Low weight ball bearing with enhanced strength and cooling effect

Abstract

The present invention discloses a light weight ball bearing with enhanced strength and cooling effect. The weight of the said ball bearing is reduced by drawing curved profiling / corrugation over the inner surface (201) of inner ring (200) and outer surface (101) of the outer ring (102) through bar / tube drawing process wherein a steel bar is converted into a hollow tube and subsequently cold drawn through a profiled die. The said technical modifications reduce the raw material / weight of outer ring by up to 22-24% and reduce the raw material / weight of the inner ring by up to 18-20%. The said profiled ball bearing has 10% increase in fatigue strength, 40% higher push / pull load capacity and 7% improvement in heat transfer efficiency, thus the said profiling enhances the strength and cooling effect of ball bearing along with weight reduction of the same.

Description

[0001] LOW WEIGHT BALL BEARING WITH ENHANCED STRENGTH AND COOLING EFFECT FIELD OF INVENTION

[0002] The present invention relates to the field of Mechanical Engineering. It relates to a ball bearing with reduced material usage and improved performance. More specifically, it pertains to a low weight ball bearing with enhanced strength and cooling effect.

[0003] BACKGROUND OF THE INVENTION

[0004] The following background includes information which is important for the better understanding of the present invention. Before proceeding into the details of the present invention, some important definitions are as below:

[0005] Corrugation:

[0006] Corrugation refers to process of shaping material including metal, cardboard, plastic etc into series of ridges and grooves, which enhance material's strength and rigidity. The ridged pattern distributes stress and pressure. The ridged pattern distributes stress and pressure, making material resistant to bending and the hollow structure reduces the weight, while providing required strength.

[0007] (https: / / www. colli nsdictionary.com / dictionary / english / corrugation#:~:text=%CB%8Ck%C9%94r %C9%99%CB%88%C9%Alei%CA%83%C9%99n%2C%20%CB%8Ck%C9%91r%2D)- ,noun,wrinkle%3B%20fold%3B%20furrow%3B%20ridge)

[0008] Corrugation of metal sheets:

[0009] Corrugation of metal refers to the process of shaping a metal sheet into a series of parallel ridges and grooves, typically done to increase the strength and rigidity of the material while maintaining its lightweight properties. Metal corrugation is a unique roll-formed process whereby a precise and specific repetitive surface pattern is achieved over sheet metal or wire. Corrugated metal sheet is defined as any type of sheet steel that is strengthened for use in construction by having a series of alternating grooves and ridges forced into it. The corrugation process is carried out by a roll forming process. It begins with steel sheets that are passed through a series of rollers in acold roll forming process. The metal is pressed into three-dimensional patterns known as corrugations, using various types of dies depending on the intended shape. In this process, the sheet metal is pulled off from large rolls and passed through dies that form the corrugated patterns. Traditionally, the corrugations have a round, wavy shape, but today, different types of die arrangements are used to create various forms of corrugation. The resulting ridges and grooves enhance the material's ability to withstand pressure and stress while remaining strong and lightweight. The corrugations are typically described in terms of pitch (the distance between two crests) and depth (the height from the top of a crest to the bottom of a trough). These features significantly improve the metal’s structural integrity, making it suitable for a wide range of applications, especially in construction for roofing, siding, and wall panels.

[0010] Ball Bearing:

[0011] A ball bearing is defined as a type of rolling element bearing that uses balls to maintain separation / distance between bearing walls. It is basically designed to reduce friction and enable smooth, low friction movement between two rotating parts. Ball bearings are commonly used in applications, where rotational movement is needed, such as in machines, motors, vehicles, fans and electronic devices. Ball bearings are made up of four main components including Inner ring is also known as shaft, mounted onto the rotating shaft, outer ring that is the stationary part supporting bearing structure, spherical rolling elements i.e., balls reducing friction between inner and outer rings and Cage or separator, that holds balls in place and evenly space them out, ensuring smooth and stable operation. The ball bearings are commonly manufactured using steel, stainless steel, soda-lime glass, borosilicate glass, aluminum oxide, etc. (https: / / www.iqsdirectory.com / articles / ba ll-bearing.html)

