost of the coil material is high, which increases the overall manufacturing cost, whereas the present invention cuts a relatively inexpensive round bar and uses a cylindrical material, thereby reducing the material cost and making the overall manufacturing. There is an advantage of reducing unit cost.

In addition, the present invention can significantly improve the quality precision of the caliper piston by supplying a cylindrical material that has undergone cutting and pretreatment to an existing part former to form a caliper piston through a single forging operation. There is an advantage that mass production can be effectively implemented by precisely controlling the timing of supply, forging operation, and withdrawal of the finished caliper piston.

1 is a cross-sectional view illustrating an embodiment of a disc brake caliper.
Figure 2 is a flow chart showing a method of manufacturing a caliper piston according to the present invention.
3 is a perspective view illustrating a cylindrical material processed through a cutting step in the method of manufacturing a piston for a caliper according to the present invention.
4 is a view showing a part former and a molding step using the same in the method of manufacturing a piston for caliper according to the present invention.
5 is a plan view illustrating a form of a forging facility to which the method of manufacturing a caliper piston according to the present invention is applicable.
FIG. 6 is a side view as viewed from the arrow A in FIG. 5.
FIG. 7 is a side view showing a transfer unit installed in the supply case of FIG. 6, showing a state in which transfer members of the transfer unit are moved downward.
8 is a view showing a state in which the transfer members are moved upward in the state of FIG. 7.
9 is a view showing an enlarged arrow B portion of FIG. 7.
10 is a view showing an enlarged arrow C of FIG. 5.
FIG. 11 is an enlarged view of arrow D of FIG. 6.
12 is a view as viewed from the direction of arrow E in FIG. 11.
13 is a perspective view showing in detail the take-out device of FIGS. 5 and 6.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. For reference, the size of the constituent elements shown in the drawings referred to in describing the present invention, the thickness of the line, etc. may be somewhat exaggerated for convenience of understanding. In addition, terms used in the description of the present invention are defined in consideration of functions in the present invention, and thus may vary according to user, operator intention, custom, and the like. Therefore, the definition of this term should be made based on the contents of the entire specification.

2 to 4 show a method of manufacturing a caliper piston according to an embodiment of the present invention.

As shown, the method of manufacturing a caliper piston according to the present invention includes a round bar material preparation step (S1) of preparing a round bar material, and a cutting step (S2) of cutting the round bar material into a cylindrical material having a height shorter than the outer diameter. Wow, the pre-treatment step (S3) of pre-treating the cylindrical material, the material supply step (S4) of supplying the cylindrical material to the parts former of the forging facility by the supply device of the forging facility, and the cylindrical material supplied to the part former at once. It consists of a forming step (S5) of forming a caliper piston through a forging operation, and a takeout step (S6) of taking out the formed caliper piston from the forging facility.

In the round bar preparation step (S1), an inexpensive round bar material such as S10C is prepared in a predetermined length. This round bar material may be a hot-rolled material hot-rolled by a pressure roll while being reheated in a heating furnace. Further, such a hot-rolled material may be cold-rolled or the surface of the hot-rolled material may be cut.

A more detailed look at the preparation stage of this round bar is as follows.

According to an embodiment, a hot-rolled material (rolled graphite material) molded into various shapes/dimensions by a rolling roll while reheating a steel ingot to a temperature of about 1200°C in a heating furnace may be prepared as a round bar material. .

On the other hand, such a hot-rolled material is inexpensive, but has surface defects such as scale, thickness, and flaws, so according to an alternative embodiment, a drawing material obtained by cold re-rolling in order to eliminate the surface defects of the hot-rolled material as a round bar material (cold drawn bar) can be prepared, and a peeled bar obtained by cutting the surface of hot-rolled material can also be prepared.

In the cutting step (S2), a cylindrical material having a height (H) shorter than the outer diameter (D) is processed by cutting the prepared round bar material to a predetermined length, and thus the cylindrical material (m) is, as shown in FIG. 3, the outer diameter ( Compared to D), the height H may be formed in a coin shape that is shorter.

In the cutting step (S2), a circular bar of a certain length, for example 6m, is cut to a certain length using a saw blade of a circular saw. In addition, the round bar material may be cut with a saw blade of a band saw, or the round bar material may be cut by shear cutting by a billet shear. Among them, cutting with a circular saw having high cutting speed and cutting efficiency of the round bar may be preferable.

