Some of the outstanding skills of MAGURA have been realized with this part:

In order to avoid any wear, the highest requirements of all are made to the surface. Realized despite the use of 50% glass fibre reinforced raw material !! As the piston is also guided in this area, the H9 fits belonging to the metal area and the required roundness must be guaranteed simultaneously over the entire length of the piston area.

A technical challenge regarding tools: The cuttings of the long pins without burr. The non-existence of burr is of particular importance, as the detaching of burr will always lead to leakage and thus to the failure of the safety-relevant system.

A further point is the calculation and execution of a rated break point planned for this part. Maximum breaking forces are given in this context. Their values must be observed and may only slightly be lower.

An injection-moulded thread is executed on the connection side. This „thread spindling off“ is a frequently used tool at MAGURA.
On another part, we have executed two M6 threads at a distance of < 10mm with fully automatic spindling off in the tool. Depending on the required strength and the number of pieces, threads can also be formed in subsequently.

This sectional drawing shows the piston area. It allows to study the considerable differences of side thickness that had to be realized.

A 2K thread can additionally be seen on this picture. It is manufactured by MAGURA using a 2K turntable injection moulder. The primary and secondary sealing as well as the oil wiper ring of this thread are moulded from one material. The hard core is also manufactured with 50% glass fibre reinforced raw material – the requirements are: roundness, high surface quality and very high measuring requirements. The non-existence of burr is, of course, as important here as it is for the case. And unfortunately, it is also not possible to realize the equal side thickness here.