US20040025688A1 - Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith - Google Patents

Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith Download PDF

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Publication number
US20040025688A1
US20040025688A1 US10/217,132 US21713202A US2004025688A1 US 20040025688 A1 US20040025688 A1 US 20040025688A1 US 21713202 A US21713202 A US 21713202A US 2004025688 A1 US2004025688 A1 US 2004025688A1
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US
United States
Prior art keywords
flange
main body
bore
cylinder
cold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/217,132
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English (en)
Inventor
Leonardus Koekenberg
Geert Jongstra
Henricus Alferink
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NEUMAN METAL FORMING NETHERLANDS BV
Original Assignee
NEUMAN METAL FORMING NETHERLANDS BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by NEUMAN METAL FORMING NETHERLANDS BV filed Critical NEUMAN METAL FORMING NETHERLANDS BV
Priority to US10/217,132 priority Critical patent/US20040025688A1/en
Priority to EP02078526A priority patent/EP1389571A1/en
Priority to JP2002269025A priority patent/JP2004142471A/ja
Assigned to NEUMAN METAL FORMING NETHERLANDS. B.V. reassignment NEUMAN METAL FORMING NETHERLANDS. B.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALFERINK, HENRICUS JOHANNES MARIA, JONGSTRA, GEERT JAN, KOEKENBERG, LEONARDUS GERHARDUS PLECHELMUS
Publication of US20040025688A1 publication Critical patent/US20040025688A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60T—VEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
    • B60T11/00—Transmitting braking action from initiating means to ultimate brake actuator without power assistance or drive or where such assistance or drive is irrelevant
    • B60T11/10—Transmitting braking action from initiating means to ultimate brake actuator without power assistance or drive or where such assistance or drive is irrelevant transmitting by fluid means, e.g. hydraulic
    • B60T11/16—Master control, e.g. master cylinders

