US20100071649A1 - Ball plunger for use in a hydraulic lash adjuster and method of making same - Google Patents
Ball plunger for use in a hydraulic lash adjuster and method of making same Download PDFInfo
- Publication number
- US20100071649A1 US20100071649A1 US12/235,919 US23591908A US2010071649A1 US 20100071649 A1 US20100071649 A1 US 20100071649A1 US 23591908 A US23591908 A US 23591908A US 2010071649 A1 US2010071649 A1 US 2010071649A1
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- Prior art keywords
- ball
- ball plunger
- slug
- bore
- forming
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
- F01L1/20—Adjusting or compensating clearance
- F01L1/22—Adjusting or compensating clearance automatically, e.g. mechanically
- F01L1/24—Adjusting or compensating clearance automatically, e.g. mechanically by fluid means, e.g. hydraulically
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/04—Making uncoated products by direct extrusion
- B21C23/14—Making other products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/20—Making uncoated products by backward extrusion
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
- F01L1/20—Adjusting or compensating clearance
- F01L1/22—Adjusting or compensating clearance automatically, e.g. mechanically
- F01L1/24—Adjusting or compensating clearance automatically, e.g. mechanically by fluid means, e.g. hydraulically
- F01L1/2405—Adjusting or compensating clearance automatically, e.g. mechanically by fluid means, e.g. hydraulically by means of a hydraulic adjusting device located between the cylinder head and rocker arm
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
- F01L1/12—Transmitting gear between valve drive and valve
- F01L1/14—Tappets; Push rods
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- F01L2303/00—Manufacturing of components used in valve arrangements
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49298—Poppet or I.C. engine valve or valve seat making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49298—Poppet or I.C. engine valve or valve seat making
- Y10T29/493—Valve guide making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49298—Poppet or I.C. engine valve or valve seat making
- Y10T29/49304—Valve tappet making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49298—Poppet or I.C. engine valve or valve seat making
- Y10T29/49307—Composite or hollow valve stem or head making
- Y10T29/49311—Composite or hollow valve stem or head making including extruding
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49298—Poppet or I.C. engine valve or valve seat making
- Y10T29/49307—Composite or hollow valve stem or head making
- Y10T29/49313—Composite or hollow valve stem or head making including casting
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49995—Shaping one-piece blank by removing material
Definitions
- the present application is directed to a ball plunger for use in a hydraulic lash adjuster and a method of manufacturing the ball plunger.
- Hydraulic lash adjusters (also sometimes referred to as “lifters”) for internal combustion engines have been in use for many years to eliminate clearance (or “lash”) between engine valve train components under varying operating conditions, in order to maintain efficiency and to reduce noise and wear in the valve train.
- Hydraulic lash adjuster operate on the principle of transmitting the energy of the valve actuating cam through hydraulic fluid trapped in a pressure chamber under a plunger.
- the plunger In a Type II valve train, the plunger is known as a “ball plunger” because it has a ball-shaped portion at one end and a seat surface at its other end.
- ball plungers have been initially made in cold-forming machines and then machined to achieve a desired final shape.
- machining processes are time consuming and add to the cost of the finished ball plunger.
- a cold-formed ball plunger blank for use in manufacturing a finished ball plunger for use in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer.
- the ball plunger blank includes a cup-shaped member that extends from a first end to a second end along a longitudinal axis.
- the cup-shaped member includes a ball portion adjacent the first end of the member and a body portion adjacent the second end of the member.
- the body portion has a cavity disposed therein, a counterbore extending from the second end of the body towards the first end of the member, and a shoulder that separates the cavity from the counterbore and at least partially closes the cavity.
- the shoulder defines a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are to sized to the final dimensions of the finished ball plunger.
- a unitary ball plunger for use in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer.
- the unitary ball plunger includes a generally tubular member that extends from a first end to a second end along a longitudinal axis.
- the tubular member includes a ball portion adjacent the first end of the member, a body portion adjacent the second end of the tubular member, and a stem portion that separates the ball portion from the body portion.
- the ball portion includes a generally ball-shaped surface that is cold-formed to its final dimensions and a hole that is generally coaxial with the tubular member, and.
- the body portion has a bore disposed therein that communicates with the hole in the ball portion, a counterbore extending from the second end of the body towards the first end of the tubular member, and a shoulder provided between the bore and the counterbore that at least partially closes the bore.
- the shoulder defines a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are both cold formed to their respective final dimensions.
- a method of cold-forming a ball plunger blank includes the steps of providing a slug having first and second ends, backward extruding the slug at its first end to form a cavity that is defined by a wall, forming a generally ball-shaped outer surface at the second end of the slug to final dimensions; and upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface to its final dimensions.
- a method of manufacturing a finished ball plunger for use in a lash adjuster assembly includes the steps of cold-forming a ball plunger blank having a longitudinal axis to near net shape and machining the ball plunger blank to complete the finished ball plunger.
- the cold-forming step includes the steps of providing a slug having first and second ends, backward extruding the slug at its first end to form a body portion having a cavity disposed therein that is defined by a wall, forming a ball portion adjacent the second end of the slug, the ball portion including a generally ball-shaped surface sized to its final dimensions, and upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface sized to its final dimensions.
- FIG. 1A illustrates a cross-sectional view of an exemplary hydraulic lash adjuster 100 .
- FIG. 1B illustrates a detailed cross-sectional view of one embodiment of a ball plunger 116 for use in the exemplary hydraulic lash adjuster 100 .
- FIG. 2 illustrates an example method 200 of producing the ball plunger 116 described above and illustrated in FIGS. 1A and 1B .
- FIG. 3 illustrates a cross-sectional view of one embodiment of a cold-formed ball plunger blank 300 following the cold-forming step (step 210 ) described in FIG. 2 .
- FIGS. 4A-4F illustrates an exemplary cold-forming, five station slug progression sequence that can be used to form the cold-formed ball plunger blank 300 .
- FIG. 5 illustrates a cross-sectional view of the finished ball plunger 116 following the machining step (step 220 ) described in FIG. 2 .
- the present application is directed to a ball plunger for use in a hydraulic lash adjuster.
- the ball plunger is of a one-piece construction that is cold-formed to near net shape, requiring a reduced amount of machining to complete the finished part as compared to prior art ball plungers.
- FIG. 1A illustrates a cross-sectional view of an exemplary hydraulic lash adjuster 100 .
- the hydraulic lash adjuster 100 which is of the Type II valve train variety, is shown by way of example only and it will be appreciated that the ball plunger employed therein can be used in any configuration of a hydraulic lash adjuster and is not limited to the configuration of the hydraulic lash adjuster 100 illustrated in FIG. 1A .
- the general structure and operation of the hydraulic lash adjuster 100 shown in FIG. 1A is known to those skilled in the art, and will therefore be described in summary fashion.
- the hydraulic lash adjuster 100 includes a body 102 that is configured to be disposed within a mating bore (not shown) in an engine cylinder head (not shown).