[0012] The ball bearings are usually heavier in weight and thus are associated with several drawbacks, some of the drawbacks associated with heavy weight ball bearings include:

[0013] Heavy ball bearings experience more friction, thus leads to faster wear and tear on the bearing components, reducing bearing efficiency and potential failure. The increased weight further leads to higher energy consumption and reduced performance in dynamic status.Heavy bearings generate more friction, which leads to heat generation leading to premature wear and tear, reduced efficiency and overheating in high speed applications. Heavy ball bearings are subjected to higher stresses resulting in surface fatigue over time, resulting in increased maintenance cost and more frequent replacements.

[0014] Heavy ball bearings have limited speed capacity compared to lighter bearing, because of which in applications requiring high speed rotational speeds such as turbine motors etc, the performance of heavy ball bearing may be compromised, requiring more frequent maintenance or replacement.

[0015] Due to heavy mass and design, heavy ball bearings can produce more vibrations and noise, leading to less smooth operation, contributing to discomfort while using high precision machinery or sensitive instruments.

[0016] In summary, heavy ball bearings come with trade-offs in terms of weight, friction, cost, and maintenance requirements. Proper design considerations and materials are essential to mitigating these drawbacks.

[0017] Thus, in order to address the drawbacks associated with heavy weight ball bearing, the weight of the same must be reduced as low-weight ball bearings contribute to improved energy efficiency, enhanced performance, reduced wear, and lower costs. These bearings typically have lighter components, which helps in reducing friction during operation, enabling high-speed performance. Because lighter bearings experience less inertia, they can accelerate and decelerate more quickly, leading to improved system responsiveness. Additionally, the reduction in weight helps to lower the overall stress and wear on both the bearings and the surrounding components, extending the lifespan of both the bearing and the machine in which it is used. Furthermore, lighter bearings reduce the risk of overheating, as they generate less heat during operation, which contributes to more efficient heat dissipation thereby more cooling efficiency and overall system reliability.

[0018] Currently, several approaches are available for reducing the weight of ball bearings. One such approach is the use of lighter materials, such as replacing conventional materials like steel with plastic. While this reduces the overall weight of the bearing, it also compromises its strength andresults in a shorter lifespan. Plastic, being less durable than steel or other high-strength materials, is also less capable of withstanding high temperatures, limiting its suitability for many applications. As a result, these existing methods do not offer a fully effective solution for achieving both weight reduction and long-term performance.

[0019] Hence, there was an immense need to manufacture low cost and light weight ball bearing with enhanced strength, durability and cooling efficiency. Present invention is thus confined to disclosure of light weight ball bearing assembly.

[0020] Innovative approach by Present invention

[0021] In order to address the drawbacks associated with heavy weight ball bearing assemblies, the inventors of present invention thought of reducing the weight of ball bearing by innovatively modifying or altering the design of the same and manufacturing process used for manufacturing of the same. The modification involves drawing curved profiling / corrugation over the outer and inner surface of the outer and inner ring of the ball bearing, through bar / tube drawing process wherein a steel bar is converted into a hollow tube and subsequently cold drawn through a profiled die. The curved profiling is integrally formed during the drawing operation without material removal. Thus, present invention discloses a novel low weight ball bearing wherein the weight reduction is achieved by bar / tube drawing-based profiling of the inner and outer rings of the ball bearing. This innovative process not only reduces the weight of the ball bearing but also enhances its strength and cooling efficiency.

