Bearing Outer Ring Extrusion for Raceway Cleanliness
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Solution Overview
Problem
Conventional manufacturing methods for double-row angular ball bearing outer rings face challenges in exposing the highest cleanliness metal material on the double-row outer ring raceways, limiting the durability and rolling fatigue life of the bearing.
Innovation Solution
A manufacturing method involving a simultaneous forward-backward extrusion process or a combination of forward and backward extrusion processes to shape the outer ring, ensuring the metal material with the highest cleanliness is uniformly distributed and exposed on the raceways, using a floating die with an elastic force to regulate the deformation and symmetry of the intermediate materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional backward extrusion process is used to manufacture outer ring, then the manufacturing process is simple, but the metal material with highest cleanliness cannot be exposed on the entire double-row outer ring raceways
Solution Approach 1:
The extrusion process is segmented into two distinct stages: forward extrusion followed by backward extrusion. This segmentation allows different portions of the metal material to be positioned strategically, enabling the highest cleanliness material to be exposed on the entire double-row outer ring raceways while maintaining a manageable manufacturing process
Solution Approach 2:
The conventional single backward extrusion approach is inverted by introducing a forward extrusion stage first. This inversion rearranges the metal material distribution so that the highest cleanliness portion is positioned to be exposed on the raceways, resolving the contradiction between reliability and manufacturing simplicity
2Manufacturing precision
If floating die with elastic force is used in extrusion process, then the symmetry and deformation control of intermediate materials is improved, but the device complexity increases
Solution Approach 1:
An elastic member is introduced as an intermediary between the pressing machine and the die. This elastic member acts as a mediator that transmits and regulates the pressing force, improving the symmetry and deformation control of intermediate materials while keeping the overall device structure relatively simple through the use of a straightforward elastic element
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 ensures the highest cleanliness metal material is exposed over the entire double-row outer-ring raceways, enhancing the rolling fatigue life and design freedom for maintaining the durability of the double-row rolling bearing.
Implementation Method 1
a floating die, which has a peripheral wall section to which an elastic force in the upward direction is applied by an elastic member
Implementation Method 2
compressing the center portion of the first intermediate material between the floating die and an extrusion punch to obtain a second intermediate material having a cylindrical section and a bulkhead portion
Data Source
AI summary
When the column-shaped raw material 10 is subjected to an upsetting process, a simultaneous forward-backward extrusion process, a punching process, a rolling process and a finishing process in order, to obtain an outer ring 3 that constitutes a back-to back double-row angular ball bearing 3, in the simultaneous forward-backward extrusion process, using a floating die 31 having a bottom plate section 35 with a circular convex section 34 and a punch 33 having a punch side convex section 37 provided on an distal end thereof, the section closer to the center in the radial direction of the first intermediate material 11a is compressed in the axial direction, causing the metal material of the first intermediate material 11a to move outward in the radial direction and move approximately uniformly in both extrusion (forward and backward) direction of the punch 33, whereby the middle metal material 29 having a high degree of cleanliness of the column-shaped raw material 10 is exposed over the entire portion that will become the double-row outer-ring raceways 2.