A stamped part for a honda shock absorber assembly and a method of manufacturing the same

Abstract

The application discloses a kind of shock absorber components, to provide a kind of honda shock absorber assembly stamping and its manufacturing method, its technical scheme main points are including: spring disc, for being welded with reservoir cylinder to carry the lower end ring of coil spring, its disc face is inverse arch shape configuration, arch shape convex surface outer circle circumference is set with several for accommodating coil spring lower end ring clamping slot according to spiral lift distribution, the lowest point of clamping slot is the starting positioning point of spring head, for clamping spring head to avoid abnormal sound caused by running position, the part of the spring disc and reservoir cylinder cooperation welding is provided with stretch straight line segment, the length of this straight line segment is 1 / 4-1 / 3 of spring disc outer diameter;Top glue assembly framework is used to support the upper end ring of coil spring and wrap outer buffer block, connecting rod limiting block, anti-vibration buffer block, it is set as conical structure, and its bottom is diamond downward flanging, for cooperating spring rubber pad to support the upper end ring of coil spring;The application is suitable for shock absorber technical field.

Description

Technical Field

[0001] This invention relates to a shock absorber component, and more specifically, to a stamped part for a Honda shock absorber assembly with a reasonable design and high forming precision, and a method for manufacturing the same. Background Technology

[0002] As the automotive industry upgrades towards high performance and comfort, consumers' demands for vehicle stability and driving experience continue to rise. As a core component of the suspension system, the shock absorber assembly's performance directly determines the vehicle's ability to suppress bumps and vibrations. The stamped parts of the rear shock absorber assembly in the third-generation Honda CR-V, namely the spring disc and top mount assembly frame, are key structures ensuring the shock absorber's precision and reliability. Existing stamped parts suffer from insufficient design rationality and poor forming precision, such as easy shifting of the spring support positioning and uneven contact at welded mating surfaces. This results in insufficient shock absorber stability, failing to meet the needs of complex road conditions, and also leads to high production costs. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a stamped part for Honda shock absorber assembly with reasonable design and high forming accuracy, and a method for manufacturing the same.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a stamped part for a Honda shock absorber assembly, comprising: A spring disc is used to weld with a liquid storage cylinder to support the lower coil of a helical spring. The disc surface has a reverse bow-shaped structure. Several slots for accommodating the lower coil of the helical spring are arranged on the outer circumference of the bow-shaped protrusion according to the helical stroke. The lowest point of the slot is the starting positioning point of the spring head, which is used to lock the spring head to prevent it from shifting and causing abnormal noise. The part of the spring disc that is welded to the liquid storage cylinder is provided with a tension straight section. The length of the straight section is 1 / 4 to 1 / 3 of the outer diameter of the spring disc. The top rubber assembly frame is used to support the upper coil of the coil spring and wrap the outer buffer block, connecting rod limiting block, and vibration damping block. It is designed with a conical structure and its bottom is diamond-shaped with a downward-turned edge, which is used to cooperate with the spring rubber pad to support the upper coil of the coil spring.

[0005] The present invention is further configured such that: the spring disc and top rubber assembly frame is made of SAPH440 steel plate material, the steel plate thickness is 3.5mm, and the ratio of the height of the protrusion of the reverse bow-shaped structure to the length of the straight segment is 1:2-1:3.

[0006] The present invention is further configured such that the shortest diagonal length of the bottom of the rhombus of the top adhesive assembly skeleton is 3 / 4 to 4 / 5 of the outer diameter of the top adhesive assembly skeleton.

