Flanged Inner Ring Conical Surface Orbital Forming
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Solution Overview
Problem
The existing flanged inner ring of wheel hub assemblies experiences significant deformation and increased diameter during the orbital forming process due to high loads applied by the press tool, leading to undesirable tension and preload effects on the inner ring.
Innovation Solution
A flanged inner ring with a tubular portion optimized for orbital forming, featuring a conical preloading surface that minimizes radial deformation and controls axial preload, allowing for a gradual material flow and distribution of thrust forces, thereby reducing the radial component of the forming tool's action and maintaining the inner ring's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a press tool exerts very high load on the rolled edge to achieve desired deformation and preloading, then the edge deformation and preload are improved, but the inner ring diameter increases significantly and the inner ring experiences unwanted tension and deformation
Solution Approach 1:
The invention introduces a conical preloading surface with a specific angle (α) between 10° and 45° on the rolled edge of the inner ring. This localized geometric feature concentrates the preloading action on a specific area, allowing the press tool to apply high load effectively for preload while the conical geometry controls the distribution of forces to minimize unwanted radial expansion and diameter increase of the inner ring.
2Reliability
If the press tool applies high load to close and preload the bearing unit, then the bearing unit closure and preload are achieved, but the radial component of the forming tool's action increases causing excessive deformation
Solution Approach 1:
The invention changes the geometric parameter of the rolled edge by introducing a conical preloading surface with a controlled angle (α). This parameter change transforms the force distribution during orbital forming, converting a significant portion of the axial pressing force into radial preloading force through the conical geometry, thereby reducing the radial component that causes unwanted deformation while maintaining effective bearing unit closure.
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 design reduces the deformation of the inner ring and optimizes the axial preload, minimizing the increase in the outer diameter of the inner ring while ensuring effective closure and preloading of the bearing unit.
Implementation Method 1
an orbital forming operation is performed by means of a press tool... the press tool exerts a very high load on a rolled edge of the hub or the flanged inner ring... to obtain a desired deformation of an edge
Data Source
AI summary
A flanged inner ring, and methods of forming the same, having a rolling edge configured to preload axially a radially inner ring of a rolling bearing after being plastically deformed; the rolling edge including a diameter of increasing variable size along an axis (X) of symmetry of the flanged inner ring and, wherein the increasing variable size increases along the axis (X) in a direction away from the radially inner ring, and the rolling edge includes an outer preloading surface configured such that in a deformed configuration the outer preloading surface is arranged against the radially inner ring and such that in an undeformed configuration the outer preloading surface is inclined away from the axis (X) of symmetry of the flanged inner ring.