Flanged Inner Ring Conical Edge Orbital Forming
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Solution Overview
Problem
The existing orbital forming process for wheel hub units requires high forces to deform the flanged inner ring, leading to excessive deformation and increased radial diameter, which is inefficient and can cause fissures and assembly issues.
Innovation Solution
Optimization of the flanged inner ring's rolling edge with a conical surface and the orbital forming tool's pressing surface, reducing the energy needed for deformation by controlling the conicity and geometry of the rolling edge and tool design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high pressing force is applied to deform the rolled edge during orbital forming, then the desired preloading of the inner ring is achieved, but the radial outer diameter of the inner ring increases significantly causing deformation issues
Solution Approach 1:
The patent changes the geometric parameters of the pressing surface, specifically optimizing the opening angle γ to be between 60° and 90°, and adjusting the radius R1 of the pressing surface. These parameter changes allow the pressing force to be more effectively directed, achieving the required deformation while minimizing the increase in radial outer diameter of the inner ring.
Solution Approach 2:
The pressing surface is designed with a specific curved geometry characterized by radius R1, which optimizes the distribution of pressing forces. This curvature allows for more uniform deformation of the rolled edge while reducing concentrated stresses that would otherwise cause excessive radial expansion of the inner ring.
2Device complexity
If conventional orbital forming tool geometry is used, then the tool structure is simple, but excessive force is required leading to high energy consumption and reduced tool life
Solution Approach 1:
The patent optimizes geometric parameters of the tool including the opening angle γ (60°-90°) and radius R1 of the pressing surface. These changes improve the mechanical efficiency of the forming operation, reducing the force required and thereby lowering energy consumption while extending tool life through more favorable stress distributions.
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 approach reduces the force required for deformation, minimizes the increase in the radial diameter of the inner ring, enhances retention force, and extends tool life while reducing power consumption and costs.
Implementation Method 1
the rolling edge 25 has been optimized in order to improve the orbital forming operation... the rolling edge 25 defines... a conical surface 27 which, widening outwards from an inner hole 26
Data Source
AI summary
Flanged inner ring of a rolling bearing forming part of a wheel hub unit of motor vehicles, having at its axially inner end a rolling edge configured to preload axially a radially inner ring after being plastically deformed by orbital forming. The rolling edge is provided with a conical surface of an axially inner portion of the rolling edge. A first parameter is defined as being the ratio between the conicity of the conical surface expressed in degrees and the thickness of the rolling edge expressed in millimeters and assumes values ranging between 0.03 mm−1 and 2 mm−1.