[0022] Present invention is not anticipated by prior art patents and non-patents literature, however related prior art is as below:

[0023] Prior art patents

[0024] Patent Application No. W02013005032A1 discloses "Profiled bearing"

[0025] The aforementioned patent discloses a bearing arranged to receive shaft including contact surface having curved surface profile and axially non-linear surface extending across the entire contact surface. When an expected or predetermined load is applied to shaft, the bend profile of the shaft will match the curved profile of inner surface of the bearing. Because of this, the loaddistribution between the shaft and bearing is uniform along the length of inner surface. This increase the life of the bearing and shaft by protecting it from uneven wearing and tearing. In cited patent, profiling over inner surface of bearing is conducted and not at the outer surface, thus the same differs from present invention.

[0026] Indian Patent Application No. 5279 / DELNP / 2014 discloses "Ball bearing cage and grooved ball bearing provided therewith"

[0027] The above cited patent discloses a ball bearing cage consisting of two ring elements made from formed sheet metal. Each ring element has sequential axial curvatures separated by support surfaces. These elements form ball guide pockets between their facing inner walls which hold a ball. The unique feature of the design is the shape of the inner walls which form a groove i.e., concave channel cross-section relative to the ball. This cross-section has an internal and external ball contact zone. The depth of the channel, particularly in the region between the contact zones, ensures that when the ball contacts the zones, a gap remains between the ball and the channel. This gap helps maintain the ball's position while allowing for proper motion within the bearing cage.

[0028] The above cited patent discloses ball bearing case with grooved / curved inner wall, whereas the present invention discloses ball bearing with corrugated outer and inner ring to reduce the weight of the ball bearing.

[0029] Indian Patent Application No. 202117041105 discloses "Deep groove ball bearing"

[0030] The above cited patent discloses a deep groove ball bearing consisting outer ring, inner ring and balls assembled between track surfaces of the rings. The bearing includes one seal plate attached to the outer ring, with a gap between the seal plate and the inner ring. The retainer is a ribbon retainer made from two annular parts, and it features a radial gap between its inner diameter surface and the outer diameter surface of the inner ring. This gap is designed to be between 0.11 and 0.35 times the diameter of the balls. The bearing is particularly suitable for applications involving outer-ring rotation and is used in guide rollers of tenter clips in film stretching machines.The deep grooves based ball bearing as disclosed in cited patent differs from ball bearing disclosed in present invention.

[0031] Patent Application No. US5051004A discloses "Radial ball bearing having a curved chamfer between a raceway groove and its shoulder"

[0032] The above cited invention discloses a radial ball bearing comprising two bearing rings, each with raceway groove that has a first radius of curvature and a shoulder. The rings are arranged so that the raceway grooves of the two rings face each other, with a set of balls positioned between them. Each bearing ring also includes a curved portion with a second radius of curvature, which is five times larger than the first radius of curvature. The curved portion smoothly transitions into the raceway groove at an inflection point. The design ensures smooth contact and reduced stress concentration between the ball and the bearing ring, improving bearing performance and durability.

[0033] The cited patent differs from present invention.

[0034] Patent Application No. US20030059142A1 discloses "4-point contact ball bearing"

[0035] The cited patent discloses a 4-point contact ball bearing consisting and inner rings and an outer ring featuring two ring-shaped contact surfaces formed on outer circumferential surface of the inner ring and the inner circumferential surface of the outer ring. Each of the four contact surface has concave curve when cut along a plane including central axis of rotation of ball and raceway. The concave curve is shaped to circumscribe the ball, with the largest radius of curvature at the ball-contact point, gradually decreasing as it moves away from the contact point.

[0036] Both the inventions employs curved profiling in the bearing components, which ensure smoother operation, better load distribution, and improved contact between the components, leading to longer service life and better performance.

[0037] Rajnikant Nagarbhai Anjara, Milan J Pandya; Weight Optimization of Deep Groove Ball Bearing; International Journal on Recent and Innovation Trends in Computing and Communication; Volume: 2 Issue: 5The above cited research article discloses optimization of the deep grooved ball bearing. The optimization of the bearing means reducing the weight of the output of the bearing among the stresses generated due to load and the overall weight of the bearing. In cited article, the weight is optimized by keeping the results of stresses same as the results generated in existing bearing design.