[0007] A method for manufacturing a stamped part for a Honda shock absorber assembly, characterized by comprising the following steps: S1. Raw material pretreatment and selection verification: SAPH440 steel plate material was selected as the base material for the spring disc and top adhesive assembly skeleton; at the same time, the initial thickness of the base material was measured, and the thickness deviation of the base material was controlled within ±0.05mm. S2. Spring disc stamping and reverse bow structure control: A precision stamping die is used to stamp the spring disc substrate. First, a circular blank is formed through a blanking process. Then, a straight segment is drawn at the mating part between the spring disc and the liquid reservoir through a stretching process. Subsequently, a reverse stamping process is used to form a reverse bow structure on the disc surface. During the stamping process, the die pressure is monitored in real time, ranging from 200-300MPa, as well as the deformation of the bow area. The deformation rate of the bow area is measured by a laser displacement sensor and is 15-20%. If the die pressure is <200MPa or >300MPa, or the deformation rate of the bow area is <15% or >20%, the stamping parameters are considered abnormal. The stamping is then paused and the die clearance is adjusted, with an adjustment range of 0.02-0.05mm. S3. Accuracy verification of the straight section and arc-shaped surface of the spring disc: After stamping, a coordinate measuring machine is used to check the length of the straight section, the flatness of the surface, and the outer circumferential contour of the arc-shaped protrusion of the spring disc and the liquid storage cylinder. If the length of the straight section exceeds the ratio of the height of the protrusion to the length of the straight section of the reverse arc-shaped structure in the range of 1:2-1:3, or the flatness is >0.05mm or the circumferential contour is >0.1mm, the stamping is deemed unqualified and reworked. At the same time, the groove parameters are checked by a contour gauge. S4. Stamping and Conical Structure Control of Top Rubber Assembly Frame: Another set of stamping dies is used to stamp the top rubber assembly frame substrate. First, a conical body is stamped out, then a rhomboid bottom with a downward-facing flange is formed through a flanging process. Finally, a stretching process is used to ensure a smooth transition between the conical body and the rhomboid bottom. After stamping, a coordinate measuring machine is used to check the diagonal length of the rhomboid bottom and the taper of the conical body. If the diagonal length exceeds 3 / 4-4 / 5 of the outer diameter or the taper deviation is > ±1°, rework is required. S5. Before welding, adjust the contact uniformity and control the projection welding parameters. Assemble the spring disc and the liquid storage cylinder, adjust the concentricity of their mating surfaces using a laser alignment instrument, and apply a thin layer of flux (0.01-0.03mm) to the contact area. Use projection welding to weld the spring disc and the liquid storage cylinder together. Before welding, use a pressure sensor to detect the contact surface pressure. If the pressure is <5MPa or >8MPa, adjust the clamping force of the clamp, i.e., increase / decrease the shim thickness by 0.1-0.3mm to ensure uniform contact. During welding, control the welding current at 8000-12000A, the welding time at 0.5-1.0s, and the electrode pressure at 6-10kN. After welding, use an ultrasonic flaw detector to check for pores and cracks inside the weld, and use a tensile testing machine to test the welding strength to ensure the welding is qualified. S6. Verification of spring disc slot and spring head positioning: Simulate the installation of a helical spring on the welded spring disc, place the lower end of the spring into the slot, measure the radial offset between the starting point of the spring head and the center of the spring disc using a displacement sensor, and apply axial tension to detect whether the spring head moves. If the radial offset is >0.1mm or the movement is >0.2mm, the slot positioning is deemed to be ineffective, and the slot size should be checked or the mold slot angle should be corrected. S7. Verification of the support performance of the top rubber assembly frame: Assemble the top rubber assembly frame with the spring pad and the upper coil of the helical spring. Simulate the working load of the shock absorber using a pressure testing machine, detect the contact pressure distribution between the bottom of the rhombus and the spring pad, and observe the axial displacement of the upper coil of the helical spring. If the uniformity deviation of the contact pressure distribution is >15% or the displacement of the upper coil is >0.3mm, the support structure is deemed to have failed. Then check the flange angle of the bottom of the rhombus or correct the overall taper of the mold. S8. Deburring and final surface treatment: Use a rotary file or electrolytic deburring process to remove burrs from the stamping and welding parts of the spring disc and top rubber assembly skeleton, and use a surface roughness meter to detect the roughness of the welding area and surrounding surface to ensure that the roughness value Ra < 3.2 μm.

[0008] The present invention is further configured such that: the reverse bow-shaped structure formed by spring disc stamping in S2 is dynamically adjusted in conjunction with the accuracy verification results of S3: when S3 detects that the circumferential profile of the bow-shaped protrusion is >0.1mm, the stamping pressure and deformation data of S2 are traced back. If the mold pressure is 200-300MPa but the deformation rate is <15%, it is determined that the mold wear caused insufficient bow-shaped forming. The mold needs to be replaced and the mold pressure increased to 250-300MPa, and the deformation rate target is adjusted to 18-20%. When S3 detects that the slot spacing error is >±0.03mm, the length of the stretching straight segment in S2 is further analyzed: if the length of the straight segment exceeds the ratio of the protrusion height of the reverse bow-shaped structure to the length of the straight segment in the range of 1:2-1:3, it will cause subsequent welding fit deviation and indirectly affect the slot positioning. Then, the stretching parameters of the straight segment are adjusted simultaneously by reworking.

[0009] The present invention is further configured such that: the projection welding parameter control in S5 also includes: when any parameter of welding current, time or electrode pressure exceeds the set range, not only are internal defects of the weld point detected, but also the temperature distribution of the welding area is monitored by an infrared thermal imager; if the temperature peak is <800℃ or >1000℃, or the temperature uniformity deviation is >10%, it is determined to be an abnormal heat input, and even if there are no visible defects in the weld point, it is still re-welded, and the current or time is adjusted to match the thickness of the substrate; at the same time, if the tensile value is 4500N≤tense value<5000N during the welding strength test, a second welding is performed, the welding current is reduced by 10% to avoid overheating, and the tensile value is re-measured after the welding is performed. If it is still <5000N, it is determined that there is a defect in the welding surface of the substrate, and the contact surface is re-grinded and the welding process is started from scratch.

[0010] The present invention is further configured such that: the spring disc slot and spring head positioning verification in S6 also includes: when simulating the installation of the helical spring, if the spring head 0.1mm < radial offset ≤ 0.15mm, or 0.2mm < axial movement ≤ 0.25mm, it is determined that it is not completely out of standard, and the uniformity of the helical lift distribution of the slot is further checked: the angle difference between adjacent circumferential slots is measured by a profilometer. If the angle difference error is > ±0.5°, it is determined that the helical angle processing deviation of the stamping die is corrected and the die slot angle is corrected; if the spring head offset or axial movement completely exceeds the standard, the welding concentricity of the spring disc and the liquid storage cylinder is checked first: the concentricity error of S5 is re-measured. If it is > 0.05mm, it needs to be re-aligned, assembled and welded.