- the body 102 includes a longitudinal axis A, a first generally cylindrical exterior surface 104 having an outwardly facing groove 106 , and an interior surface 108 that defines a blind bore 110 .
- the groove 106 is at least partially defined by a second generally cylindrical exterior surface 112 that has an outer diameter that is less than the outer diameter of the first cylindrical exterior surface 104 . Extending radially between the first cylindrical exterior surface 104 and the second cylindrical exterior surface 112 is a fluid port 114 that provides fluid communication between the groove 106 and the blind bore 110 .
- the hydraulic lash adjuster 100 also includes a ball plunger 116 disposed in the blind bore 110 .
- the ball plunger 116 which will be discussed in more detail below, is configured for reciprocal movement relative to the body 102 along the longitudinal axis A.
- a plunger spring 118 is disposed within the blind bore 104 underneath the ball plunger 116 and is configured to bias the ball plunger 116 in an upward direction relative to the body 102 .
- the plunger spring 118 acts at all times to elevate the ball plunger 116 to maintain its engagement with the hemispherical concave surface (not shown) of a rocker arm (not shown).
- a retaining member 120 such as a retaining ring or washer, is provided adjacent the upper portion of the body 102 .
- the ball plunger 116 itself defines a low pressure fluid chamber 122 , while the body 102 and the lower portion of the ball plunger 116 cooperate with each other to define a high pressure fluid chamber 124 within the blind bore 104 of the body 102 .
- the hydraulic lash adjuster 100 includes a check valve assembly 126 positioned between the plunger spring 118 and the lower portion of the ball plunger 116 .
- the check valve assembly 126 functions to either permit fluid communication, or to block fluid communication, between the low pressure fluid chamber 122 and the high pressure fluid chamber 124 , in response to the pressure differential between the two fluid chambers 122 , 124 .
- the check valve assembly 126 includes a retainer 128 that is in engagement with a lower portion of the ball plunger 116 , a check ball 130 , and a check ball spring 132 that is disposed between the retainer 128 and the check ball 130 .
- the check ball spring 132 is configured to bias the check ball 130 in an upwards direction towards the ball plunger 116 , and is therefore commonly referred to by those skilled in the art as a “normally biased closed” check valve assembly.
- FIG. 1B Illustrated in FIG. 1B is a detailed cross-sectional view of the ball plunger 116 employed in the exemplary hydraulic lash adjuster 100 illustrated in FIG. 1A . It will be appreciated that the ball plunger 116 illustrated in FIGS. 1A and 1B is shown by way of example only and is not limited to the configuration shown in these drawings.
- the ball plunger 116 is a generally tubular member having a first end 134 that extends to a second end 136 along a longitudinal axis A, a ball portion 140 adjacent to the first end 134 , a body portion 142 adjacent to the second end 136 , and a stem portion 144 disposed between the ball portion 140 and the body portion 142 .
- the ball portion 140 of the ball plunger 116 includes a generally ball-shaped or hemispherical outer surface 146 , which is configured to engage and pivot about the generally hemispherical concave surface (not shown) of a rocker arm (not shown).
- the body portion 142 of the ball plunger 116 includes a counterbore 148 configured to receive the check valve assembly 126 , a first generally cylindrical exterior surface 150 , and a radially outward facing groove 152 formed in the cylindrical exterior surface 150 .
- the groove 152 cooperates with the interior surface 108 of the body 102 to form a fluid collector channel 154 (see FIG. 1A ) and is at least partially defined by a second generally cylindrical exterior surface 156 that has an outer diameter that is less than the outer diameter of the first cylindrical exterior surface 150 .
- the counterbore 148 is defined by a generally cylindrical interior surface 158 , a flat annular surface 160 that is generally perpendicular to the axis A and extends from the cylindrical interior surface 158 , and a rounded annular surface 162 that extends from the flat annular surface 160 .
- the flat annular surface 160 is sized to receive the retainer 128 of the check valve assembly 126 and will sometimes be referred to herein as the “retainer receiving surface 160 .”
- the rounded annular surface 162 is sized to receive the check ball 130 of the check valve assembly 126 , such that when the check ball 130 engages the rounded annular surface 162 , a fluid tight seal is created between the check ball 130 and the rounded annular surface 162 (see FIG. 1A ).
- the rounded annular surface 162 may also be referred to herein as the “ball seat 162 ” or the “ball seat surface 162 .”
- the ball seat surface 162 in the illustrated embodiment of the ball plunger 116 is a rounded annular surface, it will be appreciated that the ball seat surface 162 can be an annular frusto-conical surface, so long as an appropriate fluid tight seal is created between the check ball 130 and the ball seat surface 162 .
- the stem portion 144 of the ball plunger 116 is defined by a groove 164 that separates the ball portion 140 from the body portion 142 of the ball plunger 116 .
- the groove 164 is at least partially defined by a frusto-conical surface 166 that extends from the hemispherical exterior surface 146 towards the body portion 142 , a transition surface 168 that extends from the first cylindrical exterior surface 150 towards the ball portion 140 , and a generally cylindrical exterior surface 170 disposed between the frusto-conical surface 166 and the transition surface 168 .
- the transition surface 168 includes a frusto-conical surface and a curved surface that is convex with respect to the longitudinal axis A.
- transition surface 168 can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof.
- an axially extending passage 172 disposed within the ball plunger 116 between the ball seat surface 162 and the hemispherical exterior surface 146 .
- a shoulder 173 is provided between the passage 172 and the counterbore 148 that includes, among other surfaces, the retainer receiving surface 160 and the ball seat surface 162 .
- the passage 172 (which also corresponds to the low pressure fluid chamber 122 as shown in FIG. 1A ) includes a first axially extending bore 174 defined by a first generally cylindrical interior surface 176 having a first diameter, a second axially extending bore 178 defined by a second generally cylindrical interior surface 180 having a second diameter that is less than the first diameter of the first cylindrical interior surface 176 , and a third axially extending bore 182 defined by a third generally cylindrical interior surface 184 having a third diameter that is less than the second diameter of the second cylindrical interior surface 180 .
- Extending radially between the first cylindrical interior surface 176 and the second cylindrical exterior surface 156 is a plunger fluid port 186 that provides fluid communication between the groove 152 and the first bore 174 .
- the passage 172 is also defined by three transition surfaces—a first transition surface 188 that transitions the ball seat surface 162 to the first cylindrical interior surface 176 , a second transition surface 190 that transitions the first cylindrical interior surface 176 to the second cylindrical interior surface 180 , and a third transition surface 192 that transitions the second cylindrical interior surface 180 to the third cylindrical interior surface 184 .
- each of these transition surfaces can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof.
- Illustrated in FIG. 2 is an example method 200 of producing the ball plunger 116 described above and illustrated in FIGS. 1A and 1B .
- the method 200 includes two general steps—i) cold-forming a ball plunger blank to near net shape, including cold-forming the generally ball-shaped outer surface 146 and the ball seat surface 162 to their respective final dimensions (step 210 ) and ii) machining the cold-formed ball plunger blank to complete the finished ball plunger 116 (step 220 ).
