Bearing Ring Combining Hardened Steel Raceway with Additive Manufactured Printed Material

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Solution Overview

Problem

Current additive manufacturing processes are inadequate for producing high-quality bearing rings due to insufficient material properties, particularly in terms of wear resistance and rolling contact fatigue, and the granular structure of printed materials can cause additional vibrations and noise in bearings.

Innovation Solution

A bearing ring design that combines a hardened steel raceway surface with printed material bonded to it, using additive manufacturing for the shape and structural elements, while ensuring the raceway surface is smooth to prevent vibrations and noise, and attaching printed material outside the contact area to enhance bonding and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additive manufacturing is used to produce the entire bearing ring, then manufacturing flexibility and customization are improved, but material properties (wear resistance and rolling contact fatigue) deteriorate

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidwear resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The bearing ring is divided into two functional segments: a raceway ring made of hardened steel for wear-resistant contact surfaces, and printed material portions for structural support and customization. This segmentation allows each part to be optimized for its specific function while combining them into a unified component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite construction by bonding printed material to a hardened steel raceway ring. This creates a composite structure that combines the wear resistance of hardened steel with the manufacturing flexibility and structural capabilities of additive manufactured materials.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If additive manufacturing is used to produce the raceway surface, then manufacturing simplicity is improved, but surface quality and vibration characteristics deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidvibrations and noise

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The raceway surface is separated from the structural body of the bearing ring. The raceway ring with its smooth hardened steel surface is distinct from the printed material portions, allowing the contact surface to be optimized for low vibration while the printed portions provide structural functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the bearing ring have different material properties: the raceway surface area uses smooth hardened steel to minimize vibrations and noise, while other areas use printed material for structural support. This local differentiation of material quality optimizes both vibration characteristics and manufacturing flexibility.

Inventive Principle:

Principle #3Local quality

3Strength

If printed material is bonded to the raceway ring, then structural integrity is improved, but bonding strength outside contact area may be compromised

Engineering Contradiction:

Improvestructural integrityVSAvoidbonding strength

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The bonding interface between printed material and raceway ring is strategically positioned in non-contact areas where rolling elements do not exert pressure. This local placement ensures that bonding strength is not compromised by contact forces while still providing adequate structural integrity.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The printed material is bonded to the raceway ring in advance, before the bearing is assembled and subjected to operational loads. This preliminary bonding allows for proper curing and strength development in a controlled environment, ensuring adequate bonding strength before the component enters service.

Inventive Principle:

Principle #10Preliminary action

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 solution enables the bearing ring to withstand wear and rolling contact fatigue while allowing for customizable shapes and reduced weight, improving the performance and reliability of bearings by minimizing vibrations and noise.

Implementation Method 1

printed material bonded to the steel of the raceway ring

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP3084240B1A ring for a bearing, an inner ring, an outer ring, and a bearing

Publication Date: 2019.10.09 AB SKF SKF PATENT DEPARTMENT

Figure 1A~2
Figure 3A~3C
Figure 4A~4B

AI summary

The invention provides a ring (380, 390) for a bearing (300). The invention further provides an inner ring (380), an outer ring (390) and the bearing. The ring comprises a raceway ring (310, 320) being a hardened steel metal ring (310, 320) comprising a raceway surface configured and constructed for guiding rolling elements (305) of the bearing. The ring further comprises printed material (350, 360) bonded to the steel of the raceway ring. The printed material being material printed via an additive manufacturing process. The printed material may be used to customize a shape of the ring, for example, of the inner ring or the outer ring of the bearing, thus allowing flexible customization.