Definitions

  • the invention relates to a method for manufacturing a master cylinder for a brake system, comprising a cylindrical main body, at least one flange integrally connected therewith and a bore, extending in the cylindrical main body and through said at least one flange.
  • Such cylinders are well known from the prior art. They can be used in brake systems in for instance the automotive or machine building industry and are commonly manufactured by die-casting or injection moulding. These manufacturing methods offer a large freedom to the designers and relative ease of manufacturing. However, the cylinders manufactured with these methods do not always satisfy the criteria set by the manufacturers or users. For instance, the known methods may lead to surface problems, caused by inclusions, cavities or pores and the like. These irregularities may for instance arise due to gas entrapped in the melted material or shrinkage of the material during cooling down. These surface irregularities, especially when occurring in the bore, may hinder smooth travelling of a piston within the cylinder, causing excessive wear, malfunctioning or early failure.
  • the inclusions and cavities affect the homogeneity of the cylinder and may induce local peak stresses. These peak stresses may accelerate the formation of hair cracks and, ultimately, lead to failure of the product. Also, when the pores or cavities form a continuous chain, leakage may occur.
  • the present invention has as a main object to provide a method for manufacturing cylinders according to the preamble of claim 1, with which at least a number of the problems related to the known cylinders and manufacturing methods can be avoided. To this end a method according to the present invention is characterized by the features of claim 1.
  • cycle times can be relatively short, since the product needs no cooling down time, and product precision can be high, inter alia since no substantial shrinkage does take place. Also, if carried out properly, cold forging enables efficient use of material, since little excessive material will have to be removed afterwards.
  • a method according to the present invention is characterized by the features of claim 4.
  • the part of the cylinder taking up a relatively large amount of material should be forged first, to prevent such part from suctioning material away from other, smaller parts of the cylinder, which would leave these parts with a shortage of material. It should therefore be understood that in an alternative embodiment of a cylinder according to the invention, wherein the flange accounts for a smaller material percentage of the total product, the forging order as recommended in claim 4 could be reversed.
  • the step of forging the flange and the step of forging a bore in the cylindrical main body each are subdivided in a series of substeps.
  • These substeps can be chosen such, that the asymmetry of the force distribution on the material and forging tools is kept within acceptable boundaries at each step and the material flow will be such that substantially no undesirable stresses will remain in the final product obtained.
  • the forging process can be broken down in as many substeps as necessary, to obtain at each step a controlled and preferably substantially symmetric material flow, regardless of the shape of the final product to be manufactured.
  • the tool may be profiled such that during forging the tool will be forced in a specific direction, which is opposed to the warpage direction.
  • the profile may for instance comprise a chamfered edge, extending along a portion of the free end of the tool. Such profile may particularly be advantageous during the last stage of the making of the bore.
  • a method according to the present invention is characterized by the features of claim 9 or 10.
  • the flange could also be cold forged by radial extrusion, wherein pressure is applied on two opposite sides of the material.
  • a method according to the present invention is characterized by the features of claims 11, 12 and/or 13.
  • desired properties of the material may be enhanced. For instance, the formability of the material can be improved by subjecting the material to a softening operation. Also, hardness and wear resistance may be enhanced by subjecting the final product to an annealing operation.
  • the product and/or tools are lubricated before one or each forging step, to facilitate the forging process, ease the material flow and protect the contact surfaces of the tools and the product.
  • a transfer press wherein all consecutive forging steps are executed directly after each other, it suffices to lubricate the product only once, prior to the first forging step.
  • the lubricant will retain its beneficial function throughout all subsequent forging steps.
  • the invention furthermore relates to a master cylinder, substantially manufactured by cold forging, according to the features of claims 13-16.
  • a master cylinder substantially manufactured by cold forging, according to the features of claims 13-16.
  • the chance of such a cold forged master cylinder having pores or other inclusions will be minimum if not zero. Therefore, such cylinder will be substantially free of leakage and the inner side of the cylinder will be or can easily be made smooth, ensuring good functioning of the piston.
  • the invention furthermore relates to a set of cold forging tools for use in a method according to the present invention.
  • FIGS. 1 A-B show in plan view, longitudinal cross section and transverse cross section a master cylinder for a brake system, manufactured by cold forging according to the invention
  • FIG. 2A shows a die for use in a cold forging method according to the present invention for manufacturing the product shown in FIG. 1;
  • FIG. 2B shows six punches for cooperation with the die according to FIG. 2 in six consecutive steps of a cold forging method according to the present invention.
  • FIG. 3 shows a slug from which the cylinder of FIG. 1 can be cold forged.
  • cold forging is used for all processes wherein a material, in particular a metal, is subjected to such high pressures that it becomes sufficiently plastic to flow at room temperature, at least a temperature below the recrystallisation temperature of the material concerned.
