Bearing Cage Side Ring Windows Without Punching Deformation
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Solution Overview
Problem
The existing methods for manufacturing side rings for roller bearing cages are costly and result in deformation and burr formation due to high punching forces, requiring additional work steps for straightening and deburring.
Innovation Solution
The use of pendulum broaching to introduce windows into a raw side ring made of non-ferrous metal, such as brass, eliminates the need for pre-drilling and punching, reducing stress on the material and allowing for the production of the side ring in its final contour without additional material, thereby minimizing deformation and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional punching methods are used to create windows in side rings, then windows can be formed, but high punching forces cause deformation and burr formation requiring additional straightening and deburring work steps
Solution Approach 1:
The invention changes the fundamental parameter of the window formation process from high-force punching to low-force broaching. The broaching process uses a multi-tooth tool that gradually removes material through a scraping action, completely avoiding the high punching forces that cause deformation and burr formation. This parameter change eliminates the need for subsequent straightening and deburring operations.
Solution Approach 2:
The invention replaces the conventional punching mechanical system with a broaching mechanical system. Instead of using a punch and die arrangement that applies concentrated high force, the broaching tool uses multiple teeth that progressively remove material through a scraping motion. This mechanical substitution fundamentally changes how windows are formed, eliminating the harmful effects of high punching forces while maintaining manufacturing efficiency.
2Manufacturing precision
If multiple work steps (pre-drilling, punching, straightening, deburring) are used to manufacture side rings, then windows can be formed, but production costs increase and manufacturing time is extended
Solution Approach 1:
The invention merges multiple separate work steps (pre-drilling, punching, straightening, and deburring) into a single broaching operation. The broaching tool performs all necessary window formation tasks in one pass, eliminating the need for sequential operations. This merging of processes dramatically reduces manufacturing time and production costs while maintaining high window formation quality.
Solution Approach 2:
The broaching tool is designed with a specific tool profile that corresponds to the desired window contour. The tool is guided into a pre-drilled opening and automatically forms the complete window shape including proper edges and contours in one continuous motion. This preliminary design of the tool profile ensures that all necessary geometric features are created in a single operation, eliminating subsequent correction steps.
3Productivity
If high punching forces are applied to form windows, then windows can be created, but stress on the raw side ring causes deformation and warping
Solution Approach 1:
The invention changes the force application parameter from high concentrated punching force to low distributed broaching force. The broaching tool uses multiple teeth that progressively remove material through a scraping action, distributing the mechanical stress over time and across multiple contact points. This parameter change maintains window formation efficiency while preserving the structural integrity and dimensional stability of the side ring.
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
This method significantly reduces production costs and eliminates the need for subsequent work steps like straightening and deburring, while ensuring high production quality and avoiding warping, especially in larger side rings with multiple windows.
Implementation Method 1
the windows being introduced by means of pendulum spaces—also called 'pendular broaching' in English. In particular, the windows are introduced using the method according to claim 6
Implementation Method 2
In pendulum broaching, a rotating movement of a drive device results in an oscillating movement of a tool. The oscillating tool has the same outer contour as a contour to be formed in a workpiece. By oscillating the tool, the contour of the tool is transferred to the workpiece, with a separating process being carried out during the oscillating movement.
Data Source
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AI summary
In anti-friction bearings, the rolling bodies are often guided in cages. The cages can firstly be configured as solid cages; secondly, it is possible that they are joined together from a plurality of parts. It is known, for example, to form a cage for an anti-friction bearing from two side parts and webs which run between them, wherein the webs are connected to the side parts via a riveting method to one another. A side ring (1) for a multiple-part cage for an anti-friction bearing is proposed, wherein the side ring (1) has a plurality of windows (2) for receiving webs, wherein the windows (2) are made in the side ring (1) by means of floating broaching. Furthermore, a cage having at least one side ring of this type is proposed.