TITLE
COLD FORMING OF CAM BRAKE.
Abstract:
This invention is titled as COLD FORMING OF CAM BRAKE.
The above-mentioned Cam is made of cold heading quality steel and in a brake assembly is responsible for applying brake in a Two Wheeler. This is possible because of a special forming of Braking track. The detail is shown in diagram 6.
The previous customary cam brake used on Two-wheeler brake assembly is machined out of bar stock, which has dimensional inaccuracies, and consumed lot of material and time for manufacture.
As the grains were cut during machining and improper junction radius in machining may be very unsafe after heat treatment, as it is a critical part in brake assembly, this is detrimental to efficiency of braking.
Infact the scrap generated out of machining is very much higher than in forging.
This part is assembled along with the other components in the Back plate of Front and Rear wheel in two wheelers.
a) The use of this process is to give a much stronger component since
it is Cold Forged.
b) Braking effort is very drastically reduced because of the Cold
Forming the Cam Track.
c) It will be very easy to apply the Brake if this Cam is assembled and
not much force is requked
d) The spline on the component is Cold Extruded for more strength
and continuous grain flow.
/

Details of Process:
1. Cold heading quality wire of suitable diameter is fed into the machine, wherein it is cut to the exact length that is needed for cold forming progressively the above said cam. (As per diagram 1)
2. Slug Cut-off from the cutting station is transferred through transfer finger to the first die, wherein it is cold upset to specific dimensions, to ultimately get the profile of the cam. (As per diagram 2)
3. It is forged with the help of the punch to attain the profile as shovm in Diagram 3.
4. In the third die, splines are extruded. (As per diagram 4)
5. In the fourth die with the help of trim punch, the round collar is trimmed and the cold-formed cam profile is obtained.
6. The detail of this is as per diagram 5.
The above operations complete the forging of Cam brake.
Groove machining in the spline area and cold rolling of oil grooves are secondary operations.
To make the part fiilly functional. Heat treatment and Surface treatments are carried out.
(1) Cold Trimming of Cold cam Track and Collar.
(2) Cold Extrusion of Splines.
(3) Cold rolling of Oil Grooves.
(4) Heat Treatment.

(5) Plating.
(6) Grinding.
Prior Art:
The previous customary cam brake used on Two-wheeler brake assembly is machined out of bar stock, which has dimensional inaccuracies, and consumed lot of material and time for manufacture.
As the grains were cut during machining and improper junction radius in machining may be very unsafe after heat treatment, as it is a critical part in brake assembly, this is detrimental to efficiency of braking.
Infact the scrap generated out of machining is very much higher than in forging.
Novelty of the Invention
This part is assembled along with the other components in the Back plate of Front and Rear wheel in two wheelers.
a) The use of this process is to give a much stronger component since it is Cold Forged.
b) Braking effort is very drastically reduced because of the Cold Forming the Cam Track.
c) It will be very easy to apply the Brake if this Cam is assembled and not much force is required
d) The spline on the component is Cold Extruded for more strength and continuous grain flow.


1. Cold heading quality wire of suitable diameter is fed into the machine, wherein it is cut to the exact length that is needed for cold forming progressively the above said cam. (As per diagram 1)
2. Slug Cut-off from the cutting station is transferred through transfer finger to the first die, wherein it is cold upset to specific dimensions, to ultimately get the profile of the cam. (As per diagram 2)
3. It is forged with the help of the punch to attain the profile as shown in Diagram 3.
4. In the third die, splines are extruded. (As per diagram 4)
5. In the fourth die with the help of trim punch, the round collar is trimmed and the cold-formed cam profile is obtained.
6. The detail of this is as per diagram 5.
The above operations complete the forging of Cam brake.
Groove machining in the spline area and cold rolling of oil grooves are secondary operations.
To make the part ftiUy fimctional. Heat treatment and Surface treatments are carried out.

CLAIMS:
1. Cold Trimming of Cold cam Track (As per Diagram 2)and
Collar (As per Diagram 4).
2. Cold Extrusion of Splines (As per Diagram 5).
3. Cold rolling of Oil Grooves (As per Diagram 6).