[0011] The present invention is further configured such that: the verification of the support performance of the top rubber assembly skeleton in S7 also includes: when the uniformity deviation of the contact pressure distribution between the bottom of the rhombus and the spring rubber pad is >15%, the actual value of the shortest diagonal length of the bottom of the rhombus is further detected. If the actual shortest diagonal length exceeds the design range, it is determined that the stamping flange dimension is out of tolerance, and the position of the positioning pin of the flange mold is adjusted: the flange angle is corrected to 15-20°; if the uniformity deviation of the contact pressure is normal but the axial displacement of the upper ring is >0.3mm, the hardness of the spring rubber pad is detected by a hardness tester. If the hardness is <60HA, the rubber pad is replaced. If the hardness is normal, the taper deviation of the conical body of the top rubber assembly skeleton is determined. When the taper deviation is >±1°, the taper structure of the stamping mold is corrected.

[0012] The beneficial effects of this invention are: 1. Compared to existing technologies, the spring disc of the stamped part for Honda shock absorber assembly in this invention adopts a reverse bow-shaped structure and a spiral lift distribution groove. The bow-shaped protrusion, in conjunction with the groove, can accurately hold the spring head, achieving stable positioning and preventing abnormal noise caused by the shock absorber shifting during operation, thus improving driving quietness. The design of the stretched straight section ensures more sufficient welding contact between the spring disc and the reservoir, resulting in more stable welding strength and higher welding precision. When the length of the straight section is less than 1 / 4 of the outer diameter of the spring disc, the welding contact area is insufficient, which can easily lead to uneven stress on the weld and an increased risk of detachment. When it is greater than 1 / 3, it increases the difficulty of stamping. The original design was too rigid and occupied too much installation space, affecting the overall assembly accuracy of the shock absorber. The conical structure of the top rubber assembly frame and the downward-flanged diamond-shaped bottom can effectively disperse the pressure of the upper coil of the coil spring, and achieve uniform support with the spring pad, reducing local stress concentration and extending the service life of the spring and top rubber. The diamond-shaped flange design also improves assembly adaptability and ensures no interference with surrounding components. The top rubber assembly frame, through its extended design, reduces the free height of the coil spring, optimizes the internal space of the shock absorber, and at the same time, the diamond-shaped bottom design provides better support, reduces the length of the dust cover, and further reduces abnormal noise.

[0013] 2. The stamped parts for the Honda shock absorber assembly of this invention are made of SAPH440 steel plate with a thickness of 3.5mm. This material has excellent stamping formability and welding performance. The 3.5mm thickness can balance the structural strength and lightweight requirements, avoiding insufficient load-bearing capacity due to excessive thinness and increased overall weight of the shock absorber due to excessive thickness. The design of the reverse bow-shaped structure with a ratio of 1:2 to 1:3 between the height of the protrusion and the length of the straight section can optimize the force transmission path of the spring disc and improve its resistance to deformation. When the ratio is less than 1:3, the protrusion height is relatively too small, and the damping effect of the spring disc is weakened, failing to effectively absorb road impacts. When the ratio is greater than 1:2, the protrusion height is relatively too large, which will cause the center of gravity to shift after the spring disc and the reservoir are welded, affecting the force symmetry of the coil spring and aggravating the wear of the shock absorber. This ratio, combined with the material properties, ensures that the spring disc can maintain structural stability when subjected to high-frequency impacts, meeting the usage requirements of the Honda shock absorber assembly.

[0014] 3. In this invention, the shortest diagonal length of the bottom of the rhomboid shape of the top rubber assembly frame is 3 / 4 to 4 / 5 of the outer diameter. This proportion maximizes the contact area between the bottom and the spring pad while ensuring the rigidity of the bottom structure. When the shortest diagonal length is less than 3 / 4 of the outer diameter, the contact area is insufficient, and the pressure on the upper coil of the spring is concentrated locally, which can easily lead to premature aging and deformation of the pad, affecting the support stability. When it is greater than 4 / 5 of the outer diameter, the bottom edge is likely to exceed the assembly boundary, interfering with other components of the shock absorber, and the flanging process becomes more difficult, easily resulting in molding defects such as wrinkles and cracks. This proportion ensures stable support for the upper coil of the helical spring while also taking into account assembly compatibility and stamping forming qualification rate, thus improving the reliability and production efficiency of the top rubber assembly frame.

[0015] 4. The present invention has a reasonable structure, is easy to manufacture, simple to operate, has high molding precision, avoids the defects of the prior art, and is suitable for promotion and application. Attached Figure Description

[0016] Figure 1 This is a front view of the spring disc of the present invention.

[0017] Figure 2 This is a side view of the spring disc of the present invention.

[0018] Figure 3 This is a front view of the top adhesive assembly skeleton of the present invention.

[0019] Figure 4 This is a side view of the top adhesive assembly skeleton of the present invention.

[0020] Figure 5 This is a schematic diagram of the stamped part for the Honda shock absorber assembly of the present invention mounted on the shock absorber.

[0021] Figure 6 This is a flowchart illustrating the manufacturing method of the stamped part for Honda shock absorber assembly according to the present invention.

[0022] Figure 1-6 Reference numerals: 1. Spring disc; 2. Protrusion; 3. Slot; 4. Straight segment; 5. Top rubber assembly frame; 6. Bottom. Detailed Implementation

[0023] Reference Figure 1-6 The embodiments of the stamped parts for Honda shock absorber assemblies and their manufacturing methods of the present invention are further described.