- the term “cold-forming” and its derivatives is intended to encompass what is known in the art as “cold forging,” “cold heading,” and “deep drawing.”
- machining means the use of a chucking machine, drilling machine, turning machine, grinding machine, or broaching machine to remove material.
- FIG. 3 Illustrated in FIG. 3 is a cross-sectional view of one embodiment of a cold-formed ball plunger blank 300 that is the result of the cold-forming step (step 210 ) described above. As shown in FIG. 3 , the cold-formed ball plunger blank 300 is near net shape as compared to the finished ball plunger 116 . For consistency purposes, structural features that are common between the cold-formed ball plunger blank 300 and the finished ball plunger 116 will be indicated with the same reference numerals, while different structural features will be indicated with new reference numerals.
- the cold-formed ball plunger blank 300 includes a generally cup-shaped member having a first end 134 extending toward a second end 136 along a longitudinal axis A, a ball portion 140 adjacent the first end 134 , an extended body portion 302 adjacent the second end 136 , and a transition surface 304 separating the ball portion 140 from the extended body portion 302 .
- the ball portion 140 includes a generally ball-shaped or hemispherical outer surface 146 and a dimple or indentation 306 extending therefrom.
- the transition surface 304 includes a frusto-conical surface.
- transition surface 304 can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof.
- the extended body portion 302 of the cold-formed ball plunger blank 300 includes a counterbore 148 and a generally cylindrical exterior surface 308 .
- the counterbore 148 is defined by a generally cylindrical interior surface 158 , a flat annular surface 160 that is generally perpendicular to the axis A and extends from the cylindrical interior surface 158 (also referred to as the “retainer receiving surface 160 ”), and a rounded annular surface 162 (also referred to as the “ball seat 162 ” or the “ball seat surface 162 ”) that extends from the retainer receiving surface 160 .
- an axially extending bore or cavity 310 disposed within the cold-formed ball plunger blank 300 .
- a shoulder 173 is provided between the cavity 310 and the counterbore 148 that includes, among other surfaces, the retainer receiving surface 160 and the ball seat surface 162 .
- the cavity 310 includes a first bore 174 defined by a first generally cylindrical interior surface 176 having a first diameter and a second bore 178 defined by a second generally cylindrical interior surface 180 having a second diameter that is less than the first diameter of the first cylindrical interior surface 176 .
- the cavity 310 is also defined by two transition surfaces—a first transition surface 188 that transitions the ball seat surface 162 to the first cylindrical interior surface 176 and a second transition surface 190 that transitions the first cylindrical interior surface 176 to the second cylindrical interior surface 180 .
- each of these transition surfaces can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof.
- the cold-formed ball plunger blank 300 can be formed in a variety of cold-forming machines. Suitable examples of cold-forming machines that can be used to form the cold-formed ball plunger blank 300 include Waterbury and National Machinery cold-forming machines. Generally, cold-forming machines include a cut-off station for cutting metal wire to a desired length to provide an initial workpiece (also known as a “slug”) and multiple progressive forming stations that include multiple spaced-apart die sections and a reciprocating gate having multiple punch sections, each of which cooperates with a respective die section to form a die cavity.
- initial workpiece also known as a “slug”
- progressive forming stations that include multiple spaced-apart die sections and a reciprocating gate having multiple punch sections, each of which cooperates with a respective die section to form a die cavity.
- a conventional transfer mechanism moves the slug in successive steps from the cut-off station to each of the forming stations in a synchronized fashion and is also capable of rotating the slug 180 degrees as it is being transferred from one station to another.
- cold-forming machines are well known in the art, no further description is necessary.
- the cold-formed ball plunger blank 300 is formed in a five station, cold-forming machine (not shown). It will, however, be appreciated that the cold-formed ball plunger blank 300 can be produced in a different number of forming stations.
- FIGS. 4A-4E Illustrated in FIGS. 4A-4E is an exemplary cold-forming, five station slug progression sequence that can be used to form the cold-formed ball plunger blank 300 .
- Each figure represents the state of the slug at an end-of-stroke tool position. It will be appreciated that this slug progression sequence is merely one example of a cold-forming slug progression sequence and that other slug progression sequences are possible.
- the exemplary slug progression sequence begins with shearing wire to a desired length at the cut-off station to provide an initial slug 400 , which will be described with reference to a first end 402 , a second end 404 , and a cylindrical surface 406 that extends therebetween as shown in FIG. 4A .
- the ends of the slug 400 have irregularities or unevenness inherent in the shearing process.
- the slug 400 is then transferred to the first forming station where its first end 402 faces the die section and its second end 404 faces the punch section.
- the slug 400 is squared and a slight indentation 408 is formed in the second end 404 at the punch section of the cold-forming machine as shown in FIG. 4B .
- a chamfer 410 is simultaneously formed between the first end 402 and the cylindrical surface 406 of the slug 400 .
- a deeper indentation 412 is formed in the first end 402 of the slug 400 along with a chamfer 414 formed between the indentation 412 and the first end 402 .
- the indentation 412 serves to properly center and guide the punch from the second forming station, which will be described in further detail below.
- the slug 400 is then rotated 180 degrees and transferred to the second forming station where its first end 402 faces the punch section and its second end 404 faces the die section.
- the first bore 174 is extruded through the first end 402 of the slug 400 to near final dimensions at the punch section of the cold-forming machine as shown in FIG. 4C .
- the generally hemispherical surface 146 is beginning to be formed at the second end 404 of the slug 400 .
- a slight indentation 416 is formed in the second end 404 of the slug 400 .
- the indentation 416 serves to properly center and guide the punch from the fourth forming station, which will be described in further detail below.
- the slug 400 is then transferred to the third forming station where its second end 404 faces the punch section and its first end 402 faces the die section.
- the second bore 176 having a diameter less than the first bore 174 , is backward extruded at the first end 402 of the slug 400 to near final dimensions at the punch section of the cold-forming machine as shown in FIG. 4D .
- the hemispherical surface 146 is formed at the second end 404 of the slug 400 to near final dimensions.
- the slug 400 is then rotated 180 degrees and transferred to the fourth forming station where its second end 404 faces the punch section and its first end 402 faces the die section.
- the hemispherical surface 146 is formed to near final dimensions and the dimple 306 is formed in the center-point of the hemispherical surface 146 by the punch section of the cold-forming machine as shown in FIG. 4E .
- a counterbore 148 having a diameter greater than the first bore 174 , is formed in the second end 404 of the slug 400 . Due to this diametrical difference, the die that forms the counterbore 148 upsets the wall defining the first bore 174 and thereby forms the shoulder 173 that defines the retainer receiving surface 160 and the ball seat surface 162 to near final dimensions.
- the slug 400 is then rotated 180 degrees and transferred to the fifth forming station where its first end 402 faces the punch section and its second end 404 faces the die section.