As described above, the present invention prepares a low-cost round bar material, and cuts the round bar material to form a coin-shaped cylindrical material, thereby significantly reducing the material cost. In particular, in the case of the conventional forming method using a coil material, the cost of the coil material is high, which increases the overall manufacturing cost, whereas the present invention cuts a relatively inexpensive round bar and uses a cylindrical material, thereby reducing the material cost and making the overall manufacturing. There is an advantage of reducing unit cost.

On the other hand, if the hardness of the cylindrical material (m) cut in the cutting step (S2) is high, forging is not easily performed, so the pre-treatment step (S3) in which the pre-treatment to facilitate forging of the cylindrical material (m) is performed. Can proceed.

In the pretreatment step (S3), annealing, shot blast, and bonderizing are sequentially performed on the cylindrical material m, thereby lowering the hardness and increasing the ductility of the cylindrical material m. Can be done very smoothly. Here, annealing is performed by heating the cylindrical material (m) to an appropriate temperature and then gradually cooling it to room temperature to remove internal residual stress and refine the crystal grains to increase ductility, and the shot blast is a cylindrical material (m ) By projecting a shot ball on the surface to remove black skin and scale from the surface, and the bonderizing is corroded by a chemical or electrochemical reaction by a corrosion solution (phosphate) on the surface of the cylindrical material (m) By creating a product layer (phosphate film), the lubricity during forging can be improved.

In the material supply step (S4), the cylindrical material (m) through the material supply device 20 and the material alignment device 40 of the forging facility shown in Figs. 5 to 12, the parts former of the forging module 10 ( 11) can be quickly and stably aligned and supplied.

In the forming step (S5), the cylindrical material (m) supplied by the material supply device 20 is formed into the caliper piston (cp) through a single forging operation in the part former (see FIG. 4).

As illustrated in FIG. 4, the part former 11 includes a plurality of dies 12 and a plurality of punches 13 in a number corresponding to each other, and a die 12 and a punch 13 corresponding to each other are formed. A plurality of forging stations 11a, 11b, 11c, 11d, and 11e are formed according to the forging station of The number of such forging stations (11a, 11b, 11c, 11d, 11e) can be variously configured, such as 4 to 6, so the parts foreman 11 is forging stations (11a, 11b, 11c, 11d, 11e) Depending on the number of fields, it can be made in 4~6 layers. In addition, a transfer mechanism (not shown) for sequentially transferring the cylindrical material m between the plurality of forging stations 11a, 11b, 11c, 11d, 11e is installed.

According to the present invention, among a plurality of forging stations (11a, 11b, 11c, 11d, 11e), only one forging station (11c) is selectively forged to form a cylindrical material (m) with a caliper piston (cp). And, the rest of the forging stations 11a, 11b, 11d, and 11e operate idle.

On the other hand, among the plurality of forging stations (11a, 11b, 11c, 11d, 11e), only one forging station (11a, 11b, 11c, 11d, 11e) selectively forging regardless of order In addition, the remaining forging stations 11a, 11b, 11d, and 11e operate idle to control the timing of the supply of the supplied cylindrical material m and the take-out operation of the molded product. For example, in FIG. 4, only the third forging station 11c is forged to form a cylindrical material (m) with a caliper piston (cp), and the remaining forging stations 11a, 11b, 11d, and 11e are idle. I can. In addition, if any one of the first forging station (11a), the second forging station (11b), the fourth forging station (11d), and the fifth forging station (11e) is operated forging, the remaining forging stations can be made to operate idle. have.

As described above, the present invention supplies a cylindrical material (m) that has undergone cutting and pretreatment to the existing parts former 11 to form the caliper piston (cp) through a single forging operation, so that the quality of the caliper piston (cp) Not only can the precision be greatly improved, but also the timing of the supply of the cylindrical material (m) and the take-out of the finished caliper piston (cp) can be precisely controlled, so that mass production can be effectively implemented.

On the other hand, according to the present invention, the outer diameter of the supplied cylindrical material (m) is preferably formed to be smaller than 01 ~ 02mm compared to the outer diameter of the caliper piston (cp). Thereby, when the cylindrical material (m) is forged by a single forging operation in the part former 11 in the forming step (S5), the concentricity can be precisely maintained, and thus, the caliper piston (cp) to be formed Process density can be greatly improved.

In the following, the supply of supplying the cylindrical material m to the parts former 11 of the forging module 10 by the material supply device 20 and the material alignment device 40 of the forging facility illustrated in FIGS. 5 to 12 Step S4 will be described in detail.

