High pressure die cast aluminum bearing retainer, manufacturing process, and bearing

Abstract

The application discloses a high-pressure aluminum casting bearing retainer, a preparation process and a bearing, and relates to the field of bearings.The high-pressure aluminum casting bearing retainer comprises multiple retainer segments, the retainer segments comprise inner and outer retaining edges, the inner and outer retaining edges are arc-shaped plate structures with the same center and different radii, each retainer segment is provided with multiple windows, adjacent windows are separated by crossbeams, the crossbeams have a trapezoidal structure with the width of the lower bottom being larger than that of the upper top, the two ends of the crossbeams are fixedly connected with the inner and outer retaining edges, the side, away from the crossbeams, of the inner and outer retaining edges is provided with webs, the circumferential length of the web along the inner or outer retaining edge is larger than the width of the lower bottom of the crossbeam, and the high-pressure casting is achieved through a multiple-stage injection process.The problems of cracks, fragmentation or even overall fracture of the window hole edges or side beam parts due to collision and the problem of brittle failure of the retainer are solved.

Description

Technical Field

[0001] This invention relates to the field of bearings, and more particularly to a high-pressure die-cast aluminum bearing cage, its manufacturing process, and the bearing itself. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] In rolling bearing applications, the cage, as a critical component, is mainly used to isolate and guide the rollers, ensuring their even distribution and reducing friction. Currently, some bearings use injection-molded polyoxymethylene (POM) three-row roller cages, which perform well under certain operating conditions due to their advantages such as light weight, wear resistance, and self-lubrication. However, in actual use, it has been found that this type of cage is prone to failure during operation, seriously affecting the reliability and service life of the bearing.

[0004] The main failure modes of the cage are chamfering and cracking of the aperture, as well as fracture or partial loss of the side beams of the aperture opening. The primary reason for this is that during bearing operation, there are certain design clearances between the cage and the rollers, and between the cage and the inner and outer rings of the bearing. While these clearances facilitate assembly and lubrication, they can lead to periodic collisions between the cage and the inner and outer rings under dynamic conditions. Especially under high-speed or variable load conditions, repeated impact loads accelerate the fatigue of the cage material, ultimately causing cracks, fragmentation, or even complete fracture at the aperture edge or side beams due to impact. Under long-term alternating stress, its toughness gradually decreases, further exacerbating the risk of brittle failure of the cage. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a high-pressure cast aluminum bearing cage, manufacturing process and bearing, which solves the problems of cracks, breakage or even overall fracture of window hole edges or side beams due to collision, as well as the problem of brittle failure of the cage.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: In a first aspect, embodiments of the present invention provide a high-pressure die-cast aluminum bearing cage, comprising: multiple cage segments, each cage segment including an inner flange and an outer flange, the inner flange and the outer flange being arc-shaped plate structures, each cage segment having multiple windows, adjacent windows being separated by a crossbeam, the crossbeam having a trapezoidal shape structure with its lower bottom surface wider than its upper top surface; both ends of the crossbeam being fixedly connected to the inner flange and the outer flange; a web is provided on the side of the inner flange and the outer flange away from the crossbeam, the length of the web along the circumferential direction of the inner flange or the outer flange being greater than the width of the lower bottom surface of the crossbeam.

[0007] As a further implementation, the two sides of the crossbeam are arc surfaces, namely a first arc surface and a second arc surface, and the first arc surface and the second arc surface on adjacent crossbeams are arranged opposite each other to wrap and install the rollers. As a further implementation, a first trapezoidal groove is formed on both the top and bottom surfaces of the crossbeam; a groove is also provided at the center of the bottom surface, and the length direction of the groove is along the length direction of the crossbeam.

[0008] As a further implementation, the widths of the inner and outer retaining edges are equal; the first and second arc surfaces are respectively provided with rounded corners between the inner and outer retaining edges, and the radius of the rounded corners is smaller than the radius of the rounded corners at the ends of the installed rollers.

[0009] As a further implementation, the length of the web along the axial direction of the inner or outer side is equal to the axial width of the inner or outer side.