- the slug 400 is formed to its final dimensions, including overall length and the hemispherical surface 146 being formed to its final dimensions. Also, the cylindrical interior surface 158 , the retainer receiving surface 160 , and the ball seat surface 162 are coined to their respective final dimensions by the punch section of the cold-forming machine.
- the cold-formed ball plunger blank 300 is completed and includes all of the structural features shown in FIG. 3 .
- the cold-formed ball plunger blank 300 includes all of the structural features of the finished ball plunger 116 described above and illustrated in FIGS. 1A and 1B , with the exception of several structural features.
- the cold-formed ball plunger blank 300 is machined to form the remaining structural features as discussed above and shown in FIG. 2 .
- the machining step (step 220 ) will be discussed with reference to FIG. 5 where the shaded areas of the finished ball plunger 116 represent the material removed from the cold-formed ball plunger blank 300 as a result of the machining step.
- the groove 164 is machined into the extended body portion 302 and a portion of the hemispherical surface 146 and the groove 152 is machined into the first cylindrical exterior surface 150 .
- the third bore 182 is drilled into the ball portion 140 , such that it communicates with the second bore 178
- the plunger fluid port 186 is drilled into the body portion 142 such that it communicates with the first bore 174 . It will be appreciated that these machining operations can be performed one at a time, in combination with one or more other machining operations, or all together in any sequence.
- the ball plunger 116 described above is cold formed to near net shape (including the cold formation to final dimensions of the ball portion 140 and the ball seat surface 162 ), thereby reducing the machine time to complete a finished ball plunger and thus reducing manufacturing cost of the finished ball plunger. Additionally, when compared to plunger designs that require the use of a seat insert and seal, these parts along with the associated assembly time and costs are eliminated.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Valve-Gear Or Valve Arrangements (AREA)
- Forging (AREA)
Abstract
A cold-formed ball plunger blank is provided for use in manufacturing a finished ball plunger used in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer. The ball plunger blank includes a cup-shaped member that extends from a first end to a second end along a longitudinal axis. The cup-shaped member includes a ball portion adjacent the first end of the member and a body portion adjacent the second end of the member. The body portion has a cavity disposed therein, a counterbore extending from the second end of the body towards the first end of the member, and a shoulder that separates the cavity from the counterbore and at least partially closes the cavity. The shoulder defines a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are to sized to the final dimensions of the finished ball plunger. A method of cold-forming a ball plunger blank including providing a slug having first and second ends, backward extruding the slug at its first end to form a cavity that is defined by a wall, forming a generally ball-shaped outer surface at the second end of the slug to final dimensions, and upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface to its final dimensions.
Description
- The present application is directed to a ball plunger for use in a hydraulic lash adjuster and a method of manufacturing the ball plunger.
- Hydraulic lash adjusters (also sometimes referred to as “lifters”) for internal combustion engines have been in use for many years to eliminate clearance (or “lash”) between engine valve train components under varying operating conditions, in order to maintain efficiency and to reduce noise and wear in the valve train. Hydraulic lash adjuster operate on the principle of transmitting the energy of the valve actuating cam through hydraulic fluid trapped in a pressure chamber under a plunger. In a Type II valve train, the plunger is known as a “ball plunger” because it has a ball-shaped portion at one end and a seat surface at its other end. During each operation of the cam, as the length of the valve actuating components varies as a result of temperature changes and wear, small quantities of hydraulic fluid are permitted to enter the pressure chamber, or escape therefrom, thus effecting an adjustment in the position of the ball plunger, and consequently adjusting the effective total length of the valve train.
- As is known in the art, ball plungers have been initially made in cold-forming machines and then machined to achieve a desired final shape. However, machining processes are time consuming and add to the cost of the finished ball plunger. There are continual efforts to improve upon the processes to manufacture ball plungers, particularly to reduce the machining time and costs associated therewith.
- In one embodiment, a cold-formed ball plunger blank is provided for use in manufacturing a finished ball plunger for use in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer. The ball plunger blank includes a cup-shaped member that extends from a first end to a second end along a longitudinal axis. The cup-shaped member includes a ball portion adjacent the first end of the member and a body portion adjacent the second end of the member. The body portion has a cavity disposed therein, a counterbore extending from the second end of the body towards the first end of the member, and a shoulder that separates the cavity from the counterbore and at least partially closes the cavity. The shoulder defines a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are to sized to the final dimensions of the finished ball plunger.
- In another embodiment, a unitary ball plunger is provided for use in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer. The unitary ball plunger includes a generally tubular member that extends from a first end to a second end along a longitudinal axis. The tubular member includes a ball portion adjacent the first end of the member, a body portion adjacent the second end of the tubular member, and a stem portion that separates the ball portion from the body portion. The ball portion includes a generally ball-shaped surface that is cold-formed to its final dimensions and a hole that is generally coaxial with the tubular member, and. The body portion has a bore disposed therein that communicates with the hole in the ball portion, a counterbore extending from the second end of the body towards the first end of the tubular member, and a shoulder provided between the bore and the counterbore that at least partially closes the bore. The shoulder defines a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are both cold formed to their respective final dimensions.
- In another embodiment, a method of cold-forming a ball plunger blank is provided. The method includes the steps of providing a slug having first and second ends, backward extruding the slug at its first end to form a cavity that is defined by a wall, forming a generally ball-shaped outer surface at the second end of the slug to final dimensions; and upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface to its final dimensions.
- In another embodiment, a method of manufacturing a finished ball plunger for use in a lash adjuster assembly is provided. The method includes the steps of cold-forming a ball plunger blank having a longitudinal axis to near net shape and machining the ball plunger blank to complete the finished ball plunger. The cold-forming step includes the steps of providing a slug having first and second ends, backward extruding the slug at its first end to form a body portion having a cavity disposed therein that is defined by a wall, forming a ball portion adjacent the second end of the slug, the ball portion including a generally ball-shaped surface sized to its final dimensions, and upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface sized to its final dimensions.
- It will be appreciated that the illustrated boundaries of elements in the drawings represent only one example of the boundaries. One of ordinary skill in the art will appreciate that a single element may be designed as multiple elements or that multiple elements may be designed as a single element. An element shown as an internal feature may be implemented as an external feature and vice versa.
- Further, in the accompanying drawings and description that follow, like parts are indicated throughout the drawings and description with the same reference numerals, respectively. The figures may not be drawn to scale and the proportions of certain parts have been exaggerated for convenience of illustration.
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FIG. 1A illustrates a cross-sectional view of an exemplaryhydraulic lash adjuster 100. -
FIG. 1B illustrates a detailed cross-sectional view of one embodiment of aball plunger 116 for use in the exemplaryhydraulic lash adjuster 100. -
FIG. 2 illustrates anexample method 200 of producing theball plunger 116 described above and illustrated inFIGS. 1A and 1B . -
FIG. 3 illustrates a cross-sectional view of one embodiment of a cold-formed ball plunger blank 300 following the cold-forming step (step 210) described inFIG. 2 . -
FIGS. 4A-4F illustrates an exemplary cold-forming, five station slug progression sequence that can be used to form the cold-formed ball plunger blank 300. -
FIG. 5 illustrates a cross-sectional view of the finishedball plunger 116 following the machining step (step 220) described inFIG. 2 . - Certain terminology will be used in the foregoing description for convenience in reference only and will not be limiting. The terms “upward,” “downward,” “upper,” and “lower” will be understood to have their normal meanings and will refer to those directions as the drawing figures are normally viewed. All foregoing terms mentioned above include the normal derivative and equivalents thereof.