[0024] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0025] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0026] Figures 1 to 6A stamped part for a Honda shock absorber assembly, shown, includes: Spring disc 1 is used to weld with liquid storage cylinder to support the lower end ring of helical spring. Its disc surface has a reverse bow-shaped structure. On the outer circumference of the bow-shaped protrusion 2, there are a number of slots 3 for accommodating the lower end ring of helical spring, distributed according to the helical stroke. The lowest point of the slot 3 is the starting positioning point of the spring head, which is used to lock the spring head to prevent it from moving and causing abnormal noise. The part of the spring disc 1 that is welded with the liquid storage cylinder is provided with a tension straight section 4. The length of the straight section 4 is 1 / 4 to 1 / 3 of the outer diameter of the spring disc 1. The top rubber assembly frame 5 is used to support the upper end ring of the coil spring and wrap the outer buffer block, connecting rod limiting block, and anti-vibration buffer block. It is set as a conical structure, that is, a conical high-top hat structure, and its bottom 6, that is, the brim, is a diamond-shaped downward folded edge, which is used to cooperate with the spring rubber pad to support the upper end ring of the coil spring. The spring disc 1 adopts a reverse bow-shaped structure and a spiral lift distribution groove 3. The two bow-shaped protrusions, in conjunction with the groove 3, can accurately hold the spring head, achieving stable positioning and preventing the shock absorber from shifting and causing abnormal noise during operation, thus improving driving quietness. The design of the tensioned straight section 4 ensures more sufficient welding contact between the spring disc 1 and the liquid reservoir, resulting in more stable welding strength and higher welding precision. When the length of the straight section 4 is less than 1 / 4 of the outer diameter of the spring disc 1, the welding contact area is insufficient, which can easily lead to uneven stress on the weld and an increased risk of detachment. When it is greater than 1 / 3, it increases the difficulty of stamping and forming and occupies too much installation space. The conical structure of the top rubber assembly frame 5 and the downward-flanged diamond-shaped bottom 6 effectively disperse the pressure on the upper coil of the coil spring, and together with the spring pad, achieve uniform support, reduce local stress concentration, and extend the service life of the spring and top rubber. The diamond-shaped flange design also improves assembly adaptability and ensures no interference with surrounding components. The top rubber assembly frame 5, through its extended design, reduces the free height of the coil spring, optimizes the internal space of the shock absorber, and at the same time, the diamond-shaped bottom 6 design provides better support, reduces the length of the dust cover, and further reduces abnormal noise.

[0027] The spring disc 1 and the top rubber assembly frame 5 are made of SAPH440 steel plate material with a thickness of 3.5mm, and the ratio of the height of the protrusion 2 of the reverse bow-shaped structure to the length of the straight segment 4 is 1:2-1:3. The material uses SAPH440 steel plate with a thickness of 3.5mm. This material has excellent stamping and welding properties. The 3.5mm thickness balances structural strength and lightweight requirements, avoiding insufficient load-bearing capacity due to excessive thinness and increased overall weight of the shock absorber due to excessive thickness. The 1:2-1:3 ratio of the height of the reverse bow-shaped protrusion 2 to the length of the straight segment 4 optimizes the force transmission path of the spring disc 1 and improves its resistance to deformation. When the ratio is less than 1:3, the height of the protrusion 2 is relatively too small, and the damping effect of the spring disc 1 is weakened, failing to effectively absorb road impacts. When the ratio is greater than 1:2, the height of the protrusion 2 is relatively too large, which will cause the center of gravity of the spring disc 1 to shift after welding with the reservoir, affecting the force symmetry of the coil spring and aggravating uneven wear of the shock absorber. This ratio, combined with the material properties, ensures that the spring disc 1 can maintain structural stability when subjected to high-frequency impacts, meeting the usage requirements of Honda's shock absorber assembly.

[0028] The shortest diagonal length of the rhomboid bottom 6 of the top adhesive assembly frame 5 is 3 / 4 to 4 / 5 of the outer diameter of the top adhesive assembly frame 5. The shortest diagonal length of the rhomboid bottom 6 of the top rubber assembly frame 5 is 3 / 4 to 4 / 5 of the outer diameter. This proportion maximizes the contact area between the bottom 6 and the spring pad while ensuring the structural rigidity of the bottom 6. When the shortest diagonal length is less than 3 / 4 of the outer diameter, the contact area is insufficient, and the pressure on the upper coil of the spring is concentrated locally, which can easily lead to premature aging and deformation of the pad, affecting the support stability. When it is greater than 4 / 5 of the outer diameter, the edge of the bottom 6 is likely to exceed the assembly boundary, interfering with other components of the shock absorber, and the flanging process becomes more difficult, making it prone to forming defects such as wrinkles and cracks. This proportion ensures stable support for the upper coil of the helical spring while taking into account assembly compatibility and stamping forming qualification rate, thus improving the reliability and production efficiency of the top rubber assembly frame 5.