  • FIGS. 1 A-C show a typical example of an asymmetric product 1 which can be manufactured by cold forging, according to the present invention.
  • the product 1 represents a master cylinder of a brake system for application in for instance the automotive or machine building industry.
  • the master cylinder comprises a cylindrical main body 3 , provided with a bore 6 , extending longitudinally from a first end 11 of the main body 3 towards an opposite end 12 , having a constant circular cross section along its entire length. Near the first open end 11 a flange 5 is integrally connected with the outer periphery of the main body 3 .
  • flange 5 divides the main body 3 into two cylinder parts 8 , 9 , each having a different cross section.
  • the first cylinder part 8 adjacent the open end 11 , has a circular cross section, situated concentric with regard to the bore 6 .
  • the other cylinder part 9 adjacent the bottom end 12 , has an asymmetric cross section 10 , including a half-circular section 14 , concentric with bore 6 , and a polygonal section 16 , as best seen in FIG. 1C.
  • the polygonal section 16 comprises two substantially parallel first sides 17 , extending from the half-circular section 14 in an almost tangential direction, a second side 18 extending substantially parallel to an (imaginary) intersecting plane P between the circular and the polygonal section 14 , 16 and two third sides 19 , which taper from the first sides 17 towards the second side 19 , each enclosing a different obtuse angle with the respective first side 17 .
  • the wall thickness of cylinder part 9 varies considerably and in an asymmetric way along the circumference of the bore 6 .
  • the flange 5 is substantially diamond-shaped, with rounded corners.
  • the top surface of the flange 5 that is the surface facing the open end 11 of the main body 3 , is provided with a raised ridge 13 , surrounding both acute corners of the diamond. The function thereof will become clear further on.
  • the flange 5 is positioned symmetrically with respect to bore 6 and the first cylinder part 8 (see FIG. 1A), such that the centre of the flange 5 (defined by the intersection of its two diagonals L, S) coincides with the centre line M of the bore 6 .
  • the flange 5 is positioned in such way that its longest diagonal L lies within the intersection plane P of the circular and polygonal contour sections 14 , 16 .
  • the flange 5 is dimensioned such that the second side 18 of the second cylinder part 9 substantially lies flush with one of the obtuse corners of the flange 5 , as seen in FIG. 1C.
  • bottom end 12 of the main body 3 has a bevelled edge and is provided with a tapering hole 7 , the centre line thereof being aligned with the centre line M of bore 6 .
  • FIGS. 1 A-C The product as shown in FIGS. 1 A-C has been cold forged from a solid bar-shaped piece of starting material, hereinafter referred to as a slug 15 , illustrated in FIG. 3.
  • This slug 15 in the present case, has a constant outer periphery that resembles the one of the second cylinder part 9 but is of slightly smaller dimension, to prevent the slug 15 from scraping the cold forging tools, as will be discussed in more detail below.
  • the slug 15 may for instance be manufactured by sawing a profiled pressed bar at a desired length. The length of each slug 15 is chosen such that the total material volume of the slug 15 equals the material volume of the product 1 to be manufactured.
  • a set of cold forging tools generally comprises a die and an accompanying punch and may further comprise an ejector and a stripper, both intended for removing the forged product from aforementioned die and/or punch.
  • the tools are mounted in a press, which can be of any suitable type known in the art, such as for instance a horizontal or vertical, hydraulic or mechanical type of press. As such presses are widely known, further description thereof is not necessary.
  • a die 20 is shown in plan view and in cross sectional view.
  • the die 20 comprises a cavity 22 , having an inner contour that largely corresponds to the outer contour of the product 1 to be manufactured, at least a substantial part thereof.
  • the cavity 22 comprises a first portion, hereinafter referred to as the flange-forming cavity 22 A, having a diamond-shaped bottom 24 , surrounded by an upright, circumferential sidewall 26 .
  • the dimensions of the bottom 24 are similar to those of the flange 5 .
  • an opening 27 which opens into a second portion of the cavity 22 , hereinafter referred to as the main body forming cavity 22 B.
  • This portion 22 B has an inner cross section that matches the outer contour of the second cylindrical part 9 of the product 1 to be manufactured.
  • the cavity 22 is open at its upper end, for receiving a slug 15 , and at its opposite, lower end, for receiving an ejector 29 , for discharging the slug 15 from the cavity 22 , after being cold forged.
  • the die 20 can cooperate with several punches, in the present case six punches 25 A-F, as shown in FIG. 2B, for performing six successive steps in the cold forcing method according to the present invention.
  • the first five punches 25 A-E are provided with an outer contour which matches the inner contour of the flange-forming cavity 22 A, as defined by the upright circumferential sidewall 26 .
  • a bottom side 28 of the punches 25 A-E is provided with a recess 30 A-E for forming the first symmetrical cylinder part 8 of the product 1 .
  • the recess 30 A of the first punch 25 A has a hexagonal access opening 32 , a smaller circular top wall 34 and a circumferential sidewall 35 which tapers from the access opening 32 towards the top wall 34 .
  • the second punch 25 B has a similar outer contour and a recess 30 B with a hexagonal access opening 32 and a circular top wall 34 , similar to those of the first recess 30 A, but of slightly increased dimensions, and a circumferential sidewall 35 , which starts with a first part 35 A extending substantially perpendicular to the access opening 32 and ends with a second part 35 B, tapering towards the top wall 34 .
  • a comparable tapering wall part 35 B could be incorporated in the recess 30 A of the first punch 25 A.
  • the maximum depth H B of the second recess 30 B is slightly smaller than that of recess 30 A.
  • the third punch 25 C again features the same outer contour as the previous two punches 25 A,B and furthermore comprises a recess 30 C, which largely matches the outer contour of the first cylinder part 8 (see FIG. 1B).
