Ceramic Ball Material With Controlled Band Circularity for Faster Machining
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Solution Overview
Problem
Ceramic ball materials with high sphericity are challenging to machine due to their brittleness and high hardness, requiring extensive machining time, especially during the initial process of increasing sphericity, which is time-consuming and prone to defects like cracking and chipping.
Innovation Solution
A ceramic ball material with a specific configuration of a spherical portion and a band-shaped portion, where the circularity of the band-shaped portion is optimized between 0.01% and 2.5%, ensuring uniform initial contact with the surface plate during machining, reducing the required machining amount and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press molding is used to manufacture ceramic ball material, then the material can be formed with a spherical portion and band-shaped portion, but the circularity of the band-shaped portion becomes large (worsening sphericity)
Solution Approach 1:
The patent applies parameter changes by optimizing the circularity of the band-shaped portion to a specific range (0.01% to 2.5%) after press molding. This parameter control enables the material to maintain both manufacturability through standard press molding and sufficient sphericity for reduced machining time, resolving the contradiction between ease of manufacture and manufacturing precision.
2Manufacturing precision
If extensive machining is performed to increase sphericity, then the required sphericity can be achieved, but the machining time becomes very long
Solution Approach 1:
The patent applies preliminary action by achieving sufficient sphericity (circularity of 0.01% to 2.5%) during the press molding stage itself, rather than relying on subsequent machining. This preliminary formation of the spherical shape with acceptable precision dramatically reduces the amount of machining required, thereby increasing productivity while maintaining the required sphericity.
Solution Approach 2:
The press molding process is designed to self-generate the required sphericity within the specified circularity range, eliminating the need for extensive post-processing. The molding process serves its own purpose of creating both the shape and the required precision, reducing dependency on time-consuming machining operations.
3Manufacturing precision
If extensive machining is performed on brittle ceramic material, then sphericity can be improved, but the risk of cracking and chipping increases
Solution Approach 1:
The patent applies preliminary action by achieving the required sphericity during press molding before any machining operations. By establishing the spherical shape with appropriate circularity (0.01% to 2.5%) in advance, the material undergoes minimal subsequent machining, which significantly reduces the risk of inducing cracks and chips in the brittle ceramic material, thereby improving reliability.
4Ease of manufacture
If the circularity of the band-shaped portion is large, then the press molding process is simple, but the initial contact area with surface plate becomes non-uniform
Solution Approach 1:
The patent applies parameter changes by establishing a specific circularity range (0.01% to 2.5%) for the band-shaped portion that balances molding simplicity with contact uniformity. This optimized parameter ensures that the initial contact area with the surface plate during machining is uniform, improving manufacturing precision while maintaining the simplicity of the press molding process.
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 optimized circularity configuration significantly reduces machining time and defects, enhancing processability and yield by ensuring a uniform contact area and reducing stress concentration during machining.
Implementation Method 1
In the process of manufacturing such a bearing ball material, a method of sintering a green compact is employed.
Data Source
AI summary
A ceramic ball material according to an embodiment including: a spherical portion; and a band-shaped portion formed in a band shape. When C denotes circularity of the band-shaped portion as observed from a height direction thereof, the circularity C is in a range of more than 0% and 2.5% or more.