[0038] Corrugation over the surface of inner wall and outer wall of ball bearing as discussed in present invention is nowhere disclosed in above cited patent, thus both inventions are different from each other.

[0039] Ball bearings made of polymer: 100% lubrication-free

[0040] Ref: https: / / www.igus.eu / ball-bearings

[0041] The above cited commercial product is plastic based ball bearing, which require no additional lubrication, are corrosion free and the same is lightweight. This makes the ball bearing cost effective consists tribopolymer mixture, light weight and resistant to chemicals as well as nonmagnetic.

[0042] In aforementioned commercial, weight of the ball bearing is reduced by replacing the conventionally used material with plastic, whereas in present invention corrugated profile is drawn over the surface of inner and outer walls to reduce the weight of the ball bearing. Thus, both the inventions are different from each other.

[0043] OBJECT OF THE PRESENT INVENTION

[0044] The primary object of the present invention is to disclose a low weight ball bearing with enhanced strength and cooling effect.

[0045] Another object of the present invention is to disclose a low weight ball bearing in which the weight of the inner ring (200) is reduced by up to 18%-20%

[0046] One more object of the present invention is to disclose a low weight ball bearing in which the weight of the outer ring (100) is reduced by up to 22%-24%Yet another object of the present invention is to disclose a low weight ball bearing having enhanced strength and enhanced cooling efficiency.

[0047] SUMMARY OF THE INVENTION

[0048] The present invention discloses a light weight ball bearing with enhanced strength and cooling effect. The weight of the said ball bearing is reduced by drawing curved profiling / corrugation over the inner surface (201) of inner ring (200) and outer surface (101) of the outer ring (100) through bar / tube drawing process wherein a steel bar is converted into a hollow tube and subsequently cold drawn through a profiled die. The said technical modifications reduce the raw material / weight of outer ring (100) by up to 22%-24% and reduce the raw material / weight of the inner ring (200) by up to 18%-20%. The said profiling also enhances the strength of the bearing ball along with its cooling efficiency.

[0049] The ball bearing is manufactured through bar / tube drawing process wherein a steel bar is converted into a hollow tube and subsequently cold drawn through a profiled die. The curved profiling is integrally formed during the drawing operation without material removal.

[0050] The corrugated parts are further attached / joined by the process of welding to manufacture the complete center stand assembly.

[0051] BRIEF DESCRIPTION OF DRAWINGS

[0052] Figure 1- 3D View of outer ring (100) with corrugated outer surface (101) of ball bearing of present invention

[0053] Figure 2- Isometric view of outer ring (100) with corrugated outer surface (101) of ball bearing of present invention

[0054] Figure 3- Top view of outer ring (100) of ball bearing with 1.08mm width of curved surface Figure 4- Front view of outer ring (100) of ball bearing with 1.08mm width of curved surface Figure 5- Top view of outer ring (100) of ball bearing with 1.03mm width of curved surface Figure 6- Front view of outer ring (100) of ball bearing with 1.03mm width of curved surfaceFigure 7- 3D View of inner ring (200) with corrugated inner surface (201) of ball bearing of present invention

[0055] Figure 8- Isometric view of inner ring (200) with corrugated inner surface (201) of ball bearing of present invention

[0056] Figure 9- Top view of inner ring (200) of ball bearing with 0.96mm width of curved surface Figure 10- Front view of inner ring (200) of ball bearing with 0.96mm width of curved surface Figure 11- Top view of inner ring (200) of ball bearing with 1.13mm width of curved surface Figure 12- Front view of inner ring (200) of ball bearing with 1.13mm width of curved surface The light weight ball bearing assembly is now disclosed in detail with reference to the accompanying drawings.

