WO2016105000A1

WO2016105000A1 - Precision forging method for piston of caliper housing for ball-in-ramp brake system

Info

Publication number: WO2016105000A1
Application number: PCT/KR2015/013518
Authority: WO
Inventors: 김항진; 신상복; 김정두
Original assignee: 서영정밀주식회사
Priority date: 2014-12-22
Filing date: 2015-12-10
Publication date: 2016-06-30
Also published as: KR20160076266A; KR101670798B1

Abstract

The present invention relates to a precision forging method for a piston of a caliper housing for a ball-in-ramp brake system and, more particularly, to a precision forging method for a piston of a caliper housing for a ball-in-ramp brake system, in which separate processing steps are performed in different former cold forming machines. A manufacturing method for a piston of a caliper housing for a ball-in-ramp brake system, according to the present invention, comprises, in a plurality of former cold forming machines which have molding dies and forming dies, a plurality of continuous processes of fixing a forming material to a fixing pin of each molding die and applying pressure by means of a punch of each forming die.

Description

Piston precision forging method in caliper housing for ball in ramp brake system

The present invention relates to a method for precisely forging a piston of a caliper housing for a ball in lamp brake system, and more specifically to a method for precisely forging a piston of a caliper housing for a ball in lamp brake system by performing a separate process step in a different perm cold forming machine. It is about.

The ball-in-lamp brake system applied to the parking brake structure of an automobile may consist of devices such as discs, caliper housings, wheel cylinders, pistons, hubs, pads and pad springs. The ball-in ramp brake system places a caliper between the pads for braking. Such a ball-in ramp brake system reduces the initial invalid stroke and allows the brake function and the parking function to be controlled simultaneously with a high rate of increase of the lever. The piston for movement of the caliper housing of the ball in ramp system can be produced, for example, by a cutting or forging process.

It is an object of the present invention to provide a method for precisely forging a piston of a caliper housing for a ball in lamp brake system by a continuous forging process in a perma cold forming machine independent of each other.

According to a preferred embodiment of the present invention, a method of precisely forging a piston of a caliper housing for a ball in lamp brake system is a method of manufacturing a piston of a caliper housing for a ball in lamp brake system, each of which consists of a mold die and a molding die. A plurality of perm cold forming machines includes a plurality of continuous processes of securing the molding material to the fixing pins of the respective mold dies and pressing with the punch of each molding die.

According to another suitable embodiment of the present invention, the plurality of continuous processes comprises the steps of: forming a molded material having an outer diameter shape and an inner diameter guide of one hollow portion from a base material; Forming a second molding material to form an inlet portion and a step shape in the first molding material; Forming a three molding material from the two molding materials to form an inner diameter shape by a center punch; Pressing a center portion from the three molding materials to form a four molding material for making an inner portion; Forming a 5 molding material which makes an inner shape from the 4 molding material; And making an inner 4-slot flow path hole and a bottom surface 4-groove portion symmetrical to the inner shape of the fifth molding material.

According to another suitable embodiment of the present invention, the process of making the inner portion is limited in dimension to a predetermined range such that the volume is uniformly distributed by the fixing pin of the four mold die.

According to another suitable embodiment of the present invention, the inner shape of the five molding materials is formed by punch pins.

The precision forging method according to the present invention allows the productivity to be improved while the processing time is shortened by continuously performing the forging process in different perma cold forming machines. It is also possible to simplify the manufacturing process of the piston by allowing the precision shape of the piston to be shaped by the punching process.

1A and 1B illustrate an embodiment of forming round and chamfer angles from a base material in a precision piston forging method according to the present invention.

Figures 2a and 2b shows an embodiment of the step of making the inlet and step shape in the precision piston forging method according to the present invention.

Figures 3a and 3b shows an embodiment of the step of making the inner diameter guide shape in the precision piston forging method according to the present invention.

Figures 4a and 4b shows an embodiment of the step of forming the center portion in the precision piston forging method according to the present invention.

Figures 5a and 5b shows an embodiment of the step of making the inner center shape and the inner diameter portion shape in the precision piston forging method according to the present invention.

6A and 6B illustrate an embodiment of a process of completing a lower outer diameter and a groove in a method of precise forging a piston according to the present invention.

Figure 7 shows an embodiment of a piston produced by the manufacturing method according to the present invention.

Hereinafter, the present invention will be described in detail with reference to the embodiments set forth in the accompanying drawings, but the embodiments are provided for clarity of understanding and the present invention is not limited thereto. In the following description, components having the same reference numerals in different drawings have similar functions, and thus are not repeatedly described unless necessary for understanding of the invention, and well-known components are briefly described or omitted. It should not be understood to be excluded from the embodiment of.

The method of manufacturing a piston of a caliper housing for a ball in lamp brake system according to the present invention is to fix the molding material to the fixing pins of the respective mold dies in a plurality of perma cold forming machines each consisting of a mold die and a molding die, It includes a plurality of continuous processes to press the punch of the forming die.