5 and 6, the forging facility includes a forging module 10 having a part former 11 for forming a caliper piston by a single forging process of a cylindrical material, and a forging module 10. It includes a material supply device 20 to be supplied, and a take-out device 30 for taking out the product forged by the forging module 10 to the outside.

A material transfer pipe 13 for transferring the material m to the inlet of the part former 11 is disposed inside the forging module 10.

The material supply device 20 is configured to supply a cylindrical material m that has undergone a cutting step (S2) and a pretreatment step (S3) toward the forging module 10. In addition, an alignment mechanism 40 is disposed between the material supply device 20 and the forging module 10, and the alignment mechanism 40 aligns the supplied cylindrical material m in a line, and then the transfer pipe 13 It is configured to transfer to the parts former 11 of the forging module 10 through.

The material supply device 20 includes a supply case 21, a transfer unit 50 installed in the supply case 21 to transfer the material from the bottom to the top, and a cylindrical material (m) into the supply case 21 It includes an input unit (60).

A transfer unit 50 is installed inside the supply case 21, a transfer slope 25 is formed in front of the supply case 21, and the transfer slope 25 is on the front side of the transfer unit 50. Cylindrical materials (m) positioned and input can be naturally guided to the transfer unit 50.

In addition, a recovery passage 26 is formed on one side of the supply case 21, and cylindrical materials m that are not aligned in the alignment mechanism 40 are transferred through the recovery passage 26 to the inside of the supply case 21 It can also be recovered.

As shown in Figs. 6 to 9, the transfer unit 50 is installed so as to move up and down between a plurality of step members 51 installed in the supply case 21, and a plurality of step members 51. It includes a plurality of transfer members 52.

The plurality of step members 51 are installed upright in the vertical direction from the inner rear of the supply case 21, the step members 51 are spaced apart from each other, the separation of the step members 51, the transfer member 52 Is installed to be able to move up and down.

Further, the plurality of step members 51 are fixedly installed in a stepped structure whose upper position increases from the front to the rear. An inclined surface 51a inclined downward toward the supply direction is formed at the upper end of each step member 51.

The plurality of transfer members 52 are installed to be movable up and down between the step members 51, and are installed to be movable up and down at the same time by an actuator (not shown) such as a cylinder mechanism or a transmission mechanism. In particular, each transfer member 52 moves up and down a predetermined distance (S) between the step member 51 adjacent to the lower side and the step member 51 adjacent to the upper side.

As shown in Figure 9, the lower dead center point (S1) of the vertical movement distance (S) of each transfer member 52 corresponds to the upper rear point of the step member 51 adjacent to the lower side, the upper dead center point (S2) Is configured to correspond to the upper front point of the step member 51 adjacent to the upper side.

At the top of each transfer member 52, an inclined surface 52a inclined downward toward the supply direction is formed, and the inclined surface 52a of the transfer member 52 and the inclined surface 51a of the step member 51 have the same inclination angle. Done.

When explaining in detail the operation in which the cylindrical material m is transferred by the configuration of the transfer unit 50 is as follows.

As shown in FIG. 7, when each of the transfer members 52 moves downward, the inclined surface 52a of each transfer member 52 is positioned corresponding to the inclined surface 51a of the step member 51 adjacent to the lower side thereof, and the lowermost end The inclined surface 52a of the transfer member 52 located at is positioned corresponding to the transfer inclined surface 25 of the supply case 21. In this state, the cylindrical material m inputted by the input unit 60 is placed on the inclined surface 52a of the transfer member 52 located at the lowermost end.

Then, as shown in FIG. 8, all the transfer members 52 move upward so that the inclined surface 52a of each transfer member 52 corresponds to the inclined surface 51a of the stair member 51 adjacent to the upper side thereof. When positioned, the cylindrical materials m are transported by sliding from the inclined surface 52a of the conveying member 52 to the inclined surface 51a of the step member 51. If this is described in detail with reference to FIG. 9, after the cylindrical material m is placed on the inclined surface 52a of the transfer member 52 that has moved downward, when the transfer member 52 moves upward (see dotted line) It slides from the inclined surface 52a of the transfer member 52 to the inclined surface 51a of the step member 51 and is transferred.

The cylindrical material m moves from the inclined surface 52a of the lowermost conveying member 52 to the inclined surface 51a of the step member 51 located at the next stage. Afterwards, when the transfer members 52 move downward, the cylindrical material m located on the inclined surface 51a of the step member 51 continuously moves to the inclined surface 52a of the transfer member 52 located in the next step. And, as this operation is repeated, a plurality of cylindrical materials m are transferred stepwise after rising in a stepwise manner through the inclined surface 52a of the transfer member 52 and the inclined surface 51a of the step member 51.