- The present application is directed to a ball plunger for use in a hydraulic lash adjuster. The ball plunger is of a one-piece construction that is cold-formed to near net shape, requiring a reduced amount of machining to complete the finished part as compared to prior art ball plungers.
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FIG. 1A illustrates a cross-sectional view of an exemplaryhydraulic lash adjuster 100. Thehydraulic lash adjuster 100, which is of the Type II valve train variety, is shown by way of example only and it will be appreciated that the ball plunger employed therein can be used in any configuration of a hydraulic lash adjuster and is not limited to the configuration of thehydraulic lash adjuster 100 illustrated inFIG. 1A . The general structure and operation of the hydraulic lash adjuster 100 shown inFIG. 1A is known to those skilled in the art, and will therefore be described in summary fashion. - As shown in
FIG. 1A , thehydraulic lash adjuster 100 includes abody 102 that is configured to be disposed within a mating bore (not shown) in an engine cylinder head (not shown). Thebody 102 includes a longitudinal axis A, a first generally cylindricalexterior surface 104 having an outwardly facinggroove 106, and aninterior surface 108 that defines ablind bore 110. Thegroove 106 is at least partially defined by a second generally cylindricalexterior surface 112 that has an outer diameter that is less than the outer diameter of the first cylindricalexterior surface 104. Extending radially between the first cylindricalexterior surface 104 and the second cylindricalexterior surface 112 is afluid port 114 that provides fluid communication between thegroove 106 and theblind bore 110. - The
hydraulic lash adjuster 100 also includes aball plunger 116 disposed in theblind bore 110. Theball plunger 116, which will be discussed in more detail below, is configured for reciprocal movement relative to thebody 102 along the longitudinal axis A. Aplunger spring 118 is disposed within theblind bore 104 underneath theball plunger 116 and is configured to bias theball plunger 116 in an upward direction relative to thebody 102. Theplunger spring 118 acts at all times to elevate the ball plunger 116 to maintain its engagement with the hemispherical concave surface (not shown) of a rocker arm (not shown). To limit outward movement of the ball plunger 116 relative to thebody 102 and retain theball plunger 116 within to thebody 102, aretaining member 120, such as a retaining ring or washer, is provided adjacent the upper portion of thebody 102. - With continued reference to
FIG. 1A , theball plunger 116 itself defines a lowpressure fluid chamber 122, while thebody 102 and the lower portion of theball plunger 116 cooperate with each other to define a highpressure fluid chamber 124 within theblind bore 104 of thebody 102. To control fluid flow between the lowfluid pressure chamber 122 and the highpressure fluid chamber 124, thehydraulic lash adjuster 100 includes acheck valve assembly 126 positioned between theplunger spring 118 and the lower portion of theball plunger 116. Thecheck valve assembly 126 functions to either permit fluid communication, or to block fluid communication, between the lowpressure fluid chamber 122 and the highpressure fluid chamber 124, in response to the pressure differential between the twofluid chambers - As shown in
FIG. 1A , thecheck valve assembly 126 includes aretainer 128 that is in engagement with a lower portion of theball plunger 116, acheck ball 130, and acheck ball spring 132 that is disposed between theretainer 128 and thecheck ball 130. Thecheck ball spring 132 is configured to bias thecheck ball 130 in an upwards direction towards theball plunger 116, and is therefore commonly referred to by those skilled in the art as a “normally biased closed” check valve assembly. - Illustrated in
FIG. 1B is a detailed cross-sectional view of theball plunger 116 employed in the exemplary hydraulic lashadjuster 100 illustrated inFIG. 1A . It will be appreciated that theball plunger 116 illustrated inFIGS. 1A and 1B is shown by way of example only and is not limited to the configuration shown in these drawings. - With reference to
FIG. 1B , theball plunger 116 is a generally tubular member having afirst end 134 that extends to asecond end 136 along a longitudinal axis A, aball portion 140 adjacent to thefirst end 134, abody portion 142 adjacent to thesecond end 136, and astem portion 144 disposed between theball portion 140 and thebody portion 142. Theball portion 140 of theball plunger 116 includes a generally ball-shaped or hemisphericalouter surface 146, which is configured to engage and pivot about the generally hemispherical concave surface (not shown) of a rocker arm (not shown). - The
body portion 142 of theball plunger 116 includes acounterbore 148 configured to receive thecheck valve assembly 126, a first generally cylindricalexterior surface 150, and a radially outward facinggroove 152 formed in the cylindricalexterior surface 150. Thegroove 152 cooperates with theinterior surface 108 of thebody 102 to form a fluid collector channel 154 (seeFIG. 1A ) and is at least partially defined by a second generally cylindricalexterior surface 156 that has an outer diameter that is less than the outer diameter of the firstcylindrical exterior surface 150. - With continued reference to
FIG. 1B , thecounterbore 148 is defined by a generally cylindricalinterior surface 158, a flatannular surface 160 that is generally perpendicular to the axis A and extends from the cylindricalinterior surface 158, and a roundedannular surface 162 that extends from the flatannular surface 160. The flatannular surface 160 is sized to receive theretainer 128 of thecheck valve assembly 126 and will sometimes be referred to herein as the “retainer receiving surface 160.” The roundedannular surface 162 is sized to receive thecheck ball 130 of thecheck valve assembly 126, such that when thecheck ball 130 engages the roundedannular surface 162, a fluid tight seal is created between thecheck ball 130 and the rounded annular surface 162 (seeFIG. 1A ). Hence, the roundedannular surface 162 may also be referred to herein as the “ball seat 162” or the “ball seat surface 162.” Although theball seat surface 162 in the illustrated embodiment of theball plunger 116 is a rounded annular surface, it will be appreciated that theball seat surface 162 can be an annular frusto-conical surface, so long as an appropriate fluid tight seal is created between thecheck ball 130 and theball seat surface 162. - The
stem portion 144 of theball plunger 116 is defined by agroove 164 that separates theball portion 140 from thebody portion 142 of theball plunger 116. Thegroove 164 is at least partially defined by a frusto-conical surface 166 that extends from the hemisphericalexterior surface 146 towards thebody portion 142, atransition surface 168 that extends from the firstcylindrical exterior surface 150 towards theball portion 140, and a generally cylindricalexterior surface 170 disposed between the frusto-conical surface 166 and thetransition surface 168. In the illustrated example, thetransition surface 168 includes a frusto-conical surface and a curved surface that is convex with respect to the longitudinal axis A. However, it will be appreciated that thetransition surface 168 can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof. - With continued reference to