[0057] DETAILED DESCRIPTION OF THE INVENTION

[0058] The present invention relates to a novel low-weight ball bearing that achieves weight reduction through innovative modifications in its design and manufacturing process. The modification involves drawing curved profiling / corrugation over the outer surface (101) of the outer ring (100) and inner surface (201) of the inner ring (200) of the ball bearing, through bar / tube drawing process wherein a steel bar is converted into a hollow tube and subsequently cold drawn through a profiled die. The curved profiling is integrally formed during the drawing operation without material removal. Introduction of this curved profiling not only reduces the overall weight of the ball bearing but also enhances its mechanical strength and cooling efficiency. Thus, the disclosed ball bearing design offers a significant improvement over conventional bearings by combining reduced weight, increased strength, and improved thermal performance.

[0059] Exemplary Embodiment of the Present invention:

[0060] Constructional Features of the ball bearing of present invention:

[0061] The constructional features of present invention with respect to related figures are provided below:Referring to Figure 3 and Figure 4

[0062] Figure 3 & 4 of the present invention particularly discloses top and front view of the outer ring (100) of ball bearing assembly with 1.08mm depth of curved surface.

[0063] The outer diameter of the outer ring (100) of ball bearing is 37.05 mm and the inner diameter of outer ring of ball bearing is 32.76 mm.

[0064] The bearing has curved profiling at the outer surface (101) forming a wavy or toothed outer contour, to reduce material weight. The inward curve has radius of 2.5mm and the outer protrusion has width of 1.08mm as measured from the inner edge of the wave to outermost point. Further, it consists a small fillet radius of 0.50 mm is applied at specific intersections. The noted R / M Reduction % - 24% indicating a 24% reduction in material compared to a solid structure of similar size. This is likely achieved through the curved profiling over the surface of outer ring. The reduction is not limited to the specific percentage mentioned; it may vary depending on the size and dimensions of the ball bearing selected for a particular application. Referring to Figure 5 and Figure 6

[0065] Figure 5 & 6 of the present invention particularly discloses top and front view of the outer ring (100) of ball bearing assembly with 1.03mm depth of curved surface.

[0066] The outer ring (100) has inner diameter of 31.04 mm and outer diameter of 33.04 mm. The bearing has scalloped design on outer surface (101) due to curved profiling. The radius of inward curve is 2.5mm and the width of the wavy pattern is 1.03 mm, measured from the base of the wave to its peak and a small fillet radius of 0.5 mm is included, likely for smoother transitions between curves.

[0067] The noted R / M Reduction % - 21.7% indicating material reduction of 21.7%, achieved by incorporating the curved profiling over the surface of outer ring. This reduction optimizes material use while maintaining strength and cooling efficiency. The reduction is not limited to the specific percentage mentioned; it may vary depending on the size and dimensions of the ball bearing selected for a particular application.In this design, the material reduction seems lesser in comparison to bearing disclosed in figure 3 &4.

[0068] Referring to Figure 9 and Figure 10

[0069] Figure 9 and 10 shows technical drawing of the inner ring (200) of a bearing in a top view and front view orientation with 0.96mm depth of curved surface

[0070] The inner ring (200) has an outer diameter of 19.44mm and innermost diameter of 17.44mm. The inner ring features a curved profiling / corrugation over the inner surface (201), particularly to reduce material utilization, which further leads to overall weight reduction. The curved profiling is defined by a curvature radius of 2.25 mm, giving the inner contour its scalloped appearance. The width of the curved design is 0.96mm, measured from deepest point of the curve of the innermost diameter. The radius of the innermost groove is 0.50mm

[0071] The noted raw material (R / M) Reduction % - 17.9% indicating that this design reduces material usage by 17.9%, compared to a fully solid inner ring. This reduction likely balances weight savings and structural integrity. The reduction is not limited to the specific percentage mentioned; it may vary depending on the size and dimensions of the ball bearing selected for a particular application.

[0072] The inner ring (200), like the outer ring (100), is a critical component in the bearing assembly. The curved profiled design minimizes weight and material usage while still allowing the bearing to fulfill its role in supporting loads and enabling smooth rotation.