[0010] As a further implementation, the inner and outer retaining edges are uniformly provided with second trapezoidal grooves; the second trapezoidal grooves are disposed between two adjacent webs.

[0011] As a further implementation, the edge of the web is provided with a slope to avoid stress concentration at the boundary of the web and the inner or outer edge.

[0012] As a further implementation, the segmented cage is formed by one-piece high-pressure casting.

[0013] Secondly, the present invention also provides a process for manufacturing a high-pressure die-cast aluminum bearing cage, comprising the following steps: Step 1: The cage blank is prepared by high pressure casting using a cold chamber die casting machine. The cage mold is pre-sprayed with release agent and closed. High pressure is applied by the mold locking mechanism to lock the mold. Step 2: The injection punch advances at a low speed to avoid splashing molten metal and entraining gas; when it approaches the cavity, it switches to high speed to ensure complete filling; then instantaneous pressure is applied to compensate for shrinkage; the metal solidifies rapidly in the mold (cooling rate can reach 100~1000℃ / s), and the casting is ejected after the mold is opened; Step 3: Use a sandblasting machine to brush the surface of the blank to improve the surface quality of the blank; Step 4: Use a through-type cleaning machine to rinse off the contaminants adhering to the surface of the blank; Step 5: Machin the blank and perform a qualification test on the cage.

[0014] Thirdly, the present invention also provides a bearing, including the aforementioned high-pressure die-cast aluminum bearing cage and rollers mounted on the high-pressure die-cast aluminum bearing cage.

[0015] The beneficial effects of this invention are as follows: This invention designs the crossbeam as a trapezoidal structure with a lower base wider than the upper top, increasing the crossbeam's strength and preventing failure. Both ends of the crossbeam are fixedly connected to the inner and outer side guards. By optimizing the crossbeam's structure, the contact area between the crossbeam and the inner or outer side guards is increased. A web is provided on the side of the inner or outer side guard away from the crossbeam, and the length of the web along the circumferential direction of the inner or outer side guard is greater than the width of the lower base of the crossbeam, preventing the chamfer of the window opening from falling off or cracking, and preventing the breakage or partial loss of the side beam of the window opening.

[0016] This invention arranges the first and second arc surfaces of adjacent crossbeams opposite each other to form a symmetrical enveloping space, which can closely fit the roller surface, reduce the radial runout of the roller during movement, increase the effective contact area, disperse the load pressure, and avoid local stress concentration. The oppositely arranged arc surfaces form a natural guide channel, constraining the movement trajectory of the roller and preventing lateral deviation. By opening the first trapezoidal grooves on both the top and bottom surfaces of the crossbeams, a lubricating oil flow channel is formed, guiding the lubricating oil to be evenly distributed, avoiding the oil film being scraped and destroyed by the edge of the crossbeam, and reducing frictional heat and energy consumption. The second trapezoidal groove is connected to the first trapezoidal groove to form a lubricating oil channel, further reducing lubricating oil retention or splashing, preventing the oil from being "scooped up" by the retaining edge when the bearing is running, ensuring lubrication efficiency, and reducing wear and temperature rise.

[0017] This invention optimizes the cross-sectional structure distribution of the crossbeam by creating first trapezoidal grooves on both the top and bottom surfaces of the crossbeam, thereby improving the bending stiffness and torsional resistance of the crossbeam. The grooves are designed at the center of the bottom surface of the crossbeam, reducing its own weight and forming a stable oil storage space, which can effectively store lubricating oil and ensure that mechanical parts are continuously lubricated during operation. When the lubricating oil decreases due to long-term use, the lubricating oil stored in the grooves can be slowly released, realizing automatic replenishment of friction parts and reducing the need for frequent manual replenishment. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0019] Figure 1 This is a top view of the high-pressure die-cast aluminum bearing cage of the present invention; Figure 2 This is a bottom view of the high-pressure die-cast aluminum bearing cage of the present invention.