In this way, as the transfer members 52 repeat the downward movement and upward movement between the step members 51, the cylindrical materials m are transferred stepwise from the lower front to the upper rear.

The inclination angle of the conveying inclined surface 25 may be the same as or slightly smaller than the inclined surfaces 52a and 51a of the conveying member 52 and the step member 51, and in particular, the inclined angle of the conveying inclined surface 25 is the conveying member 52 And by being made in the same way as the inclined surfaces 52a and 51a of the step member 51, the injected cylindrical material m may be more smoothly guided toward the transfer unit 50.

In addition, the lowermost transfer member 51 is located at the lower end of the transfer inclined surface 25, and the inclined surface 51a of the transfer member 51 in a state in which the lowermost transfer member 51 moves downward as shown in FIG. 7 It is located corresponding to the transfer inclined surface 25. Accordingly, the cylindrical material m inputted by the input unit 60 naturally slides on the inclined surface 52a of the lowermost transfer member 51 along the transfer inclined surface 25.

The input unit 60 includes an input frame 61 disposed adjacent to the front end of the supply case 21, and an input hopper 64 rotatably installed on the input frame 61 via a hinge part 63. Include.

A receiving container (not shown) in which a plurality of cylindrical materials (m) are accommodated is installed in the input hopper 64 to be replaced, and when the input hopper 64 is rotated through the hinge part 63, a plurality of cylindrical materials (m) They are put into the feed inclined surface 25 of the supply case 21.

The material alignment device 40 is disposed between the material supply device 20 and the forging module 10, and arranges a cylindrical material (m) supplied by the transfer unit 50 of the material supply device 20 in a line. It is configured to be transferred to the parts former 11 of the forging module 10 after.

As shown in FIGS. 10 and 11, the material aligning device 40 includes an alignment insert 41 disposed adjacent to the material supply device 20, and a guide transfer unit located under the alignment insert 41 ( 43), and a pressure transfer unit 45 for transferring the cylindrical material m transferred by the guide transfer unit 43 by pressing toward the forging mold 11 side.

The alignment injection part 41 includes an inclined input plate 41a disposed adjacent to the transfer unit 50 of the material supply device 20, a cover 41b installed on the top of the inclined input plate 41a, and the inclined input It includes a plurality of alignment members (41c, 41d) disposed on the upper portion of the plate (41a).

The inclined input plate 41a is formed to be inclined downward toward the guide transfer unit 43, and a plurality of cylindrical materials (m) supplied by the transfer unit 50 of the material supply device 20 are the inclined input plate 41a. It slides along the inclined surface of and is fed into the guide transfer unit 43.

The cover 41b is disposed above the inclined input plate 41a and is configured to prevent the cylindrical material m supplied by the transfer unit 50 of the material supply device 20 from splashing or escaping to the outside.

A plurality of alignment members (41c, 41d) are installed between the inclined input plate (41a) and the cover (41b), the upper end of each alignment member (41c, 41d) is fixed to the bottom of the cover (41b), each alignment member The lower end of (41c) is located adjacent to the inclined input plate (41a).

Each of the alignment members (41c, 41d) is inclined to the left and right to align the posture of the cylindrical material (m) in a state lying down along the inclined direction of the inclined input plate (41a) as shown in Figure 12 (41e) It is formed in an inverted "V"-shaped structure, whereby the cylindrical materials (m) are erected in a direction orthogonal to the inclined input plate (41a) as they slide on the inclined surfaces (41e) of the alignment members (41c, 41d). The wide surface of the cylindrical material (m) is aligned in a laid down state so as to contact the inclined input plate (41a), so that it can be stably introduced into the guide transfer unit (43).

And, the plurality of alignment members (41c, 41d) is a plurality of first alignment member (41c) and a plurality of second alignment members (41d) are arranged to be spaced apart from each other in the input direction, as shown in FIG. The first alignment member 41c and the plurality of second alignment members 41d are arranged to be offset from each other ('zigzag type' arrangement), thereby further improving the alignment efficiency of the cylindrical materials m.

Guide transfer unit 43, as shown in Figs. 9 and 10, the transfer belt (43a) installed in the lower portion of the alignment input portion 41, and to be upright in a vertical direction on the top of the transfer belt (43a) The installed guide vertical wall 43b, a pair of curved guide plates 43c provided at the ends of the guide vertical walls 43b, and a pair of inclined guide members connected to the ends of the pair of curved guide plates 43c Include (43d).

