Flange Bearing Shell Axial Radial Assembly Caulking
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Solution Overview
Problem
The deformation of end regions in built-up flange bearing shells to attach disk-shaped axial bearing parts to half-shell-shaped radial bearing parts introduces stresses and deformations that are difficult to control, affecting dimensional accuracy and assembly reliability.
Innovation Solution
The axial direction caulking of retaining tongues into undercut open-edged retaining recesses on the radial bearing part, ensuring a stable engagement without plastic deformation of the radial bearing part, and using a wedge-shaped tool for targeted material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end regions of the radial bearing part are deformed to attach the axial bearing part, then the axial bearing part can be fixed on the radial bearing part, but stresses and deformations are introduced that affect dimensional accuracy
Solution Approach 1:
The attachment structure is segmented into three functional zones: the retaining tongue (deformable element), the retaining recess (reception structure), and the undercut region (locking zone). This segmentation allows deformation to be localized to the retaining tongue while protecting the radial bearing part from stresses, thereby maintaining dimensional accuracy while achieving strong attachment.
Solution Approach 2:
The retaining recess is designed with an undercut in the axial direction, creating a three-dimensional locking geometry. The retaining tongue is deformed in the axial direction to engage with this undercut, transforming a simple linear attachment into a multi-dimensional captive connection that prevents removal while minimizing stress on the radial bearing part.
2Reliability
If the retaining tongue is deformed to create a form fit, then the axial bearing part is securely attached, but the deformation process is difficult to control in production
Solution Approach 1:
The retaining recess is pre-formed with an undercut geometry during manufacturing of the radial bearing part. This preliminary preparation creates a built-in deformation path that guides the retaining tongue during the attachment process, making the deformation controllable and repeatable in production while ensuring reliable captive engagement.
Solution Approach 2:
The retaining tongue undergoes controlled plastic deformation in the axial direction, changing its physical state from a free element to a permanently deformed captive element. The undercut geometry in the retaining recess provides a defined deformation zone where material flow can be controlled, ensuring consistent attachment reliability across production batches.
3Stability of the object's composition
If the retaining tongue is caulked in the axial direction, then the axial bearing part is held captive on the radial bearing part, but forces are applied to the radial bearing part
Solution Approach 1:
The undercut in the retaining recess creates a localized stress concentration zone that is spatially separated from the critical bearing surfaces of the radial bearing part. When the retaining tongue is caulked, stresses are confined to the undercut region and retaining tongue, while the main body of the radial bearing part experiences minimal stress, preserving its dimensional stability and bearing capacity.
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 a reliable, economical, and dimensionally accurate assembly of the flange bearing shell with captive engagement of the axial bearing part on the radial part, avoiding stress buildup and maintaining component precision.
Implementation Method 1
The impact process, i.e. the caulking, takes place perpendicularly to the areal extent of the retaining tongue of the axial bearing part
Implementation Method 2
the retaining tongue engaging therein is caulked in the axial direction and thereby displaced in the circumferential direction into the undercut area of the retaining recess
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
The lining (2) has a disk shaped axial bearing part (6) fixed in an area of an axial front side (8) of a radial bearing part (4). The axial bearing part has retaining tongues (18) that are provided in contact with retaining recesses in an area of the axial front side. The retaining recesses are sectioned at the back in an axial direction (12). The tongues are fixed in the axial direction and displaced in a circumferential direction (22) in rear cut areas of the retaining recesses so that the axial bearing part is held at the radial bearing part in an undetectable manner.