Precisely, this invention relates to a novel method of manufacturing brake shoe webs and a system of manufacturing brake shoe webs.

Description of related art: In any automobile, for each wheel there will be two numbers of brake shoe assembly. The brake shoe assembly consists of components like shoe web, rim and brake lining. The purpose of the shoe web is to augment rib strength and to transmit force from Cam Assembly to hold the brake.

The salient features of the invention resides in technology, a novel method and a system by virtue of which a novel process of manufacturing brake shoe webs are achieved.

In the conventional method of manufacturing brake shoe webs a method of blanking operation is widely used. In order to execute the conventional method of blanking operation, various devices are used.

Essential devices are as follows : a) Blanking Press Tool b) Mechanical Press Machine c) Input raw material in the form strips as per the requirement

In the conventional process of manufacturing webs hot rolled steel strip material is used. The said material is stacked near the machine and fed one by one inside the press tool which is bolted in the machine. Once the operator initiates the operation, due to force of descending ram of the press the die penetrates into the punch through metal strip and cold cutting takes place thereby required shape of the component is achieved.

The problem associated with the conventional process is that of enormous amount of wastage material. To be precise for every 100 kg of raw material input only 53.5% input is obtained as output material and the balance become wasted material in the form of scrap.

The salient feature of the invention is to address the problem of wastage of raw material, resulting in the conventional process being expensive.

This invention offers a solution to overcome the problem as mentioned in the prior art. This is achieved by inventing a novel process of manufacturing brake shoe webs. In this novel process, instead of using a conventional blanking method and using mechanical press the invention envisages adaptation of forming process using hydraulic press.

At the outset of the description which follows it is to be understood that ensuing description only illustrate a particular form of this invention.

However, such particular form is only an exemplary embodiment, and without intending to imply any limitation on the scope of this invention.

Accordingly, the description is to be understood as an exemplary embodiment and reading of the invention is not intended to be taken restrictively.

The foregoing description of outlined rather broadly preferred and alternative feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing and modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should realise such equivalent conception do not depart from the spirit and scope of the invention in its broadest form.

It is to be noted that the prior art description give in detail information of the technology, method, process and system known in the art. It explains the deficiency in the related art and the object of the invention being to overcome or surmount the problem associated with the prior art. This forms the essential feature and the object of the invention.

Summstfy of indention : The inventors have made great efforts to provide a method and system which meet the requirement of the industry and overcome the problem associated with the prior art.

To achieve the above object according to first aspect and feature of the present invention there is provided a novel process of manufacturing brake shoe webs.

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According to another aspect of the invention there is provided a system by which the novel process is carried out.

It is another object of the invention to invent a process which reduces depletion of raw material by reduction of raw material consumption.

The above and other objects which are apparent will be clear from the following description of preferred embodiment taken in conjunction with accompanying drawings.

Accordingly, this invention relates to a technology for manufacturing brake shoe webs by novel forming process leading to substantial reduction of waste material thereby leading to better yield.

Further the invention relates to a process of manufacturing brake shoe webs by forming process wherein the process comprises the following steps : a) Feeding a metal strip as specified in the description into the hydraulic press b) Forming using specially developed tool such that the web undergoes radial forming operation across the cross-sectional strip and gets formed when the ram of hydraulic press descend with a force on the job, c) Taking out the formed web from the hydraulic press for execution of second operation d) Cropping and punching the hole in the web with the help of a mechanical press and special press tool leading to formation of brake shoe web.

In addition, this invention relates to a system of manufacturing brake shoe webs by forming process wherein the process comprises the following steps: a) Means for feeding a metal strip as specified in the description into the hydraulic press b) Means for forming using specially developed tool such that the web undergoes radial forming operation across the cross-sectional strip and gets formed when the ram of hydraulic press descend with a force on the job, c) Means for taking out the formed web from the hydraulic press for execution of second operation d) Means for cropping and punching the hole in the web with the help of a mechanical press and special press tool leading to formation of brake shoe web.

Brief description of drawings : The accompanying drawings are intended to provide further understanding of the invention and is incorporated in and constitute a part of invention. These drawings illustrate an embodiment of invention and together with the description illustrate the principle of the invention.

The drawings are given by way of non-limitative example to explain the nature of the invention.

For a more complete understanding of the instant invention, reference is now made to the following description taken in conjunction with accompanying-drawings wherein-

Figure 1 of the drawings shows in elevation, illustrate the brake assembly and lined shoe assembly.

Figure 2 of the drawings shows in elevation, brake shoe assembly.