The method for producing a piston according to the invention comprises six process steps, in which each perm cooling molding machine consisting of different mold dies and forming dies can be operated. It can be determined according to the shape of each mold die and the molding material to be molded of the molding die. However, the process step may be appropriately adjusted and the present invention is not limited thereto.

The plurality of continuous processes may include forming one molding material having an outer diameter shape and an inner diameter guide of one hollow portion from a base material; Forming a second molding material to form an inlet portion and a step shape in the first molding material; Forming a three molding material from the two molding materials to form an inner diameter shape by a center punch; Pressing a center portion from the three molding materials to form a four molding material for making an inner portion; Forming a 5 molding material which makes an inner shape from the 4 molding material; And making an inner 4-slot flow path hole and a bottom surface 4-groove portion symmetrical to the inner shape of the fifth molding material.

The process of making the inner part is limited in dimension to the range of 0.15 to 2.56 mm so that the volume is uniformly distributed by the fixing pin of the four mold die. And the inner shape of the five molding material may be formed by a punch pin.

A forging process is applied to the method for producing a piston according to the present invention, and preferably a cold forging process with high surface precision and dimensional accuracy can be applied. The material for the manufacture of the piston may be aluminum or an aluminum alloy, specifically Al 6061-0 corresponding to an unannealed aluminum alloy or Al 6061-T4 or Al 6061-T6 corresponding to an aluminum alloy that has been heat treated and It may include the same but is not limited thereto. A press, such as a hydraulic press or a mechanical press, may be used to forge the primary piston, and the forging may be performed by two forging dies, and a lubricant such as mineral oil may be used as necessary. Forging temperature may be, for example, 15 ℃ to 30 ℃ temperature or room temperature, but is not limited thereto. In addition, the inner surface of the inlet portion of the molding material may be made of a cemented carbide special coating, and the cemented carbide special coating may be, for example, titanium carbide coating (TiC), aluminum coating (Al ₂ O ₃ ), titanium nitride (TiN) by chemical vapor deposition. ) Coating or titanium carbon coating (MT-TiCN), but is not limited thereto. The cemented carbide special coating can be applied in each process of forging, and the uniformity of the surface, the surface strength or the dimensional uniformity of the molded article can be improved during the forging process.

The manufacturing method according to the present invention includes a step of determining a molding position by a perm cold forming machine, and sequentially forming hollow portions by a pressure punching process according to the determined molding position. For example, rounding and chamfering may be made by the central punch of one perm cold forming machine, and inlet portions may be made by the central punch of two perm cold forming machine. The inner diameter guide may be formed by the three-perm cold forming machine, and the center inner guide may be formed by the four-perm cold forming machine. And the inner diameter part is made by the 5 perm cold forming machine, and a flow path hole and a bottom groove can be formed by the 6 perm cold forming machine. Such a process can be carried out continuously and each part can be formed by suitable pressing punches, punch pins and fixing pins.

It is described in detail below.

1A and 1B, the first perm forming cold machine includes a first mold die 11 having a first fixing pin 111 and a first forming die 12 having a first pressing punch 111 disposed therein. It may be made of. The base material may have a cylindrical shape or a circular shape, and may be fixed to the fixing pin 111 of the first mold die 11. An outer diameter shape and a first hollow portion inner diameter guide may be formed by the first pressing punch 111. In addition, the round R may be formed by the fixing pin 111. The first molding material 100 may be molded by the first perm forming cold machine. 1 The inner diameter guide 101 may be formed above the molding material 100, and a round may be formed below the molding material 100. Thereafter, the first molding material 100 may be forged in the second perm forming cold machine.

Referring to FIG. 2A, the second perm molding cold machine may press-punch the second molding die 21 to which the first molding material 100 is fixed and the fixed first molding material 100 to form the two molding materials 200. It may consist of a punching die 22. The first molding material 100 may be fixed by the fixing pin 211, and the inlet and staircase shapes 201 may be molded by the two pressing punches 221 installed in the two punching dies 22. The fixing pin 211 may have a bottom surface capable of maintaining the shape of the round R and the two pressing punches 221 may have a protruding step forming portion. In addition, the inlet and the staircase shapes 201 may be formed by the center portion of the one molding material 100 being a pressure punch by the two pressure punches 221. Through this process, the two molding materials 200 may be molded and transferred to the three perm forming cold machine.

Referring to FIGS. 3A and 3B, the three-perma-molding cold machine forms a 3 mold die 31 and 2 molding material 200 to which the 2 molding material 200 is fixed to form a 3 molding material 300 by pressure punching. It may consist of a punching die 32. The three mold die 31 may have a fixing pin 311 with a center fixing pin 312 formed in the center portion, and three punching

The inner diameter shape 301 and the center portion 302 may be formed by the three pressing punches 321 formed in the die 32. In the process of forming the inner diameter shape 301 by the pressing punch 321, the central axis of the central portion 302 of the inner diameter shape 301 needs to be made to have an error of 0.05 mm or less. To this end, a linear guide 323 for measuring the movement deviation while linearly moving the induction cylinder 322 for inducing the movement of the three pressing punches 321 to the three punching dies 32 and the three pressing punches 321 is provided. Can be arranged.