[0020] Among them, 1. outer edge; 2. inner edge; 3. first arc surface; 4. web; 5. first trapezoidal groove; 6. inclined surface; 7. second trapezoidal groove; 8. second arc surface; 9. window; 10. groove. Detailed Implementation

[0021] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0022] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] Example 1 Currently, some bearings use injection-molded polyoxymethylene (POM) three-row roller cages, which perform well under certain operating conditions due to their advantages such as light weight, wear resistance, and self-lubrication. However, in actual use, it has been found that such cages are prone to failure during operation, mainly manifested as chamfering and cracking of the aperture opening, as well as breakage or partial loss of the side beam of the aperture opening. Because dynamic operating conditions cause periodic collisions between the cage and the bearing races; especially under high-speed or variable load conditions, repeated impact loads accelerate the fatigue of the cage material, ultimately leading to cracks, fragmentation, or even complete fracture at the edge of the aperture or the side beam due to impact. Based on this, this embodiment provides a high-pressure cast aluminum bearing cage, comprising: multiple cage segments, which are formed by circumferentially assembling at least two cage segments into a ring structure, the length of each cage segment being determined according to actual installation requirements.

[0025] like Figures 1-2 As shown, the cage segment includes an inner flange 2 and an outer flange 1. The inner flange 2 and the outer flange 1 are arc-shaped plate structures. Each cage segment has multiple windows 9. The number of windows 9 varies for different sizes and models of bearing cages. In this embodiment, the cage segment has three windows 9. Adjacent windows 9 are separated by a crossbeam. The crossbeam has a trapezoidal shape with its lower bottom surface wider than its upper top surface. The two ends of the crossbeam are fixedly connected to the inner flange 2 and the outer flange 1. A web 4 is provided on the side of the inner flange 2 and the outer flange 1 away from the crossbeam. The length of the web 4 along the circumference of the inner flange 2 or the outer flange 1 is greater than the width of the lower bottom surface of the crossbeam.

[0026] Existing retainers are prone to failure during operation, mainly manifested as chamfering and cracking of window openings, as well as breakage or partial loss of the side beams of the window openings. Therefore, in this embodiment, the crossbeam is designed as a trapezoidal structure with a lower bottom surface wider than the upper top surface, increasing the crossbeam's own strength and preventing failure. The two ends of the crossbeam are fixedly connected to the inner side 2 and the outer side 1. By optimizing the crossbeam's own structure, the connection contact area between the crossbeam and the inner side 2 or the outer side 1 is increased. A web plate 4 is provided on the side of the inner side 2 and the outer side 1 away from the crossbeam, and the length of the web plate 4 along the circumference of the inner side 2 or the outer side 1 is greater than the width of the lower bottom surface of the crossbeam, preventing chamfering and cracking of window openings, as well as breakage or partial loss of the side beams of the window openings.

[0027] As a further implementation, the two sides of the crossbeam are arc surfaces, namely a first arc surface 3 and a second arc surface 8. The first arc surface 3 and the second arc surface 8 on adjacent crossbeams are arranged opposite each other to wrap and install the rollers. The first arc surface 3 and the second arc surface 8 are respectively provided with rounded corners between them and the inner flange 2 or the outer flange 1. The radius of the rounded corners is smaller than the radius of the rounded corners at the ends of the installed rollers, which can effectively prevent the rollers from impacting the connection between the inner flange or the outer flange and the crossbeam. Specifically, by arranging the first arc surface 3 and the second arc surface 8 of adjacent crossbeams opposite each other, a symmetrical wrapping space is formed, which can closely fit the roller surface, reduce the radial runout of the rollers during movement, increase the effective contact area, disperse the load pressure, avoid local stress concentration, and the oppositely arranged arc surfaces form a natural guide channel, constraining the movement trajectory of the rollers and preventing lateral deviation. As a further implementation, a first trapezoidal groove 5 is formed on both the top and bottom surfaces of the crossbeam. The trapezoidal grooves on the top and bottom surfaces of the crossbeam form a lubricating oil flow channel, guiding the lubricating oil to be evenly distributed, avoiding the oil film being scraped and destroyed by the edge of the crossbeam, and reducing frictional heat and energy consumption. A concave groove 10 is also provided at the center of the bottom surface, and the length direction of the groove 10 is set along the length direction of the crossbeam. The groove 10 is preferably a V-shaped groove. By forming a first trapezoidal groove 5 on both the top and bottom surfaces of the crossbeam, the crossbeam cross-sectional structure distribution is optimized, and the bending stiffness and torsional performance of the crossbeam are improved. The V-shaped groove is designed at the center of the bottom surface of the crossbeam to form a stable oil storage space, which can effectively store lubricating oil and ensure that the mechanical parts are continuously lubricated during operation. When the lubricating oil decreases due to long-term use, the lubricating oil stored in the V-shaped groove can be slowly released to achieve automatic replenishment of the friction parts and reduce the maintenance needs of frequent manual addition.