[0073] Referring to Figure 11 and Figure 12

[0074] Figure 11 and 12 shows technical drawing of the inner ring (200) of a bearing in a top view and front view orientation with 1.13mm depth of curved surface

[0075] The inner ring (200) has an outer diameter of 21.95mm and innermost diameter of 19.95mm. The inner ring features a curved profiling / corrugation over the inner surface (201), particularly to reduce material utilization, which further leads to overall weight reduction. The curved profiling is defined by a curvature radius of 2.50 mm, giving the inner contour its scallopedappearance. The width of the curved design is 1.13mm, measured from deepest point of the curve of the innermost diameter. The radius of the innermost groove is 0.75mm.

[0076] The noted raw material (R / M) Reduction^, - 20%, indicating that material or mass is reduced by 20% possibly due to the curved profiling drawn over the surface of the inner ring, while maintaining the structural integrity of the same. The reduction is not limited to the specific percentage mentioned; it may vary depending on the size and dimensions of the ball bearing selected for a particular application.

[0077] It is pertinent to mention here that the number of profiles formed may vary depending on the application area in which the ball bearing is intended to be used. Similarly, the dimensions of the ball bearing will also differ based on its specific application requirements. Furthermore, the extent of weight reduction and raw material savings will vary according to the dimensions of the ball bearing and the number of profiles incorporated on the inner and outer rings of the said ball bearing.

[0078] To summarize, the key changes in inner and outer ring assembly of ball bearing w.r.t existing are as below:

[0079]

[0080] Table 1: Material reduction dataThe aforementioned technical modifications and improvements by way of corrugation and curved profiling have reduced the weight of outer ring (100) of ball bearing by up to 22%-24% and reduced the weight of inner ring (200) of ball bearing by up to 18%-20%. The reduction is not limited to the specific percentage mentioned; it may vary depending on the size and dimensions of the ball bearing selected for a particular application.

[0081] The drawings and description appended to the present specification are provided solely as illustrative examples to depict the general design and configuration of the ball bearing's outer and inner rings. The percentage reduction in weight indicated in the illustrative embodiment pertains specifically to the example shown and may vary during actual manufacturing, depending on modifications to the radius, curvature, or profile of the rings. The dimensional profiles of both the outer and inner rings may be increased or decreased in accordance with specific application requirements. Furthermore, in the case of larger-sized ball bearings, the profile depth, curvature, and radius dimensions of both the outer and inner rings may be suitably altered or optimized to achieve desired operational performance and structural efficiency.

[0082] Manufacturing process

[0083] Raw material used for used for manufacturing the ball bearing is SAE-52100 steel, which is a deep hardening alloy used for production of bearings, where good rolling contact figure strength is required. Further, other raw materials including chrome steel AISI SAE52100, stainless steel AISI 440C, 340, 316, Case hardened steels (8620, 4320 alloys) etc can also be used for manufacturing of ball bearing.

[0084] The manufacturing process for obtaining such light weight ball bearing assembly consists the following steps:

[0085] Drawing the steel bar:

[0086] A high-carbon chromium steel bar (e.g., SAE 52100) is provided as raw material. The bar is drawn through a series of dies to achieve the required diameter and mechanical properties, improving surface finish and material uniformity for further processing.

[0087] Ball bearing manufacturing process:The ball-bearing manufacturing process consists of the following major steps:

[0088] Providing blank steel bar as input material for making bearing;

[0089] Cutting blank bar stock into predetermined lengths on band saw or automatic cutting machines; Induction heating of bar at temperature ranging between 1240oC to 1260oC;

[0090] Hot pearcing the bar by piercer mill to form red hot rough hollow tube;

[0091] Annealing at furnace at temperature ranging between 750oC to 780oC to improve material's ductility and reduces its hardness;

[0092] Tube straightening;

[0093] Surface treatment of hollow tube by STP process;

[0094] Acid pickling by dipping in HCI acid tank for 30 minutes;

