Sheet Metal Bearing Cage Segments With Single-Tool Forming
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Solution Overview
Problem
Existing manufacturing methods for rolling-element bearing cages are complex and costly, requiring large amounts of material and multiple machine tools, leading to high material waste and expenses.
Innovation Solution
A cage segment for rolling-element bearings is manufactured from sheet metal using cutting, punching, and bending techniques, eliminating the need for finish machining and reducing material usage and manufacturing costs by using a single machine tool for detaching and shaping the cage segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods (flow forming, punching, stamping, or laser cutting) are used for rolling-element bearing cages, then the cages can be produced with adequate structural integrity, but the process requires large amounts of material and multiple complex machine tools, leading to high manufacturing costs and material waste
Solution Approach 1:
The bearing cage is divided into multiple cage segments, each with one or more pockets for receiving rolling elements. This segmentation allows each segment to be manufactured separately using simple sheet metal forming processes, avoiding the need for complex multi-step manufacturing of a complete cage. The segments can then be assembled to form the complete cage structure.
Solution Approach 2:
The invention changes the manufacturing approach from traditional flow forming and punching of solid material to using sheet metal with controlled bending and forming parameters. By adjusting sheet metal thickness, bending radii, and forming temperatures, the cage segments achieve the required structural integrity without requiring multiple complex machining operations.
2Strength
If solid material is rolled and machined to manufacture larger metal cages, then sufficient structural strength is achieved, but the material utilization is poor and manufacturing expense is high due to extensive machining requirements
Solution Approach 1:
The cage segments are manufactured from sheet metal instead of solid material, utilizing the flexibility and formability of thin metal sheets. The sheet metal is bent and formed into the required cage segment shapes with adequate structural strength, significantly reducing material waste compared to rolling and machining solid material.
Solution Approach 2:
The invention transitions from three-dimensional solid material forming to two-dimensional sheet metal forming followed by bending. This dimensional change allows for more efficient material utilization, as the sheet metal can be cut and formed with minimal waste, and the bending process creates the required three-dimensional cage structure without removing material.
3Manufacturing precision
If multiple machine tools are used for detaching and shaping cage segments from sheet metal, then precise geometric accuracy is achieved, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The invention combines the detaching and shaping operations into a single integrated process step. The cage segments are detached from the sheet metal in an unfolded form and then shaped by bending in one continuous operation, eliminating the need for multiple machine tools and intermediate handling, thereby improving productivity while maintaining geometric accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for a cost-effective and simple production of cage segments with reduced material waste, enabling the creation of large rolling-element bearings with improved stability and lubricant supply through textured surfaces and attachment elements, while minimizing manufacturing expenses.
Implementation Method 1
the detaching comprises a cutting, punching, and/or nibbling
Implementation Method 2
the detaching comprises a cutting, punching, and/or nibbling
Implementation Method 3
the detaching comprises a cutting, punching, and/or nibbling
Implementation Method 4
the cage segment can subsequently be shaped by bending and/or folding the detached, unfolded form of the cage segment
Implementation Method 5
the cage segment can subsequently be shaped by bending and/or folding the detached, unfolded form of the cage segment
Data Source
AI summary
A cage segment is for a rolling-element bearing cage, particularly for large rolling-element bearings. The cage segment includes a first side element and a second side element that are connected by a first bridge and a second bridge. At least one pocket is formed between the first and second bridges which is suitable for receiving at least one rolling element. The cage segment is manufactured from sheet metal.