FIG. 1B , disposed within theball plunger 116 between theball seat surface 162 and the hemisphericalexterior surface 146 is anaxially extending passage 172. Provided between thepassage 172 and thecounterbore 148 is ashoulder 173 that includes, among other surfaces, theretainer receiving surface 160 and theball seat surface 162. - Generally, the passage 172 (which also corresponds to the low
pressure fluid chamber 122 as shown inFIG. 1A ) includes a firstaxially extending bore 174 defined by a first generally cylindricalinterior surface 176 having a first diameter, a secondaxially extending bore 178 defined by a second generally cylindrical interior surface 180 having a second diameter that is less than the first diameter of the first cylindricalinterior surface 176, and a thirdaxially extending bore 182 defined by a third generally cylindricalinterior surface 184 having a third diameter that is less than the second diameter of the second cylindrical interior surface 180. Extending radially between the first cylindricalinterior surface 176 and the secondcylindrical exterior surface 156 is aplunger fluid port 186 that provides fluid communication between thegroove 152 and thefirst bore 174. - The
passage 172 is also defined by three transition surfaces—afirst transition surface 188 that transitions theball seat surface 162 to the first cylindricalinterior surface 176, asecond transition surface 190 that transitions the first cylindricalinterior surface 176 to the second cylindrical interior surface 180, and athird transition surface 192 that transitions the second cylindrical interior surface 180 to the third cylindricalinterior surface 184. It will be appreciated that each of these transition surfaces can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof. - Illustrated in
FIG. 2 is anexample method 200 of producing theball plunger 116 described above and illustrated inFIGS. 1A and 1B . As shown inFIG. 2 , themethod 200 includes two general steps—i) cold-forming a ball plunger blank to near net shape, including cold-forming the generally ball-shapedouter surface 146 and theball seat surface 162 to their respective final dimensions (step 210) and ii) machining the cold-formed ball plunger blank to complete the finished ball plunger 116 (step 220). As used herein, the term “cold-forming” and its derivatives, is intended to encompass what is known in the art as “cold forging,” “cold heading,” and “deep drawing.” As used herein, the term “machining” means the use of a chucking machine, drilling machine, turning machine, grinding machine, or broaching machine to remove material. - Illustrated in
FIG. 3 is a cross-sectional view of one embodiment of a cold-formed ball plunger blank 300 that is the result of the cold-forming step (step 210) described above. As shown inFIG. 3 , the cold-formed ball plunger blank 300 is near net shape as compared to thefinished ball plunger 116. For consistency purposes, structural features that are common between the cold-formed ball plunger blank 300 and thefinished ball plunger 116 will be indicated with the same reference numerals, while different structural features will be indicated with new reference numerals. - As shown in
FIG. 3 , the cold-formed ball plunger blank 300 includes a generally cup-shaped member having afirst end 134 extending toward asecond end 136 along a longitudinal axis A, aball portion 140 adjacent thefirst end 134, anextended body portion 302 adjacent thesecond end 136, and atransition surface 304 separating theball portion 140 from theextended body portion 302. Theball portion 140 includes a generally ball-shaped or hemisphericalouter surface 146 and a dimple orindentation 306 extending therefrom. In the illustrated embodiment, thetransition surface 304 includes a frusto-conical surface. However, it will be appreciated that thetransition surface 304 can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof. - The
extended body portion 302 of the cold-formed ball plunger blank 300 includes acounterbore 148 and a generally cylindricalexterior surface 308. Thecounterbore 148 is defined by a generally cylindricalinterior surface 158, a flatannular surface 160 that is generally perpendicular to the axis A and extends from the cylindrical interior surface 158 (also referred to as the “retainer receiving surface 160”), and a rounded annular surface 162 (also referred to as the “ball seat 162” or the “ball seat surface 162”) that extends from theretainer receiving surface 160. - With continued reference to
FIG. 3 , disposed within the cold-formed ball plunger blank 300 is an axially extending bore orcavity 310 extending from theball seat surface 162 towards theball portion 140. Provided between thecavity 310 and thecounterbore 148 is ashoulder 173 that includes, among other surfaces, theretainer receiving surface 160 and theball seat surface 162. - Generally, the
cavity 310 includes afirst bore 174 defined by a first generally cylindricalinterior surface 176 having a first diameter and asecond bore 178 defined by a second generally cylindrical interior surface 180 having a second diameter that is less than the first diameter of the first cylindricalinterior surface 176. - The
cavity 310 is also defined by two transition surfaces—afirst transition surface 188 that transitions theball seat surface 162 to the first cylindricalinterior surface 176 and asecond transition surface 190 that transitions the first cylindricalinterior surface 176 to the second cylindrical interior surface 180. It will be appreciated that each of these transition surfaces can include an annular surface that is generally perpendicular to the axis A, a frusto-conical surface, a curved surface that is concave or convex with respect to the longitudinal axis A, or any combination thereof. - The cold-formed ball plunger blank 300 can be formed in a variety of cold-forming machines. Suitable examples of cold-forming machines that can be used to form the cold-formed ball plunger blank 300 include Waterbury and National Machinery cold-forming machines. Generally, cold-forming machines include a cut-off station for cutting metal wire to a desired length to provide an initial workpiece (also known as a “slug”) and multiple progressive forming stations that include multiple spaced-apart die sections and a reciprocating gate having multiple punch sections, each of which cooperates with a respective die section to form a die cavity. A conventional transfer mechanism moves the slug in successive steps from the cut-off station to each of the forming stations in a synchronized fashion and is also capable of rotating the slug 180 degrees as it is being transferred from one station to another. As cold-forming machines are well known in the art, no further description is necessary.
- In one embodiment, the cold-formed ball plunger blank 300 is formed in a five station, cold-forming machine (not shown). It will, however, be appreciated that the cold-formed ball plunger blank 300 can be produced in a different number of forming stations.