[0028] As a further implementation, the widths of the inner flange 2 and the outer flange 1 are equal. Preferably, the distance between the top and bottom surfaces of the beam is equal to the width of the inner flange 2 or the outer flange 1. The length of the web 4 along the axial direction of the inner flange 2 or the outer flange 1 is equal to the axial width of the inner flange 2 or the outer flange 1. Specifically, by making the distance between the top and bottom surfaces of the beam equal to the width of the inner / outer flange 1 and maintaining the consistent width of the inner and outer flanges 1, the symmetry and stress balance of the overall structure are ensured, effectively improving the load-bearing capacity and deformation resistance of the beam. The fact that the length of the web 4 along the axial direction of the inner / outer flange 1 is equal to the flange width maximizes the contact area between the web 4 and the flange, thereby significantly improving the connection strength between the beam, the inner flange 2, and the outer flange 1, reducing stress concentration, and extending service life.

[0029] As a further implementation, the inner flange 2 and the outer flange 1 are uniformly provided with second trapezoidal grooves 7 at their edges; the second trapezoidal grooves 7 are provided between the two adjacent web plates 4, and the second trapezoidal grooves 7 and the first trapezoidal grooves 5 work together to form a continuous oil passage network, further reducing lubricating oil retention or splashing, preventing the oil from being "scooped up" by the flanges when the bearing is running, ensuring lubrication efficiency, and reducing wear and temperature rise.

[0030] As a further implementation, a slope 6 is provided at the edge of the web 4 to avoid stress concentration at the boundary of the web 4 and the inner or outer retaining edge 2. Specifically, the slope 6 structure can smoothly transition the connection between the web 4 and the inner / outer retaining edge 1, avoiding sudden increases in local stress caused by right angles or sharp corners, thereby significantly reducing the risk of structural fatigue and extending the overall service life. By optimizing the edge geometry, the damage to key parts caused by stress concentration is reduced, ensuring that the component maintains higher stability and safety under long-term loads or dynamic working conditions. The slope 6 design promotes more uniform load distribution along the contact surface between the web 4 and the retaining edge, reducing stress concentration, which can delay crack initiation and reduce the frequency of later maintenance.

[0031] As a further implementation, the segmented cage is integrally cast.

[0032] Example 2 This embodiment provides a manufacturing process for a high-pressure die-cast aluminum bearing cage, including the following steps: Step 1: The cage blank is prepared by high-pressure casting using a cold chamber die-casting machine, which can achieve one-time forming of the cage and reduce subsequent processing. The cage mold is pre-sprayed with a release agent and closed. A high-temperature resistant release agent is used, and the mold cavity is evenly covered by a spraying robot to ensure smooth demolding and extend the mold life. The mold is locked by applying high pressure through a mold-locking mechanism. A servo hydraulic system is used to dynamically adjust the pressure to prevent molten metal leakage and mold bulging. Step 2: The injection punch advances at a low speed to avoid splashing molten metal and entraining gas; it then accelerates to high speed as it approaches the cavity, using vacuum-assisted venting technology to reduce porosity and ensure complete filling; subsequently, instantaneous pressurization compensates for shrinkage, reducing shrinkage defects, and the multi-stage injection process results in a higher casting density; the metal solidifies rapidly within the mold, with a cooling rate of 100~1000℃ / s, which inhibits grain growth and improves mechanical properties; after mold opening, the casting is ejected. Step 3: Use a sandblasting machine to brush the surface of the blank, spraying from multiple angles to remove burrs and oxide layers, improve the surface quality of the blank, and enhance the adhesion of subsequent coatings or platings. Step 4: Use a through-type cleaning machine to rinse off the contaminants adhering to the surface of the blank; Step 5: Machin the blank and perform a qualification test on the cage.