[0095] Water rinsing of hollow tube by dipping in water for 1 minutes;

[0096] Activation of hollow tube by dipping in activator chemical Bonderlite M-AC for 1 minute;

[0097] Dipping of hollow tube in phosphate chemical for 30 minutes at temperature ranging from 60oC to 70oC;

[0098] Dipping in neutralizer tank containing Bonderite M-AD 5021 JC chemical for 1 minute;

[0099] Rinsing of hollow tube by dipping in water for 1 minute;

[0100] Dipping in soap bath for 40 minutes at 60-70oC for soaping;

[0101] Blowing hot air to dry the inside diameter of the tube;

[0102] Push pointing the tube for making a notch for draw process;

[0103] Cold drawing the hollow tube using die of specific radius and profiling for making final profiled tube;

[0104] Final tube strengthening of tube by straightener machine;Cutting of profile tube as per the requirement to form the bearing on CNC turning machine / automatic lathes machine.

[0105] Further, any excess ring material is trimmed and bearings are cleaned, coated with rustpreventive oil, and packed.

[0106] RESULTS

[0107] A comparative analysis between profiled and plain ball bearings was conducted to evaluate their performance in terms of fatigue strength, load capacity, and thermal performance. The fatigue strength, push / pu 11 load capacity and thermal performance of both plain ball bearing and profiled ball bearing is disclosed below:

[0108] Fatigue strength: Profiled ball bearing exhibited 10% increase in fatigue strength compared to plain ball bearing. This enhancement is attributed to the optimized geometry of bearing profiles, which facilitates better load distribution across the contact surfaces. The reduced stress concentration helps delay the initiation and propagation of fatigue cracks, thereby extending the bearing's operational life under cyclic loading conditions.

[0109] Push / Pull load capacity: In load bearing applications, profiled ball bearing demonstrates a 40% higher push / pu II load capacity relative to plain ball bearings. This significant improvement is due to enhanced contact mechanics provided by profiled design, allowing greater mechanical stability under axial loads. The profiled structure minimizes deformation and improves stiffness, resulting in better resistance to both compressive and tensile forces.

[0110] Thermal performance: Thermal analysis revealed that the profiled ball bearings offer a 7% improvement in heat transfer efficiency compared to plan ball bearings. The profiled design promotes more effective dissipation of heat generated during operation by increasing surface contact area and improving thermal pathway. This contributes to more stable temperature regulation during high-speed or high-load applications, which is crucial for maintaining performance and longevity.

[0111] The results clearly indicate that profiled ball bearings outperform plain ball bearings across multiple critical performance metrics. The improvements in fatigue strength, load capacity, andthermal efficiency underscore the advantages of the profiled design in demanding mechanical systems. These enhancements support the adoption of profiled ball bearings in high-performance or reliability-critical applications.

[0112] Novelty of the present invention is duly clear as per the non-disclosure of above features in the prior art patent and other non-patent literature.

[0113] Inventive step by way of technical advancement of knowledge lies in altering the design of the inner and outer ring of the ball bearings by drawing curved profiling / corrugation over the surface of the same, which not only reduces the raw material utilization and weight of the said bearing but also enhances the strength and cooling efficiency of the same. Since lighter bearings reduce the risk of overheating, as they generate less heat during operation meaning more efficient heat dissipation thereby more cooling efficiency.

[0114] In essence, the technical advancement brought by the curved profiling or corrugation is a holistic improvement in the design of ball bearings. It not only optimizes material use and operational efficiency but also aligns with contemporary demands for lightweight, high-performance, and environmentally friendly engineering solutions.

[0115] Industrial Application is duly clear as the present invention will boost the mechanical industry, by providing low weight and low cost ball bearing assembly with enhanced strength and cooling efficiency.

[0116] As used herein, the word "a" or "an" should be understood as not excluding plural elements or operations, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0117] The present disclosure is not to be limited in scope by the specific embodiments described herein. Other embodiments and modifications apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of above, those of ordinary skill in the art will recognize that its usefulness is notlimited thereto and that the present disclosure may be beneficially implemented in any pump for similar purpose.