- Illustrated in
FIGS. 4A-4E is an exemplary cold-forming, five station slug progression sequence that can be used to form the cold-formedball plunger blank 300. Each figure represents the state of the slug at an end-of-stroke tool position. It will be appreciated that this slug progression sequence is merely one example of a cold-forming slug progression sequence and that other slug progression sequences are possible. - The exemplary slug progression sequence begins with shearing wire to a desired length at the cut-off station to provide an initial slug 400, which will be described with reference to a
first end 402, asecond end 404, and a cylindrical surface 406 that extends therebetween as shown inFIG. 4A . At this stage, the ends of the slug 400 have irregularities or unevenness inherent in the shearing process. The slug 400 is then transferred to the first forming station where itsfirst end 402 faces the die section and itssecond end 404 faces the punch section. - At the first forming station, the slug 400 is squared and a
slight indentation 408 is formed in thesecond end 404 at the punch section of the cold-forming machine as shown inFIG. 4B . At the die section of the cold-forming machine, achamfer 410 is simultaneously formed between thefirst end 402 and the cylindrical surface 406 of the slug 400. Additionally, at the die section, adeeper indentation 412 is formed in thefirst end 402 of the slug 400 along with achamfer 414 formed between theindentation 412 and thefirst end 402. Theindentation 412 serves to properly center and guide the punch from the second forming station, which will be described in further detail below. The slug 400 is then rotated 180 degrees and transferred to the second forming station where itsfirst end 402 faces the punch section and itssecond end 404 faces the die section. - At the second forming station, the
first bore 174 is extruded through thefirst end 402 of the slug 400 to near final dimensions at the punch section of the cold-forming machine as shown inFIG. 4C . Simultaneously, at the die section of the cold-forming machine, the generallyhemispherical surface 146 is beginning to be formed at thesecond end 404 of the slug 400. Additionally, aslight indentation 416 is formed in thesecond end 404 of the slug 400. Theindentation 416 serves to properly center and guide the punch from the fourth forming station, which will be described in further detail below. The slug 400 is then transferred to the third forming station where itssecond end 404 faces the punch section and itsfirst end 402 faces the die section. - At the third forming station, the
second bore 176, having a diameter less than thefirst bore 174, is backward extruded at thefirst end 402 of the slug 400 to near final dimensions at the punch section of the cold-forming machine as shown inFIG. 4D . Simultaneously, at the die section of the cold-forming machine, thehemispherical surface 146 is formed at thesecond end 404 of the slug 400 to near final dimensions. The slug 400 is then rotated 180 degrees and transferred to the fourth forming station where itssecond end 404 faces the punch section and itsfirst end 402 faces the die section. - At the fourth forming station, the
hemispherical surface 146 is formed to near final dimensions and thedimple 306 is formed in the center-point of thehemispherical surface 146 by the punch section of the cold-forming machine as shown inFIG. 4E . Simultaneously, at the die section of the cold-forming machine, acounterbore 148, having a diameter greater than thefirst bore 174, is formed in thesecond end 404 of the slug 400. Due to this diametrical difference, the die that forms thecounterbore 148 upsets the wall defining thefirst bore 174 and thereby forms theshoulder 173 that defines theretainer receiving surface 160 and theball seat surface 162 to near final dimensions. The slug 400 is then rotated 180 degrees and transferred to the fifth forming station where itsfirst end 402 faces the punch section and itssecond end 404 faces the die section. - At the fifth forming station, as shown in
FIG. 4F , the slug 400 is formed to its final dimensions, including overall length and thehemispherical surface 146 being formed to its final dimensions. Also, the cylindricalinterior surface 158, theretainer receiving surface 160, and theball seat surface 162 are coined to their respective final dimensions by the punch section of the cold-forming machine. At the conclusion of the fifth forming station, the cold-formed ball plunger blank 300 is completed and includes all of the structural features shown inFIG. 3 . - As discussed above, the cold-formed ball plunger blank 300 includes all of the structural features of the
finished ball plunger 116 described above and illustrated inFIGS. 1A and 1B , with the exception of several structural features. To complete themethod 200 of producing thefinished ball plunger 116 described above and illustrated inFIGS. 1A and 1B , the cold-formed ball plunger blank 300 is machined to form the remaining structural features as discussed above and shown inFIG. 2 . - The machining step (step 220) will be discussed with reference to
FIG. 5 where the shaded areas of thefinished ball plunger 116 represent the material removed from the cold-formed ball plunger blank 300 as a result of the machining step. As shown inFIG. 5 , thegroove 164 is machined into theextended body portion 302 and a portion of thehemispherical surface 146 and thegroove 152 is machined into the firstcylindrical exterior surface 150. Additionally, thethird bore 182 is drilled into theball portion 140, such that it communicates with thesecond bore 178, and theplunger fluid port 186 is drilled into thebody portion 142 such that it communicates with thefirst bore 174. It will be appreciated that these machining operations can be performed one at a time, in combination with one or more other machining operations, or all together in any sequence. - Unlike prior art ball plungers, the
ball plunger 116 described above is cold formed to near net shape (including the cold formation to final dimensions of theball portion 140 and the ball seat surface 162), thereby reducing the machine time to complete a finished ball plunger and thus reducing manufacturing cost of the finished ball plunger. Additionally, when compared to plunger designs that require the use of a seat insert and seal, these parts along with the associated assembly time and costs are eliminated. - For the purposes of this disclosure and unless otherwise specified, “a” or “an” means “one or more.” To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or multiple components. As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to plus or minus 10% of the particular term. From about X to Y is intended to mean from about X to about Y, where X and Y are the specified values.
- While the present application illustrates various embodiments, and while these embodiments have been described in some detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claimed invention to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's claimed invention. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.
Claims (20)
1. A cold-formed ball plunger blank used to manufacture a finished ball plunger for use in a hydraulic lash adjuster including a check valve assembly having a check ball and a retainer, the ball plunger blank comprising:
a cup-shaped member that extends from a first end to a second end along a longitudinal axis, the cup-shaped member including:
a ball portion adjacent the first end of the member; and
a body portion adjacent the second end of the member, the body portion having a cavity disposed therein, a counterbore extending from the second end of the body towards the first end of the member, and a shoulder that separates the cavity from the counterbore and at least partially closes the cavity,
the shoulder defining a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer,
wherein the ball seat surface and the retainer receiving surface are to sized to the final dimensions of the finished ball plunger.
2. The ball plunger blank of claim 1 , wherein the ball portion includes a generally ball-shaped outer surface sized to the final dimensions of the finished ball plunger.
3. The ball plunger blank of claim 1 , wherein the generally hemispherical outer surface of the ball portion includes a dimple that extends along the longitudinal axis of the member.
4. The ball plunger blank of claim 1 , wherein the ball seat surface includes a rounded annular surface.
5. The ball plunger blank of claim 1 , wherein the retainer receiving surface includes a flat annular surface that is oriented substantially perpendicular to the longitudinal axis of the member.
6. The ball plunger blank of claim 1 , wherein the cavity includes a first bore adjacent the first end and a second bore adjacent the second end, the second bore having a larger inner diameter than the first bore.
7. A unitary ball plunger for use in a hydraulic lash adjuster that includes a check valve assembly having a check ball and a retainer, the ball plunger comprising:
a generally tubular member that extends from a first end to a second end along a longitudinal axis, the tubular member including:
a ball portion adjacent the first end of the member, the ball portion including a generally ball-shaped surface that is cold-formed to its final dimensions and a hole that is generally coaxial with the tubular member;
a body portion adjacent the second end of the tubular member, the body portion having a bore disposed therein that communicates with the hole in the ball portion, a counterbore extending from the second end of the body towards the first end of the tubular member, and a shoulder provided between the bore and the counterbore that at least partially closes the bore, the shoulder defining a ball seat surface configured to receive the check ball and a retainer receiving surface configured to receive the retainer, wherein the ball seat surface and the retainer receiving surface are both cold formed to their respective final dimensions; and
a stem portion that separates the ball portion from the body portion.