The transfer belt (43a) is installed long in the horizontal direction from the lower portion of the alignment insert (41), and is configured to transfer the cylindrical material (m) input to the upper surface of the transfer belt (43a) in the horizontal direction.

The guide vertical wall 43b is installed vertically on the top of the transfer belt 43a and extends long along the longitudinal direction of the transfer belt 43a. Cylindrical materials (m) introduced into the upper surface of the transfer belt (43a) can be arranged in a vertical position by hanging on the guide vertical wall (43b), and also the external separation of the materials (m) by the guide vertical wall (43b) is effectively Can be prevented.

A pair of curved guide plates 43c are formed to have a curved surface to guide the cylindrical material m to the lower side of the transfer belt 43a, as shown in FIG. 9, and the pair of curved guide plates 43c have a cylindrical shape. It is possible to smoothly guide the cylindrical materials m by being spaced apart at intervals slightly larger than the thickness of the material m.

The pair of inclined guide members 43d are connected to the ends of the pair of curved guide plates 43c and installed inclined downward.

And, the spacing between the pair of inclined guide members (43d) corresponds to the spacing between the pair of curved guide plates (43c).

The pressure transfer unit 45 is disposed at the lower end of the inclined guide member 43d and is configured to pressurize and transfer the cylindrical material m transferred through the guide transfer unit 43 toward the forging mold 11.

The pressure transfer unit 45 includes a seating portion 45a located below the inclined guide member 43d of the guide transfer portion 43, a transfer pipe 45b installed at the front end of the seating portion 45a, and a seating portion ( It includes a pressure plunger (45c) arranged in a row at the rear of the 45a), and a driving cylinder (45d) for driving the pressure plunger (45c) back and forth.

A support jig 46 that supports the cylindrical material (m) transferred through the inclined guide member (43d) is installed in the seating portion (45a), and the cylindrical material (m) is in its correct position by the support jig (46). Will be located.

The transfer pipe (45b) is installed to extend from the front end of the seating portion (45a) to the forging mold (11) of the forging module (10), and the inner diameter of the transfer pipe (45b) so as not to interfere with the transfer of the cylindrical material (m) Is formed larger than the outer diameter of the cylindrical material (m).

The pressure plunger 45c is installed so as to be able to move forward and backward in the plunger housing 47, and a buffer spring 48 is installed on one side of the pressure plunger 45c. Accordingly, as the pressure plunger 45b moves forward and backward in the plunger housing 47, the pressure plunger 45b is configured to press the material m located in the seating portion 45a toward the transfer pipe 45d on the front side.

The driving cylinder 45c is installed at the rear end of the plunger housing 47 to drive the forward and backward operation of the pressure plunger 45b.

In this way, when the cylindrical material m is supplied by the material supply device 20, the cylindrical material m supplied by the material aligning device 40 is arranged in a row very quickly and stably, and then the forging module 10 ) There is an advantage that can be effectively transferred to the part former (11) side.

In the take-out step (S6), the caliper piston cp, which has been molded through the molding step (S5), is taken out from the forging facility.

In this take-out step (S7), the caliper pistons cp formed by the parts former 11 of the forging module 10 are taken out bufferedly by the take-out device 30 so that they are not damaged.

As shown in Figure 13, the take-out device 30 is configured to take out the forged caliper pistons (cp) forged in the forging module 10, in particular, the take-out device 30 guides the products to be taken out And a take-out guide unit 31 and a drop buffer unit 35 disposed at the lower end of the take-out guide unit 31.

The take-out guide unit 31 includes a guide frame 32 disposed inclined downward from the discharge part 15 of the forging module 10, and a plurality of guide members 33 installed inside the guide frame 32. .

A discharge opening (32a) is formed at the lower end of the guide frame (32), and the plurality of guide members (33) are spaced apart from each other to form a discharge passage (34) inside the guide frame (32) in a diagonal direction and a zigzag direction. Is placed.

As shown in Figure 13, the drop buffer unit 35 is a moving frame 37 installed to be movable up and down by a driving unit 39 on the support frame 36, and at the lower end of the moving frame 37 It includes a fall buffer frame 38 provided, and a plurality of buffer blades (38a) rotatably installed in the drop buffer frame (38).

The moving frame 37 is configured to move up and down with respect to the support frame 36 by a driving part 39 composed of a drive motor 39a and a drive strip 39b.