The three forming material 300 in which the inner diameter shape 301 and the central portion 302 are formed by the three perm forming cold machine may be moved to the four perm forming cold machine.

Referring to FIG. 4A, the four-perm molding cold machine performs pressure punching of the four mold dies 41 and the three molding materials 300 to which the three molding materials 300 are fixed, and thus the inner side of the four perm molding cold machines. It may consist of four punching dies 42 having four pressing punches 421 forming the portion 401. The inner part 401 may be formed on the basis of the center part molded in the molding material 300. In the process of forming the inner part 401, it is necessary to make the volume of the three molding materials 300 uniformly distributed. For this purpose, the dimension range of the inner portion 401 may be limited according to the inner diameter portion IR formed below. For example, if the length of the inner diameter portion IR is 2.56 mm, the dimension of the inner portion 401 may be limited to the range of 0.15 mm. As such, the dimensions of the inner portion 401 may be limited depending on the dimensions of the inner diameter portion IR and may be limited to, for example, 1/17 or less of the dimensions of the inner diameter portion IR. When the inner part 401 having the inclined side is formed out of the dimension range presented, it is difficult to uniformly distribute the volume due to a process error.

The balance frame 412 may be disposed below the four mold die 41 so that the process is stably progressed while the volume is uniformly distributed. If necessary, the balance member 413 may be disposed in the balance frame 412 at a position corresponding to the four fixing pins 421 subjected to a strong pressure in the pressure punching process.

The four molding material in which the inner portion 401 is molded may be transferred to a five perm forming cold machine.

5A and 5B, the 5-perm cold forming machine punches and presses the 5 mold die 51 and the 4 molding material 400 to which the 4 molding material 400 is fixed to form a central inner shape 501 and an inner diameter portion. 5 punching die 52 forming 503. A fixing pin 511 may be disposed on the five mold die 51 to fix the four molding material 400, and a punch pin 521 may be disposed on the five punching die 52. By making the shape and the dimensions of the inner diameter guide 502 are maintained in the process of making the inner diameter portion shape 503, the volume of the five molding material 500 can be made uniform. In addition, burrs may be prevented from being generated upward by the inner diameter guide 502. The dimension of the inner diameter guide 502 may be limited to within 0.15 mm, as described above. The five molding material 500 formed by the five perm cold forming machine may be transferred to the six perm forming cold machine.

6A and 6B, the six-perm cold forming machine is a four-slot flow path hole 603 and 4 by pressure punching the mold die 61 and the five forming material 500 to which the five forming material 500 is fixed. -Six punching dies 62 forming bottom grooves 604. A fixing pin 611 corresponding to the shape of the four-bottom groove 604 may be disposed in the die die 61, and a punch pin for forming the four slot flow hole 603 in the six punching die 62. 621 may be disposed. The 4-slot flow path hole 603 and the four-bottom groove 604 can be formed to be symmetrical and the 4-slot flow path hole 603 and the inner diameter portion 602 are precisely predetermined dimensions so as not to be separately machined in the finishing process. Is processed into.

The piston shaped by FIG. 6A is shown in FIG. 7.

Referring to FIG. 7, an inner diameter portion 602 may be formed below the inner diameter guide 601, and a four-slot flow path hole 603 may be formed outside the inner diameter portion 602. A four-bottom groove 604 may be formed on the bottom surface, and the four-slot flow path hole 603 and the four-bottom groove 604 may be formed to be symmetrical.

Although the present invention has been described in detail above with reference to the presented embodiments, those skilled in the art may make various modifications and modifications without departing from the technical spirit of the present invention with reference to the presented embodiments. . The invention is not limited by the invention as such variations and modifications but only by the claims appended hereto.

The present invention can be applied to the molding of parts of automobiles.

Claims

A method of manufacturing a piston of a caliper housing for a ball in ramp brake system,

Ball in ramp brakes comprising a plurality of continuous processes, each of which consists of a mold die and a molding die, in which a molding material is fixed to a fixing pin of each of the mold dies and pressed with a punch of each molding die. Piston precision forging method in caliper housing for the system.
The method of claim 1, wherein the plurality of continuous processes comprises: forming, from a base material, one molded material having an outer diameter shape and an inner diameter guide of one hollow portion; Forming a second molding material to form an inlet portion and a step shape in the first molding material; Forming a three molding material from the two molding materials to form an inner diameter shape by a center punch; Pressing a center portion from the three molding materials to form a four molding material for making an inner portion; Forming a 5 molding material which makes an inner shape from the 4 molding material; And making the inner four-slot flow path hole and the bottom four-groove portion symmetrical to the inner shape of the fifth molding material.
3. The piston precision of a caliper housing for a ball in lamp brake system according to claim 2, wherein the process of making the inner portion is limited in dimensions to a predetermined range such that the volume is uniformly distributed by the fixing pin of the four mold die. Forging method.
The method of claim 2, wherein the inner shape of the five forming material is formed by a punch pin.