[0029] A method for manufacturing a stamped part for a Honda shock absorber assembly, characterized by comprising the following steps: S1. Raw material pretreatment and selection verification: SAPH440 steel plate material was selected as the base material for spring disc 1 and top adhesive assembly skeleton 5; at the same time, the initial thickness of the base material was measured, and the thickness deviation of the base material was controlled within ±0.05mm. S2. Spring disc 1 stamping forming and reverse bow structure control: The spring disc 1 substrate is stamped using a precision stamping die. First, a circular blank is formed through a blanking process. Then, a straight segment 4 is stretched at the mating part between the spring disc 1 and the liquid storage cylinder through a stretching process. Subsequently, a reverse stamping process is used to form a reverse bow structure on the disc surface. During the stamping process, the die pressure is monitored in real time, ranging from 200-300MPa, as well as the deformation of the bow area. The deformation rate of the bow area is measured by a laser displacement sensor and is 15-20%. If the die pressure is <200MPa or >300MPa, or the deformation rate of the bow area is <15% or >20%, the stamping parameters are judged to be abnormal. The stamping is paused and the die clearance is adjusted, with an adjustment range of 0.02-0.05mm. S3. Accuracy verification of the straight segment 4 of spring disc 1 and the arc-shaped surface: After stamping, a coordinate measuring machine is used to check the length, surface flatness, and outer circumferential contour of the straight segment 4 that mates with the liquid storage cylinder of spring disc 1. If the length of the straight segment 4 exceeds the ratio of the height of the protrusion 2 of the reverse arc-shaped structure to the length of the straight segment 4 in the range of 1:2-1:3, or the flatness is >0.05mm, or the circumferential contour is >0.1mm, then the stamping is deemed unqualified and reworked. At the same time, the parameters of the slot 3 are checked by a contour meter. S4. Stamping and Conical Structure Control of Top Adhesive Assembly Frame 5: Another set of stamping dies is used to stamp the base material of top adhesive assembly frame 5. First, a conical body is stamped out, and then a downward-flanged rhomboid bottom 6 is formed through a flanging process. Finally, a stretching process is used to ensure a smooth transition area between the conical body and the rhomboid bottom 6. After stamping, a coordinate measuring machine is used to check the diagonal length of the rhomboid bottom 6 and the taper of the conical body. If the diagonal length exceeds 3 / 4-4 / 5 of the outer diameter or the taper deviation is > ±1°, rework is required. S5. Before welding, adjust the uniformity of contact and control the projection welding parameters. Assemble the spring plate 1 and the liquid storage cylinder. Adjust the concentricity of the mating surfaces of the two using a laser alignment instrument. Apply a thin layer of flux (0.01-0.03mm) to the contact area. Use projection welding to weld and fix the spring plate 1 and the liquid storage cylinder. Before welding, use a pressure sensor to detect the pressure on the contact surface. If the pressure is <5MPa or >8MPa, adjust the clamping force of the clamp, i.e., increase / decrease the shim thickness by 0.1-0.3mm to ensure uniform contact. During welding, control the welding current to 8000-12000A, the welding time to 0.5-1.0s, and the electrode pressure to 6-10kN. After welding, use an ultrasonic flaw detector to check for pores and cracks inside the weld point, and use a tensile testing machine to test the welding strength to ensure that the welding is qualified. S6. Verification of the positioning of the spring head and the slot 3 of the spring disc 1: Simulate the installation of a helical spring on the welded spring disc 1, place the lower end of the spring into the slot 3, measure the radial offset between the starting point of the spring head and the center of the spring disc 1 using a displacement sensor, and apply axial tension to detect whether the spring head moves. If the radial offset is greater than 0.1 mm or the movement is greater than 0.2 mm, the positioning of the slot 3 is deemed to be ineffective. Then check the size of the slot 3 or correct the angle of the mold slot 3. S7. Verification of the support performance of the top rubber assembly frame 5: Assemble the top rubber assembly frame 5 with the spring pad and the upper end ring of the helical spring. Simulate the working load of the shock absorber using a pressure testing machine, detect the contact pressure distribution between the diamond bottom 6 and the spring pad, and observe the axial displacement of the upper end ring of the helical spring. If the uniformity deviation of the contact pressure distribution is >15% or the displacement of the upper end ring is >0.3mm, the support structure is deemed to have failed. Then check the flange angle of the diamond bottom 6 or correct the overall taper of the mold. S8. Deburring and final surface treatment: Use a rotary file or electrolytic deburring process to remove burrs from the stamping and welding parts of the spring disc 1 and the top rubber assembly frame 5, and use a surface roughness meter to detect the roughness of the welding area and surrounding surface to ensure that the roughness value Ra < 3.2 μm. This manufacturing method ensures the performance and assembly accuracy of stamped parts through meticulous control throughout the entire process; strict control of thickness deviation during raw material pretreatment lays the foundation for subsequent forming; real-time monitoring of pressure and deformation during spring disc 1 stamping, combined with precision verification, avoids reverse bow-shaped structures and excessive parameters of slot 3; the stamping of the top rubber assembly frame 5 focuses on the smooth transition and dimensional accuracy of the structure, ensuring support performance; before welding, the uniformity of contact and projection welding parameters are adjusted, combined with flaw detection and tensile testing, to eliminate weld defects; positioning verification and support performance testing ensure stable spring installation and uniform force distribution; deburring and surface treatment improve product texture and service life; effectively solves problems such as stamping forming deviation, insufficient welding strength, and assembly movement, significantly improving the pass rate of stamped parts and the overall performance of the shock absorber assembly.

