Bearing Element Cold Press Forming for Fewer Machining Steps
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Solution Overview
Problem
The existing methods for manufacturing bearing elements, such as outer and inner races for radial rolling bearings, are costly and require a large number of steps and significant cutting and grinding processes, which increase production costs and complexity.
Innovation Solution
A bearing element manufacturing method that involves processing a single columnar material into large and small diameter cylindrical members using a multi-stage press working process, reducing the number of steps and minimizing cutting and grinding through the use of specialized tools and techniques, such as chamfering and metal flow patterns, to produce rings with asymmetric metal patterns for enhanced strength and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to manufacture bearing elements, then manufacturing precision can be maintained, but manufacturing cost increases and production complexity increases
Solution Approach 1:
The patent combines the manufacturing of outer race and inner race into a single integrated press working process. A single press working device performs multiple operations (upsetting, extruding, forming) to produce both bearing elements from one columnar material, eliminating the need for separate manufacturing processes and reducing overall production complexity
Solution Approach 2:
The press working device is divided into multiple working portions (first press working portion for outer race, second press working portion for inner race) that operate simultaneously or sequentially on different sections of the same columnar material. This segmentation allows independent optimization of each race's forming process while maintaining overall process integration
2Productivity
If multiple processing steps are used to manufacture bearing elements, then manufacturing precision can be ensured, but the number of steps increases and production time increases
Solution Approach 1:
The press working process continues uninterrupted through multiple stages within a single device. The columnar material undergoes upsetting, extruding, and forming operations in continuous sequence without removal or repositioning, maintaining dimensional accuracy while reducing the total number of processing steps and improving production efficiency
Solution Approach 2:
The press working device performs preliminary forming operations (upsetting and extruding) that pre-shape the columnar material into configurations close to the final bearing element geometry. This preliminary action reduces the amount of finishing work required and maintains precision while accelerating production
3Loss of substance
If extensive cutting and grinding processes are used, then manufacturing precision can be achieved, but material utilization decreases and manufacturing cost increases
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive (cutting and grinding) to additive/plastic deformation (press working). The columnar material is plastically deformed into the final bearing element shape through controlled pressing, minimizing material removal and maximizing material utilization while achieving the required precision through the forming process itself
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 allows for the efficient production of bearing elements with reduced manufacturing costs, fewer processing steps, and improved material utilization, resulting in cost-effective and high-quality bearing components.
Implementation Method 1
a first press working device (6) to process the columnar material (5) into a first intermediate material (7), the first intermediate material (7) being obtained by cold upsetting and front extruding processes
Implementation Method 2
the punch (6a) is moved downward so that the billet (5) is axially crushed between the lower surface of the punch (6a) and the upper surface of the counter punch (6b). Accordingly, the first intermediate material (7) which includes a disc-shaped portion (7a) and a small diameter cylindrical portion (7b) is obtained
Implementation Method 3
the first intermediate material (7) is subjected to a cold rear extruding process using a second press working device (8) to obtain a second intermediate material (9)
Data Source
Figure 1
Figure 2~3
Figure 4~4(H)
AI summary
A first piece (13) includes a first ring portion (13b) and a second ring portion (13c) which are arranged side by side in an axial direction and an inner diameter and an outer diameter of the first ring portion (13b) are respectively larger than an inner diameter and an outer diameter of the second ring portion (13c). A second piece (16) is obtained by pressing the first piece (13) while the first piece (13) is disposed between a first set and a second set.