Captive Plain Bearing Manufacturing via Additive Monobloc Machining
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Solution Overview
Problem
The manufacturing of plain bearings with captive inner parts is complex and costly, and achieving high surface quality in heavily loaded bearings is challenging due to the limitations of integrating monobloc bearing parts.
Innovation Solution
A method involving a one-piece outer part with a concave running surface and a one-piece inner part with a convex surface, where the inner part is machined and held captive within the outer part using an auxiliary tool, allowing for additive production and post-processing to achieve high surface quality, with centering rings and friction-reducing agents used to secure the parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer part is produced in multiple pieces to hold the inner part captive, then the inner part can be secured in the outer part, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the outer part and inner part into a single monobloc structure through additive manufacturing, eliminating the need for multiple separate pieces while maintaining the captive relationship. The inner part is integrated directly into the outer part, reducing assembly complexity and manufacturing steps.
Solution Approach 2:
The monobloc structure serves multiple functions simultaneously: it provides the outer housing, contains the inner part, and enables relative movement all in one component. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process.
2Ease of manufacture
If monobloc bearing parts are integrated, then the manufacturing process is simplified, but the surface quality deteriorates
Solution Approach 1:
The patent applies preliminary machining operations after additive manufacturing to achieve the required surface quality. The rough monobloc structure is first created, then specific surfaces are machined to the required precision, combining the benefits of additive manufacturing with traditional machining.
Solution Approach 2:
Different manufacturing approaches are applied to different parts of the bearing: additive manufacturing is used for the overall monobloc structure where complex geometries are needed, while traditional machining is applied locally to critical surfaces requiring high precision and smooth finish.
3Stability of the object's composition
If the inner part is held captively in the outer part, then the bearing structure is stabilized, but the machining accessibility is reduced
Solution Approach 1:
The patent segments the manufacturing process into distinct phases: first creating the monobloc structure with the inner part in a non-concentric position for easy machining access, then transitioning to the concentric running position for operation. This temporal segmentation allows both good machining accessibility and structural stability.
Solution Approach 2:
The inner part is designed to be movable relative to the outer part during machining operations, allowing it to be tilted or positioned for access, and then fixed in the running position for operation. This dynamic approach enables both machining accessibility and structural stability at different stages.
Data Source
AI summary
A method for manufacturing a bearing includes the following steps: a) providing of an outer part with a concave running surface which forms a receiving area for receiving an inner part, b), providing an inner part that is arranged inside the outer part, which inner part is shaped annularly, c) arranging the inner part within the outer part in a machining position in which at least a part of an outer surface of the inner part is exposed for machining, and d), generating of a convex running surface of the inner part, which running surface engages with the receiving area of the outer part whereby the inner part is held captively in the outer part. Subsequently, the inner part may be tilted from the machining position into a running position in which the inner part is concentric with the outer part.