[0030] The reverse bow-shaped structure formed by stamping spring disc 1 in S2 is dynamically adjusted in conjunction with the accuracy verification results of S3: When S3 detects that the circumferential profile of the bow-shaped protrusion 2 is >0.1mm, the stamping pressure and deformation data of S2 are traced back. If the mold pressure is 200-300MPa but the deformation rate is <15%, it is determined that the mold wear caused insufficient bow-shaped forming. The mold needs to be replaced and the mold pressure increased to 250-300MPa, and the deformation rate target is adjusted to 18-20%. When S3 detects that the spacing error of the slot 3 is >±0.03mm, the length of the stretching straight segment 4 in S2 is further analyzed: If the length of the straight segment 4 exceeds the ratio of the height of the protrusion 2 of the reverse bow-shaped structure to the length of the straight segment 4 in the range of 1:2-1:3, it will cause subsequent welding fit deviation and indirectly affect the positioning of the slot 3. Then the stretching parameters of the straight segment 4 are adjusted simultaneously by reworking. By dynamically linking and adjusting the stamping and verification results, precise control of the reverse bow-shaped structure and the parameters of slot 3 is achieved. When the bow-shaped profile exceeds the standard and the deformation rate is insufficient, mold wear is determined and the pressure and deformation rate targets are adjusted to avoid uneven spring force due to insufficient bow-shaped forming. When the spacing error of slot 3 exceeds the standard and the proportion of straight segment 4 is abnormal, the stretching parameters are adjusted simultaneously to solve the problem of welding fit deviation indirectly affecting the positioning of slot 3. If this dynamic adjustment is not performed and only rework stamping is performed, the root causes such as mold wear and proportional imbalance are easily overlooked, leading to a repeated increase in the defect rate. This method can quickly trace the root cause of the problem and optimize the process parameters in a targeted manner, which not only improves the dimensional accuracy and positioning reliability of stamped parts, but also reduces ineffective rework, improves production efficiency, and reduces manufacturing costs.

[0031] The projection welding parameter control in S5 also includes: when any parameter of welding current, time, or electrode pressure exceeds the set range, not only are internal defects of the weld point detected, but also the temperature distribution of the welding area is monitored by an infrared thermal imager; if the temperature peak is <800℃ or >1000℃, or the temperature uniformity deviation is >10%, it is determined to be an abnormal heat input, and the weld point is re-welded even if there are no visible defects, and the current or time is adjusted to match the thickness of the substrate; at the same time, if the tensile strength value is 4500N≤tense value<5000N during the welding strength test, a second welding is performed, the welding current is reduced by 10% to avoid overheating, and the tensile strength value is re-measured after the welding. If it is still <5000N, it is determined that there is a defect in the welding surface of the substrate, and the contact surface is re-grinded and the welding process is started from scratch. The addition of infrared thermal imaging to monitor temperature distribution allows for re-welding even if the weld joint has no visible defects, when the temperature peak exceeds 800-1000℃ or the uniformity deviation exceeds 10%, thus avoiding hidden strength problems caused by abnormal heat input. When the tensile force is between 4500-5000N, current-reducing welding is used to solve the problem of insufficient strength and prevent overheating damage to the substrate. Without these supplementary controls, relying solely on conventional flaw detection and tensile testing can easily miss defects such as heat-affected zone embrittlement and hidden cracks. This effectively avoids quality risks caused by fluctuations in welding parameters, ensures that the internal quality and strength of the weld joint meet the standards, prevents weld joint breakage failure during vibration damper operation, and refines the handling measures for different scenarios, thereby improving the stability of the welding process.

[0032] The positioning verification of the spring disc 1 slot 3 and the spring head in S6 also includes: when simulating the installation of the helical spring, if the radial offset of the spring head is 0.1mm < 0.15mm or the axial movement is 0.2mm < 0.25mm, it is determined that it is not completely out of standard, and the uniformity of the helical lift distribution of the slot 3 is further checked: the angle difference between adjacent circumferential slots 3 is measured by a profilometer. If the angle difference error is > ±0.5°, it is determined that the helical angle of the stamping die is deviated, and the angle of the die slot 3 is corrected; if the spring head offset or axial movement is completely out of standard, the welding concentricity of the spring disc 1 and the liquid storage cylinder is checked first: the concentricity error of S5 is re-measured. If it is > 0.05mm, it needs to be re-aligned, assembled and welded. For cases where the deviation is not completely out of tolerance, the uniformity of the spiral lift of slot 3 is checked and the mold angle is corrected to avoid insufficient positioning accuracy due to mold spiral angle deviation. For cases where the deviation is completely out of tolerance, the welding concentricity is retested first to eliminate the influence of assembly alignment deviation. If a graded judgment is not made and rework or mold repair is used uniformly, it is easy to lead to insufficient targeted handling measures. For example, the concentricity problem may be mistakenly attributed to the dimensional deviation of slot 3, increasing ineffective operations. This solution, through layered investigation and precise measures, not only ensures that the radial offset and axial movement of the spring head are controlled within the qualified range, but also reduces unnecessary mold correction and assembly rework, improves the efficiency and accuracy of positioning verification, and ensures reliable cooperation between the spring and spring plate 1.

[0033] The performance verification of the top rubber assembly frame 5 in S7 also includes: when the uniformity of the contact pressure distribution between the rhomboid bottom 6 and the spring pad is greater than 15%, the actual value of the shortest diagonal length of the rhomboid bottom 6 is further detected. If the actual shortest diagonal length exceeds the design range, it is determined that the stamping flange dimension is out of tolerance, and the position of the positioning pin of the flange mold is adjusted: the flange angle is corrected to 15-20°; if the uniformity of the contact pressure is normal but the axial displacement of the upper ring is greater than 0.3mm, the hardness of the spring pad is tested by a hardness tester. If the hardness is less than 60HA, the pad is replaced. If the hardness is normal, the taper deviation of the conical body of the top rubber assembly frame 5 is determined. When the taper deviation is greater than ±1°, the taper structure of the stamping mold is corrected. When the contact pressure uniformity deviation exceeds the standard, the length of the bottom 6 diagonals is checked and the flanging die is adjusted to solve the problem of out-of-tolerance stamping flanging dimensions. When the axial displacement exceeds the standard and the hardness of the rubber pad is normal, the taper of the conical main body is corrected to avoid instability of the support due to taper deviation. If these in-depth tests are not carried out, and the support structure is simply judged to be ineffective and reworked, key influencing factors such as rubber pad hardness and flanging angle are easily overlooked, leading to repeated problems. Through step-by-step investigation and targeted treatment, the compatibility between the top rubber assembly frame 5 and the spring rubber pad and coil spring is ensured, guaranteeing uniform distribution of contact pressure and compliance of the upper ring displacement, thereby improving the support stability and driving comfort of the shock absorber. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.