  • the recess 30 C has a circular cross section, which is reduced twice towards its top wall 34 . From said top wall 34 , a rod shaped core 36 , having a circular cross section, extends concentric within the recess 30 C. A free end thereof lies substantially flush with the bottom side 28 of the punch 25 C.
  • the fourth punch 25 D is provided with a groove 38 of superficial depth, extending from the bottom side 28 around the acute corners of the diamond.
  • Recess 30 D largely corresponds to recess 30 C.
  • the reduction 31 adjacent the top wall 34 is removed and the depth of recess 30 D is larger than the depth of recess 30 C
  • the fifth punch 25 E largely corresponds to the fourth punch 25 D.
  • the core 36 E is elongated to extend beyond the bottom side 28 of the punch 25 E, over a predefined distance H E which at least equals the thickness D of the flange 5 (as indicated in FIG. 1B), for reasons to be explained below.
  • the sixth punch 25 F finally comprises a rod-shaped portion 39 , having a constant circular outer contour, which corresponds to the inner contour of bore 6 .
  • the free end of the rod 39 is provided with an at least partly chamfered edge 40 .
  • the tools previously described can be used in following way. Firstly, die 20 and the first punch 25 A are mounted in the press. Then, the slug 15 is placed into the cavity 22 of die 20 . Because the outer contour of the slug 15 is slightly smaller than that of the cavity 22 , the slug 15 can be inserted without damaging, that is scraping the sidewalls of the cavity 22 . The depth of the cavity 22 is dimensioned such that an upper part of the inserted slug 15 will extend in the flange-forming portion 22 A. Next, the press is operated to move punch 25 A towards the die 20 , in the direction of arrow A (FIG. 2A), into the flange-forming portion 22 A.
  • first three punches 25 A-C will, in cooperation with the flange-forming cavity 22 A of die 20 form the flange 5 of the product 1 by upsetting an upper part of the slug 15 , in three consecutive steps.
  • first cylinder part 8 is formed, on top of the flange 5 , by means of the recesses 30 A-C in the punches 25 A-C.
  • the tapered second part 35 B of the circumferential sidewall 35 of recess 30 B (and of recess 30 A, in case provided) contributes to direct the material flow in a desired direction.
  • the first cylinder part 8 is provided with a bore 6 . And with the fourth punch 25 D, the cylinder part 8 is extruded to its final length. During this step, excessive material from the previous step or steps may be discarded into groove 38 along the outer contour of the fourth punch 25 D. This will result in the forming of ridge 13 on the flange 5 of the final product (see FIG. 1A,B). The ridge 13 therefore forms no functional part of the cylinder 1 but merely serves as an overflow for excessive material during the fourth and possible subsequent steps of the forging process.
  • the bore 6 in the first cylinder part 8 is extended, at least till beyond flange 5 .
  • This is a critical step in the formation of the bore 6 since during this step, the flange 5 is pierced, which may initiate undesired material flows between the flange and main body.
  • the fifth step is limited to merely extend the bore 6 to just passed the flange 5 .
  • the bore 6 may be completed to its final length in a sixth step, by means of the sixth punch 25 F.
  • the second cylinder part 9 is extruded to its final length, using material expelled from the bore 6 .
  • a different die 20 ′ (not shown) may be provided, which can cater for the increase in length of the cylinder part 9 .
  • the chamfered edge 40 of the punch 25 E assists in directing the punch in a specific direction to counteract warpage caused by resultant forces on the punch, due to the asymmetric cross section of the second cylinder part 9 .
  • FIGS. 1 A-C show the product in its rough shape, directly coming from the cold forging process. It will be clear that the product may be subjected to follow up treatments known in the art, in order to provide the product with desired properties. For instance, attachment holes may be drilled in the flange 5 . Certain surfaces of the product 1 , for instance the bore 6 or the topside of the flange 5 may be machined to meet certain surface criteria. Also the ridges 13 may be removed. The product 1 may be annealed to enhance its strength and wear resistance.
  • the product may be treated prior to each or certain forging steps.
  • the product is lubricated prior to each step.
  • the product may be softened prior to each or certain forging steps, whereby the product is heated to soften the material and improve its deformability, so that the necessary forging pressure can be decreased.
  • the above-described product represents only one example of a product that can be manufactured with a cold forging method according to the invention.
  • the cross section of the cylindrical part may have a different outer contour.
  • the position of the flange 5 may vary, for instance be positioned nearer to the bottom end 12 of the main body 3 than currently shown.
  • the orientation of the flange 5 may be rotated with respect to the centre line M of the bore 6 .
  • the shape of the flange 5 can differ.
  • the flange 5 may have a non-rotation symmetric or even an asymmetric shape, for instance by extending in only one radial direction from the main body 3 .
  • the method may furthermore be successfully applied to other products, having a cylindrical portion of highly asymmetric design and varying wall thickness, combined with a flange portion, which may equally be of asymmetric design.
  • a cylindrical portion of highly asymmetric design and varying wall thickness combined with a flange portion, which may equally be of asymmetric design.
  • the forging process can be divided in more or less steps than the six steps shown. Generally, the number of necessary steps will be closely related to amongst others the complexity of the shape to be manufactured and the mechanical properties of the material.
  • the die may be exchanged as well, at every step or at some specific steps only.
  • Automatic transfer means may be provided to transfer the (intermediate) product between successive steps and associated tools.