8. The ball plunger of claim 7 , wherein the body portion includes an annular groove positioned closer to the second end of the member than the first end of the member.
9. The ball plunger of claim 8 , wherein the body portion includes a hole that is located within the groove in the body portion, that is oriented generally perpendicular to the longitudinal axis of the tubular member, and that communicates with the bore.
10. The ball plunger of claim 7 , wherein the ball seat surface includes a rounded annular surface.
11. The ball plunger of claim 7 , wherein the retainer receiving surface includes a flat annular surface that oriented substantially perpendicular to the longitudinal axis of the tubular member.
12. The ball plunger of claim 7 , wherein the cavity includes a first bore adjacent the first end and a second bore adjacent the second end, the second bore having a larger inner diameter than the first bore.
13. A method of cold-forming a ball plunger blank comprising the steps of:
providing a slug having first and second ends;
backward extruding the slug at its first end to form a cavity that is defined by a wall;
forming a generally ball-shaped outer surface at the second end of the slug to final dimensions; and
upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface to final dimensions.
14. The method of claim 13 , wherein the providing step includes shearing wire to a desired length to form the slug.
15. The method of claim 13 , further comprising the step of squaring the first and second ends of the slug before the backward extruding step.
16. The method of claim 13 , further comprising the step of forming a first indentation in the first end of the slug and a second indentation in the second end of the slug before the backward extruding step.
17. The method of claim 13 , further comprising the step of forming a dimple in the ball-shaped outer surface.
18. A method of cold-forming a ball plunger blank using a cold-forming machine having a cutoff station and five forming stations, the method comprising the steps of:
at the cutoff station, shearing wire to a desired length to form a slug having first and second ends;
at the first forming station, squaring the first and second ends of the slug and forming an indentation in the first end of the slug;
at the second forming station, backward extruding the slug at its first end to form a first bore that is defined by a tubular wall and forming a generally ball-shaped surface to near final dimensions;
at the third forming station, backward extruding the slug through its first end to form a second bore in the slug having a smaller diameter than the first bore;
at the fourth forming station, upsetting at least a portion of the tubular wall to form a shoulder that at least partially closes the first bore and defines a ball seat surface to near final dimensions; and
at the fifth forming station, coining the shoulder to form the ball seat surface to final dimensions.
19. A method of manufacturing a finished ball plunger for use in a lash adjuster assembly, the method comprising the steps of:
cold-forming a ball plunger blank having a longitudinal axis to near net shape including the steps of:
providing a slug having first and second ends;
backward extruding the slug at its first end to form a body portion having a cavity disposed therein that is defined by a wall,
forming a ball portion adjacent the second end of the slug, the ball portion including a generally ball-shaped surface sized to its final dimensions, and
upsetting at least a portion of the wall to form a shoulder that at least partially closes the cavity and defines a ball seat surface sized to its final dimensions; and
machining the ball plunger blank to complete the finished ball plunger.
20. The method of claim 19 , wherein the machining step includes:
cutting an annular groove in the ball plunger blank to form a stem portion between the ball portion and the body portion;
cutting an annular groove in the body portion of the ball plunger blank;
drilling a hole in the ball portion of the ball plunger blank that is generally coaxial with the longitudinal axis of the ball plunger blank and communicates with the cavity; and
drilling a hole in the body portion of the ball plunger blank that is located within the groove in the body portion, that is oriented generally perpendicular to the longitudinal axis of the ball plunger blank, and that communicates with the cavity.
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/235,919 US20100071649A1 (en) | 2008-09-23 | 2008-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
PL09736672T PL2342430T3 (en) | 2008-09-23 | 2009-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
EP09736672.8A EP2342430B1 (en) | 2008-09-23 | 2009-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
JP2011528450A JP2012503143A (en) | 2008-09-23 | 2009-09-23 | Ball plunger used for hydraulic lash adjuster and method of manufacturing the ball plunger |
CN2009202171733U CN201593451U (en) | 2008-09-23 | 2009-09-23 | Ball plunger blank and ball plunger for hydraulic gap adjusting device |
PCT/IB2009/007017 WO2010035131A1 (en) | 2008-09-23 | 2009-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
CN201410211207.3A CN104061033B (en) | 2008-09-23 | 2009-09-23 | Ball plunger for use in hydraulic lash adjuster and method of making same |
CN200910176624.8A CN101684738B (en) | 2008-09-23 | 2009-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
US13/484,701 US9388714B2 (en) | 2008-09-23 | 2012-05-31 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
JP2013234242A JP5820454B2 (en) | 2008-09-23 | 2013-11-12 | Manufacturing method for ball planer used for hydraulic lash adjuster |
US15/180,751 US10253659B2 (en) | 2008-09-23 | 2016-06-13 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/235,919 US20100071649A1 (en) | 2008-09-23 | 2008-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/484,701 Division US9388714B2 (en) | 2008-09-23 | 2012-05-31 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100071649A1 true US20100071649A1 (en) | 2010-03-25 |
Family
ID=41426446
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/235,919 Abandoned US20100071649A1 (en) | 2008-09-23 | 2008-09-23 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
US13/484,701 Active 2029-04-21 US9388714B2 (en) | 2008-09-23 | 2012-05-31 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
US15/180,751 Active 2029-09-19 US10253659B2 (en) | 2008-09-23 | 2016-06-13 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
Family Applications After (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/484,701 Active 2029-04-21 US9388714B2 (en) | 2008-09-23 | 2012-05-31 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
US15/180,751 Active 2029-09-19 US10253659B2 (en) | 2008-09-23 | 2016-06-13 | Ball plunger for use in a hydraulic lash adjuster and method of making same |
Country Status (6)
Country | Link |
---|---|
US (3) | US20100071649A1 (en) |
EP (1) | EP2342430B1 (en) |
JP (2) | JP2012503143A (en) |
CN (3) | CN104061033B (en) |
PL (1) | PL2342430T3 (en) |
WO (1) | WO2010035131A1 (en) |
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- 2009-09-23 JP JP2011528450A patent/JP2012503143A/en active Pending
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Also Published As
Publication number | Publication date |
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PL2342430T3 (en) | 2013-12-31 |
JP2014076488A (en) | 2014-05-01 |
JP2012503143A (en) | 2012-02-02 |
CN101684738A (en) | 2010-03-31 |
CN104061033B (en) | 2020-11-27 |
CN101684738B (en) | 2014-06-18 |
JP5820454B2 (en) | 2015-11-24 |
US10253659B2 (en) | 2019-04-09 |
EP2342430B1 (en) | 2013-07-03 |
CN201593451U (en) | 2010-09-29 |
CN104061033A (en) | 2014-09-24 |
US20160290178A1 (en) | 2016-10-06 |
US20120234067A1 (en) | 2012-09-20 |
WO2010035131A1 (en) | 2010-04-01 |
EP2342430A1 (en) | 2011-07-13 |
US9388714B2 (en) | 2016-07-12 |
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