[0033] Example 3 This embodiment provides a bearing, including a high-pressure die-cast aluminum bearing cage and rollers mounted on the high-pressure die-cast aluminum bearing cage. The rollers are disposed in windows 9 of the high-pressure die-cast aluminum bearing cage. Since the high-pressure die-cast aluminum bearing cage is injection molded, the rollers are simply pressed into windows 9 when assembling them with the cage. The first arc surface 3 and the second arc surface 8 enclose the rollers, effectively limiting their movement and increasing the bearing's reliability and service life.

[0034] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A high-pressure die-cast aluminum bearing cage, characterized in that, include: The cage comprises multiple cage segments, each including an inner and outer retaining edge, both of which are arc-shaped plate structures. Each cage segment has multiple windows, with adjacent windows separated by a crossbeam. The crossbeam has a trapezoidal shape, with its lower base wider than its upper top surface. Both ends of the crossbeam are fixedly connected to the inner and outer retaining edges. A web is provided on the side of the inner and outer retaining edges away from the crossbeam. The length of the web along the circumferential direction of the inner or outer retaining edge is greater than the width of the lower base of the crossbeam, and the edge of the web is positioned... The crossbeam has a sloping surface to prevent stress concentration at the boundary of the web and the inner or outer flange. A first trapezoidal groove is formed on both the top and bottom surfaces of the crossbeam. Second trapezoidal grooves are evenly distributed along the edges of the inner and outer flanges. These second trapezoidal grooves are positioned between adjacent webs. The second and first trapezoidal grooves work together to form a continuous oil passage network. A groove is also provided at the center of the bottom surface of the crossbeam. This groove is V-shaped and forms a stable oil storage space.

2. The high-pressure die-cast aluminum bearing cage according to claim 1, characterized in that, The two sides of the crossbeam are arc surfaces, namely the first arc surface and the second arc surface. The first arc surface and the second arc surface on adjacent crossbeams are arranged opposite each other to wrap and install the rollers.

3. The high-pressure die-cast aluminum bearing cage according to claim 2, characterized in that, The length direction of the groove is along the length direction of the crossbeam.

4. A high-pressure die-cast aluminum bearing cage according to claim 2, characterized in that, The inner and outer retaining edges are of equal width; the first and second arc surfaces are respectively provided with rounded corners between the inner and outer retaining edges, and the radius of the rounded corners is smaller than the radius of the rounded corners at the ends of the installed rollers.

5. A high-pressure die-cast aluminum bearing cage according to claim 4, characterized in that, The length of the web along the inner or outer side axial direction is equal to the axial width of the inner or outer side.

6. A high-pressure die-cast aluminum bearing cage according to claim 1, characterized in that, The multi-segment cage is formed by integral casting.

7. The manufacturing process of a high-pressure cast aluminum bearing cage as described in any one of claims 1-6, characterized in that, Includes the following steps: Step 1: The cage blank is prepared by high pressure casting using a cold chamber die casting machine. The cage mold is pre-sprayed with release agent and closed. High pressure is applied by the mold locking mechanism to lock the mold. Step 2: The injection punch advances at low speed; it switches to high speed when it approaches the cavity; then it instantly increases pressure to compensate for the contraction; the metal solidifies rapidly in the mold, and the casting is ejected after the mold opens; Step 3: Use a sandblasting machine to brush the surface of the blank to improve the surface quality of the blank; Step 4: Use a through-type cleaning machine to rinse off the contaminants adhering to the surface of the blank; Step 5: Machin the blank and perform a qualification test on the cage.

8. A bearing, characterized in that, Includes the high-pressure die-cast aluminum bearing cage as described in any one of claims 1-6 and the rollers mounted on the high-pressure die-cast aluminum bearing cage.

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