Flanged Bearing Ring with Interlocking Composite Structure
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Solution Overview
Problem
Existing motor vehicle wheel bearing rings face challenges in achieving weight reduction without compromising strength and safety, particularly in maintaining effective connections between different materials under varying temperature conditions.
Innovation Solution
A flanged bearing ring composed of two materials joined as a single piece, featuring a radially inner insert made of a hard material and a radially outer body made of a lightweight material, with interlocking means such as radially recessed and protruding portions to prevent axial and rotary movement, and utilizing a semi-solid casting process for enhanced strength and thermal expansion management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bearing ring is made of conventional bearing steel to ensure strength and safety, then the mechanical performance and durability are improved, but the weight increases
Solution Approach 1:
The bearing ring is divided into two distinct portions: an inner portion made of hard material (bearing steel or ceramic) and an outer portion made of lightweight material (aluminum or magnesium alloy). This segmentation allows each portion to contribute its optimal properties - the inner portion provides strength and raceway functionality while the outer portion reduces overall weight.
Solution Approach 2:
The invention combines two different materials with complementary properties into a single integrated bearing ring structure. The hard material (steel or ceramic) provides wear resistance and structural integrity for the raceways, while the lightweight material (aluminum or magnesium alloy) provides weight reduction and heat dissipation, creating a composite structure that optimizes both strength and weight.
2Weight of moving object
If a bearing ring is made of lightweight material to reduce weight, then the weight decreases, but the strength and ability to resist rolling contact stresses deteriorates
Solution Approach 1:
The bearing ring is divided into two distinct portions: an inner portion made of hard material (bearing steel or ceramic) and an outer portion made of lightweight material (aluminum or magnesium alloy). This segmentation allows each portion to contribute its optimal properties - the inner portion provides strength and raceway functionality while the outer portion reduces overall weight.
Solution Approach 2:
The invention combines two different materials with complementary properties into a single integrated bearing ring structure. The hard material (steel or ceramic) provides wear resistance and structural integrity for the raceways, while the lightweight material (aluminum or magnesium alloy) provides weight reduction and heat dissipation, creating a composite structure that optimizes both strength and weight.
3Weight of moving object
If two different materials are joined to form a bearing ring, then weight reduction is achieved, but the connection stability under varying temperature conditions deteriorates
Solution Approach 1:
The invention accounts for differential thermal expansion between the two materials by designing interlocking means with complementary protrusions and recesses that maintain mechanical engagement across temperature ranges. The geometry of these interlocking features is specifically designed to accommodate expansion and contraction while preventing relative movement between the inner and outer portions.
Solution Approach 2:
The interlocking means incorporate curved or tapered surfaces that allow for thermal expansion accommodation while maintaining mechanical interlock. The geometry of the protrusions and recesses is designed to maintain contact and prevent relative movement even when the materials expand or contract at different rates due to temperature changes.
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 achieves a lower weight while maintaining high strength capabilities, ensuring effective connection and stability across all temperature conditions, thereby addressing the need for weight reduction without compromising safety or performance.
Implementation Method 1
The second material is joined to the first material by a semi-solid casting process
Implementation Method 2
The insert is made of a first material with a first thermal expansion coefficient. The outer body is made of a second material with a second thermal expansion coefficient higher than that of the first material
Data Source
AI summary
A flanged bearing ring is made up of two different materials joined together as a single piece, namely a radially inner annular insert and a flanged, radially outer lightweight body formed around the insert. The insert forms one or more raceways and is made of a hard material, such as bearing steel. The outer body is made of a lightweight material, such as aluminium alloy, with a higher thermal expansion coefficient higher than that of the hard material which the inner insert is made of. A relief formed by the insert extends into a groove of the outer body. Another relief, formed by the outer body, extends into a further groove of the insert. These reliefs and grooves interlock the insert and the outer body together against relative movement under all temperature conditions.