Claims

1. A stamped part for a Honda shock absorber assembly, characterized in that: include: Spring disc (1) is used to weld with liquid storage cylinder to support the lower end ring of helical spring. Its disc surface has a reverse bow-shaped structure. On the outer circumference of the bow-shaped protrusion (2), there are several slots (3) for accommodating the lower end ring of helical spring distributed according to the helical stroke. The lowest point of the slot (3) is the starting positioning point of the spring head, which is used to hold the spring head to avoid displacement and abnormal noise. The part where the spring disc (1) is welded with the liquid storage cylinder is provided with a tension straight section (4). The length of the straight section (4) is 1 / 4-1 / 3 of the outer diameter of the spring disc (1). The top rubber assembly frame (5) is used to support the upper end ring of the helical spring and wrap the outer buffer block, connecting rod limiting block and anti-vibration buffer block. It is set as a conical structure, and its bottom (6) is a diamond-shaped downward flange, which is used to cooperate with the spring rubber pad to support the upper end ring of the helical spring.

2. A stamped part for a Honda shock absorber assembly according to claim 1, characterized in that, The spring disc (1) and the top rubber assembly frame (5) are made of SAPH440 steel plate material with a thickness of 3.5mm, and the ratio of the height of the protrusion (2) of the reverse bow structure to the length of the straight segment (4) is 1:2-1:

3.

3. A stamped part for a Honda shock absorber assembly according to claim 1, characterized in that, The shortest diagonal length of the rhomboid bottom (6) of the top adhesive assembly frame (5) is 3 / 4 to 4 / 5 of the outer diameter of the top adhesive assembly frame (5).

4. A method for manufacturing a stamped part suitable for the Honda shock absorber assembly according to any one of claims 1-3, characterized in that, Includes the following steps: S1. Raw material pretreatment and selection verification: SAPH440 steel plate material was selected as the base material for spring disc (1) and top adhesive assembly skeleton (5); at the same time, the initial thickness of the base material was measured, and the thickness deviation of the base material was controlled within ±0.05mm. S2. Spring disc (1) stamping and reverse bow structure control: The spring disc (1) substrate is stamped using a precision stamping die. First, a circular blank is formed through the blanking process. Then, a straight section (4) is stretched at the joint between the spring disc (1) and the liquid storage cylinder through the stretching process. Subsequently, the reverse bow structure is formed on the disc surface through the reverse stamping process. The die pressure is monitored in real time during the stamping process, ranging from 200 to 300 MPa, as well as the deformation of the bow area. The deformation rate of the bow area is 15-20% as measured by a laser displacement sensor. If the die pressure is <200 MPa or >300 MPa, or the deformation rate of the bow area is <15% or >20%, the stamping parameters are deemed abnormal. The stamping is paused and the die clearance is adjusted, with an adjustment range of 0.02-0.05 mm. S3. Verification of the accuracy of the straight section (4) and the arc-shaped surface of the spring disc (1). After stamping, a coordinate measuring machine is used to check the length of the straight section (4) that fits with the liquid storage cylinder, the surface flatness, and the outer circumferential contour of the arc-shaped protrusion (2). If the length of the straight section (4) exceeds the ratio of the height of the protrusion (2) of the reverse arc structure to the length of the straight section (4) in the range of 1:2-1:3, or the flatness is >0.05mm or the circumferential contour is >0.1mm, then the stamping is deemed unqualified and reworked. At the same time, the parameters of the slot (3) are checked by a contour meter. S4. Stamping and conical structure control of top adhesive assembly skeleton (5): Another set of stamping dies is used to stamp the substrate of top adhesive assembly skeleton (5). First, a conical body is stamped out, and then a downward-flanged rhomboid bottom (6) is formed through the flanging process. Finally, the stretching process is used to ensure that the connection transition area between the conical body and the rhomboid bottom (6) is smooth. After stamping, a coordinate measuring machine is used to detect the diagonal length of the rhomboid bottom (6) and the taper of the conical body. If the diagonal length exceeds 3 / 4-4 / 5 of the outer diameter or the taper deviation is > ±1°, rework is required. S5. Before welding, adjust the uniformity of contact and control the projection welding parameters. Assemble the spring plate (1) and the liquid storage cylinder. Adjust the concentricity of the mating surfaces of the two by using a laser alignment instrument. Apply a thin layer of flux with a thickness of 0.01-0.03mm to the contact area. Use projection welding to weld and fix the spring plate (1) and the liquid storage cylinder. Before welding, use a pressure sensor to detect the pressure on the contact surface. If the pressure is <5MPa or >8MPa, adjust the clamping force of the clamp, i.e., increase / decrease the thickness of the shim by 0.1-0.3mm to make the contact uniform. Control the welding current at 8000-12000A, the welding time at 0.5-1.0s, and the electrode pressure at 6-10kN during welding. After welding, use an ultrasonic flaw detector to check whether there are pores or cracks inside the weld point. Test the welding strength with a tensile testing machine to ensure that the welding is qualified. S6. Verification of the positioning of the spring disc (1) slot (3) and the spring head: Simulate the installation of a helical spring on the welded spring disc (1), place the lower end of the spring into the slot (3), measure the radial offset between the starting point of the spring head and the center of the spring disc (1) using a displacement sensor, and apply axial tension to detect whether the spring head moves; if the radial offset is >0.1mm or the movement is >0.2mm, the positioning of the slot (3) is determined to be ineffective, and the size of the slot (3) is checked or the angle of the mold slot (3) is corrected. S7. Verification of the support performance of the top rubber assembly frame (5): Assemble the top rubber assembly frame (5) with the spring pad and the upper end ring of the helical spring. Simulate the working load of the shock absorber using a pressure testing machine, detect the contact pressure distribution between the rhomboid bottom (6) and the spring pad, and observe the axial displacement of the upper end ring of the helical spring. If the uniformity deviation of the contact pressure distribution is >15% or the displacement of the upper end ring is >0.3mm, the support structure is deemed to have failed. Then check the flange angle of the rhomboid bottom (6) or correct the overall taper of the mold. S8. Deburring and final surface treatment: Use a rotary file or electrolytic deburring process to remove burrs from the stamping and welding parts of the spring disc (1) and top glue assembly skeleton (5), and use a surface roughness meter to detect the roughness of the welding area and surrounding surface to ensure that the roughness value Ra < 3.2 μm.