As shown in Fig. 13, the drop buffer frame 38 has a structure in which the inside is opened up and down. And, as shown in Figure 5, a plurality of buffer blades (38a) are symmetrically rotatably installed at the lower opening of the drop buffer frame (38), and each buffer blade (38a) is rotated by a hinge (38b) It is installed as possible.

With the configuration of the take-out device 30, the caliper pistons cp forged in the forging module 10 are buffered by a plurality of guide members 33 in the guide frame 32 of the take-out guide unit 31. Being guided. As the guided caliper pistons (cp) move up and down, the caliper pistons (cp) taken out as the buffer blades (38a) of the fall buffer frame (37) rotate as the moving frame (35) moves up and down are in the packaging container (P). When it is dropped, it is sufficiently buffered so that damage at the time of taking out can be minimized.

As described above, specific embodiments of the present invention have been described, but the present invention is not limited by the embodiments disclosed in this specification and the accompanying drawings, and may be variously modified by those skilled in the art within the scope not departing from the technical spirit of the present invention. .

10: forging module 11: parts former
20: material supply device 30: take-out device
40: material alignment device 50: transfer unit

Claims (5)

Round bar material preparation step of preparing a round bar material;
A cutting step of cutting the round bar to form a cylindrical material having a height shorter than the outer diameter;
A material supply step of arranging the cylindrical material in a line by a material supply device and a material alignment device of the forging facility and supplying it to a part former of the forging facility;
A forming step of forming a cylindrical material supplied to a part former into a caliper piston through a single forging operation;
Consists of; a take-out step of taking out the molded caliper piston from the forging facility,
The outer diameter of the cylindrical material supplied in the material supply step is formed smaller than the outer diameter of the caliper piston molded in the forming step,
The material alignment device includes an alignment injection unit disposed adjacent to the material supply unit, a guide transfer unit located below the alignment injection unit, and a pressure transfer unit for pressing and transferring the materials transferred by the guide transfer unit toward the forging mold. and,
The alignment insert has an inclined input plate disposed adjacent to the transfer unit of the material supply device, a cover installed on the inclined input plate, and a plurality of alignment members disposed on the inclined input plate,
Each alignment member is formed in an inverted "V"-shaped structure with inclined surfaces inclined on both left and right sides to guide and align the postures of the cylindrical materials while lying on the inclined surface of the inclined input plate,
The guide transfer unit includes a transfer belt installed under the alignment insertion unit, a guide vertical wall installed vertically on the top of the transfer belt, a pair of curved guide plates provided at ends of the guide vertical walls, and a pair of It has a pair of inclined guide members connected to the ends of the curved guide plate,
The pressure transfer unit includes a seating portion provided with a support jig for supporting the cylindrical material transferred through the inclined guide member of the guide transfer portion, a transfer pipe extending from the front end of the seating portion to a forging mold of the forging module, and the seating portion. It has a pressure plunger disposed at the rear to press the material supported by the support jig of the seating portion toward the transfer pipe on the front side, and a drive cylinder for moving the pressure plunger forward and backward,
In the forming step, the cylindrical material is transferred to the forging stations of the part former for forging molding, and only one of the forging stations selectively performs the forging operation, and the remaining forging stations are used to supply the cylindrical material and , A method for manufacturing a caliper piston, characterized in that the forging operation of the cylindrical material and the idle operation to control the timing of the take-out of the molded caliper piston are used to form the caliper piston by a single forging process. . The method according to claim 1,
In the step of preparing the round bar, the round bar is a hot-rolled material hot-rolled by a pressure roll while being reheated in a heating furnace. The method according to claim 2,
In the step of preparing the round bar material, the round bar material removes surface defects by cold re-rolling the hot-rolled material or cutting the surface of the hot-rolled material. The method according to claim 1,
Between the cutting step and the material supply step, a pretreatment step of lowering the hardness of the cylindrical material and increasing the ductility, and forming a film on the surface of the cylindrical material. The method according to claim 1,
The material supply device includes a plurality of step members installed in a step-like structure in which the position of each upper end increases from the front to the rear, and a plurality of transfer members installed to be movable up and down between the plurality of step members,
It is characterized in that the bottom dead center of the vertical movement distance of each transfer member corresponds to the upper rear point of the stair member adjacent to the lower side, and the top dead center of the vertical movement distance corresponds to the upper front point of the stair member adjacent to the upper side. Method of manufacturing a caliper piston.

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