Claims

im1. A low weight ball bearing assembly characterized in that:A curved profile is drawn over the outer surface (101) of the outer ring (100) and inner surface (201) of the inner ring (200) of the ball bearing forming wavy / toothed outer contour;a chamfer or fillet radius ranging between 0.5mm to 075mm is applied at the curve intersections to reduce stress concentration and improve structural integrity.

2. The low weight ball bearing as claimed in claim 1 wherein the profiled outer ring (100) of ball bearing having 37.05mm outer diameter, 27.76mm inner diameter and 0.50mm fillet radius has a curved profiling depth of 1.08mm and inward curve radius 2.5mm drawn over surface of outer ring to reduce material usage upto 24%, to enhance the strength and cooling efficiency of the ball bearing.

3. The low weight ball bearing as claimed in claim 1 wherein the profiled inner ring (200) of ball bearing having 21.95mm outer diameter, 19.95mm inner diameter has a curved profiling depth of 1.13mm and curve radius 2.5mm drawn over the outer surface of the inner ring to reduce material usage upto 20%, to enhance strength and cooling efficiency of the ball bearing.

4. The low weight ball bearing as claimed in claim 1 wherein the same is manufactured using raw material high-carbon chromium steel bar selected from SAE 52100, chrome steel AISI 52100, stainless steels AISI 440C, 340, 316, or case-hardened steels including 8620 or 4320 alloys.

5. The low weight ball bearing as claimed in claim 1 wherein the weight of the outer ring (100) is reduced by 20-24% and weight of inner ring (200) is reduced by 18-20% due to the profiling which reduces sharp transitions and reduces material between the curved radius and the flat diameter of outer ring (100) of the ball bearing.

6. The low weight ball bearing as claimed in claim 1 wherein the profiling enhances the mechanical strength and cooling efficiency as per the following parameters:fatigue strength by 10%;push / pu 11 load capacity by 40% andheat transfer efficiency improved by 7%.

7. The process of obtaining low weight ball bearing as claimed in claim 1, having the steps of:Providing blank steel bar as input material;drawing the steel bar through one or more dies to reduce its diameter and to improve surface finish and material uniformity;cutting the drawn steel bar into predetermined lengths using a band saw or an automatic cutting machine to obtain bar blanks;induction heating the bar blanks to a temperature in a range of 1240°C to 1260°C; hot piercing the heated bar blanks in a piercer mill to form a red-hot rough hollow tube;annealing the rough hollow tube at a temperature between 750°C and 780°C to increase ductility and reduce hardness;straightening the annealed tube;performing surface treatment of the hollow tube by an STP process;acid pickling the hollow tube by dipping the tube in a hydrochloric acid tank for 30 minutes;water rinsing the pickled tube by dipping in water for 1 minute;activating the tube surface by dipping the tube in an activator chemical comprising Bonderlite M-AC for 1 minute;phosphating the activated tube by dipping it in phosphate chemical at a temperature between 60°C and 70°C for 30 minutes;neutralizing the phosphated tube by dipping it in Bonderite M-AD 5021 JC for 1 minute;rinsing the neutralized tube by dipping it in water for 1 minute;soaping the tube by dipping it in a soap bath at 60-70°C for 40 minutes;drying the inside diameter of the tube using hot-air blowing;push-pointing the tube to form a notch for a subsequent drawing operation;cold drawing the tube through a die of predetermined radius to obtain a final profiled hollow tube suitable for forming bearing rings;strengthening the drawn profiled tube using a straightener machine;cutting the profiled tube into required dimensions and machining the cut pieces on a CNC turning machine or automatic lathe to form bearing rings; andtrimming excess material, cleaning the machined bearing rings, coating the rings with rust-preventive oil, and packaging the resulting ball bearing assembly.

Images