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  • Engineering & Computer Science (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Transmission Of Braking Force In Braking Systems (AREA)
US10/217,132 2002-08-12 2002-08-12 Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith Abandoned US20040025688A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/217,132 US20040025688A1 (en) 2002-08-12 2002-08-12 Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith
EP02078526A EP1389571A1 (en) 2002-08-12 2002-08-27 Method for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith
JP2002269025A JP2004142471A (ja) 2002-08-12 2002-09-13 ブレーキ装置用マスタシリンダを製造するための方法および工具ならびにこれらによって製造されるシリンダ

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/217,132 US20040025688A1 (en) 2002-08-12 2002-08-12 Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith

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US20040025688A1 true US20040025688A1 (en) 2004-02-12

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US10/217,132 Abandoned US20040025688A1 (en) 2002-08-12 2002-08-12 Method and tools for manufacturing a master cylinder for a brake system, and cylinder manufactured therewith

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EP (1) EP1389571A1 (ja)
JP (1) JP2004142471A (ja)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103624205A (zh) * 2013-12-04 2014-03-12 江苏威鹰机械有限公司 制动器螺纹管精锻件冷锻塑性成型工艺
CN106862879A (zh) * 2017-01-23 2017-06-20 江苏创汽车零部件有限公司 一种带有法兰边的中空输出轴的冷锻成形工艺

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4580431A (en) * 1983-02-02 1986-04-08 Hitachi, Ltd. Method and apparatus for producing a stepped hollow article
US4932251A (en) * 1987-12-22 1990-06-12 Miyamatool Kabushikikaisha Method of producing a core for a fuel injector
US6012288A (en) * 1995-12-20 2000-01-11 Kelsey-Hayes Company Master cylinder having radially formed end plugs and press-fit caged spring assembly pin
US6371224B1 (en) * 2000-03-09 2002-04-16 Brush Wellman, Inc. Threaded spacer

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5429108U (ja) * 1977-07-30 1979-02-26
US4679680A (en) * 1983-11-07 1987-07-14 Lucas Industries Public Limited Company Clutch master cylinder with internal reservoir

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4580431A (en) * 1983-02-02 1986-04-08 Hitachi, Ltd. Method and apparatus for producing a stepped hollow article
US4932251A (en) * 1987-12-22 1990-06-12 Miyamatool Kabushikikaisha Method of producing a core for a fuel injector
US6012288A (en) * 1995-12-20 2000-01-11 Kelsey-Hayes Company Master cylinder having radially formed end plugs and press-fit caged spring assembly pin
US6371224B1 (en) * 2000-03-09 2002-04-16 Brush Wellman, Inc. Threaded spacer

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103624205A (zh) * 2013-12-04 2014-03-12 江苏威鹰机械有限公司 制动器螺纹管精锻件冷锻塑性成型工艺
CN106862879A (zh) * 2017-01-23 2017-06-20 江苏创汽车零部件有限公司 一种带有法兰边的中空输出轴的冷锻成形工艺

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JP2004142471A (ja) 2004-05-20
EP1389571A1 (en) 2004-02-18

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Owner name: NEUMAN METAL FORMING NETHERLANDS. B.V., NETHERLAND

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KOEKENBERG, LEONARDUS GERHARDUS PLECHELMUS;JONGSTRA, GEERT JAN;ALFERINK, HENRICUS JOHANNES MARIA;REEL/FRAME:013492/0398;SIGNING DATES FROM 20020902 TO 20020903

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