Figure 3 of the drawing shows in elevation, the input steel sheet used for the purpose of manufacturing webs.

Figure 4 of the drawings shows the various steps involved in the conventional blanking process.

Figure 5 of the drawing shows in elevation, blanking of web according to conventional process.

Figure 6 shows in elevation the actual scrap produced in the conventional process and a sample of shoe web.

Figure 7 shows in elevation the input sheet material used in the novel process of manufacturing shoe webs.

Figure 8 illustrates various steps involved in the novel process.

Figure 9 illustrates the formation of shoe webs according to novel invention.

Figure 10 illustrates the output of sheet metal undergoing various stages of formation.

Figure 11 illustrates the press tool arrangement to execute the process according to the invention.

Figure 12 illustrate the amount of scrap wasted in the conventional process.

Figure 13 illustrate the amount of scrap wasted according to the novel process.

Figure 14 illustrate, by way of comparison, scçap loss between conventional and novel process.

Detailed description of the preferred embodiment : In the novel process of manufacturing, independent small strips having width more or less equal to web width are used. To produce a required form of web, one need to calculate development length based on radius of the web.

These strips are fed individually into a hya'raulic press and the formation takes place using a specially developed tool. The salient feature of the invention is that in this method the strip undergoes a radial forming operation across the cross-section of the strip and gets formed when the ram of the press descend with a force on to the job. Due to forming, the cross section of the, web becomes slightly tapered which is acceptable to said application. The formed web is taken out for execution of second operation namely end cropping and hole punching. This operation is carried out with a mechanical press with a specially designed press tool.

The webs produced by the execution of this method undergoes quality test.

Figure 1 of the drawing shows in detail the principal components namely brake lining (1) lined shoe assembly (2) carrier (3) cam assembly (4) and retracting springs (5). The brake shoe opens, on application of brake and holds the rotating wheel and stops the vehicle. When the brake is released, the retracting springs bring back the shoes to home position and allows the wheel to rotate.

Figure 2 of the drawing shows a brake shoe assembly. Brake shoe assembly is a part of brake assembly created by welding of rim (6) and web (7).

Figure 3 of the drawing shows the input steel sheet. The steel sheet is sheared and converted into strips which is used in the conventional process.

Figure 4 of the drawing illustrates various steps involved in the conventional blanking process. Normally higher tonnage mechanical press is used for blanking process.

Figure 5 & 6 of the drawings shows the blanked web (8) and the wastage skeleton scrap (9) results by the execution of this conventional process.

Figure 7 illustrates the input sheet material used in the novel process according to the invention. This sheet material is sheared and converted into strips (10).

Figure 8 of the drawing illustrate the various steps involved in the novel process instead of blanking process. The invention envisages use of forming process using a lower tonnage hydraulic press. The advantages of this process is explained in the following description.

Figure 9 & 10 of the drawing show the formation of the web in the novel process wherein the input strip (10) undergoes two stage formation leading to, formed web (13). The input strip, intermediate formed strip and fully formed web are shown by numerals 10, 11 and 13 respectively.

The scrap material is indicated by numeral 12.

Figure 11 of the drawing shows various tooling arrangement to execute the novel process. The top and bottom tool assemblies are clamped to the machine bed (14) and (18) respectively. Initially, when the tool is opened the steel strip (10) is loaded in the locator provided in the die holder assembly (17) The punch and die are suitably designed so as to obtain the radial formation of the web. When the operator initiates the press, the top assembly (15) comes down and forms the profile. The top tool and bottom tools are suitably guided by a guide (16) which is provided for proper alignment of top and bottom tool assemblies.

This embodiment is invention with reference to the hydraulic press. The same operation can be executed using a mechanical press also with suitable tool arrangement.

Figure 12 to 14 of the drawings shows the comparison of the percentage of scrap according to conventional process and the process according to the invention.

Advantages of the New Process : The new process of manufacturing of Webs have great advantage over the conventional method right from material purchasing and the difference between the two process is listed below : SI. No. Description Before Novel Method 01 Raw material input weight for 100 246. 99 kgs. 168.15 kgs Webs 02 Scrap 107. 99 kgs. 29.15 kgs.

The invention has been explained in relation to specific embodiment. It is inferred that the foregoing description is only illustrative of the present invention and it is not intended that the invention be limited or restrictive thereto., Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. All substitution, alterations and modification of the present invention which come within the scope of the following claims are to which the present invention is readily susceptible without departing from the spirit of the invention.

The scope of the invention should therefore be determined not with reference to the above description but should determined with reference to appended claims along with full scope of equivalents to which such claims are entitled.