5. The method for manufacturing a stamped part for a Honda shock absorber assembly according to claim 4, characterized in that, The reverse bow-shaped structure of the spring disc (1) in S2 is dynamically adjusted in conjunction with the accuracy verification results of S3: When S3 detects that the circumferential profile of the bow-shaped protrusion (2) is >0.1mm, the stamping pressure and deformation data of S2 are traced back. If the mold pressure is 200-300MPa but the deformation rate is <15%, it is determined that the mold wear caused insufficient bow-shaped forming. The mold needs to be replaced and the mold pressure is increased to 250-300MPa. The deformation rate target is adjusted to 18-20%. When S3 detects that the spacing error of the slot (3) is >±0.03mm, the length of the stretching straight section (4) of S2 is further analyzed: If the length of the straight section (4) exceeds the ratio of the height of the protrusion (2) of the reverse bow-shaped structure to the length of the straight section (4) in the range of 1:2-1:3, it will cause subsequent welding fit deviation and indirectly affect the positioning of the slot (3). Then the stretching parameters of the straight section (4) are adjusted simultaneously by reworking.

6. The method for manufacturing a stamped part for a Honda shock absorber assembly according to claim 4, characterized in that, The projection welding parameter control in S5 also includes: when any parameter of welding current, time or electrode pressure exceeds the set range, not only are internal defects of the weld point detected, but also the temperature distribution of the welding area is monitored by an infrared thermal imager; if the temperature peak is <800℃ or >1000℃, or the temperature uniformity deviation is >10%, it is determined to be an abnormal heat input, and the weld point is re-welded even if there are no visible defects, and the current or time is adjusted to match the thickness of the substrate; at the same time, if the tensile strength value is 4500N≤tense value<5000N during the welding strength test, a second welding is performed, the welding current is reduced by 10% to avoid overheating, and the tensile strength value is re-measured after the welding. If it is still <5000N, it is determined that there is a defect in the welding surface of the substrate, and the contact surface is re-grinded and the welding process is started from scratch.

7. The method for manufacturing a stamped part for a Honda shock absorber assembly according to claim 4, characterized in that, The verification of the positioning of the spring disc (1) slot (3) and the spring head in S6 also includes: when simulating the installation of the helical spring, if the spring head 0.1mm < radial offset ≤ 0.15mm, or 0.2mm < axial movement ≤ 0.25mm, it is determined that it is not completely out of standard, and the uniformity of the helical lift distribution of the slot (3) is further checked: the angle difference between adjacent circumferential slots (3) is measured by a profilometer. If the angle difference error is > ±0.5°, it is determined that the helical angle of the stamping die is deviated, and the angle of the die slot (3) is corrected; if the spring head offset or axial movement is completely out of standard, the welding concentricity of the spring disc (1) and the liquid storage cylinder is checked first: the concentricity error of S5 is re-measured. If it is > 0.05mm, it needs to be re-aligned, assembled and welded.

8. The method for manufacturing a stamped part for a Honda shock absorber assembly according to claim 4, characterized in that, The verification of the support performance of the top rubber assembly skeleton (5) in S7 also includes: when the uniformity of the contact pressure distribution between the rhomboid bottom (6) and the spring pad is greater than 15%, the actual value of the shortest diagonal length of the rhomboid bottom (6) is further detected. If the actual shortest diagonal length exceeds the design range, it is determined that the stamping flange size is out of tolerance. Then the position of the positioning pin of the flange mold is adjusted: the flange angle is corrected to 15-20°. If the uniformity of the contact pressure is normal but the axial displacement of the upper ring is greater than 0.3mm, the hardness of the spring pad is detected by a hardness tester. If the hardness is less than 60HA, the pad is replaced. If the hardness is normal, the taper deviation of the conical body of the top rubber assembly skeleton (5) is determined. When the taper deviation is greater than ±1°, the taper structure of the stamping mold is corrected.

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