Flow Forming Bearing Rings with Spiral Lubricant Channels
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Solution Overview
Problem
The existing methods for producing bearing rings are labor-intensive and costly due to multiple work steps, significant material loss during machining, and the need for numerous tools, which increases production costs and reduces material strength.
Innovation Solution
A method using pressure rolling to form a bearing ring blank with a spinning mold having a negative structure, allowing for the creation of complementary positive structures without material loss, reducing the number of work steps, and incorporating a spiral design for lubricant channels, thereby simplifying the production process and enhancing strength through strain hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional machining methods (turning, honing) are used to produce bearing rings, then bearing rings can be manufactured with existing technology, but material loss is significant and production costs are high
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive machining to flow forming. The blank is formed by plastic deformation under controlled pressure and temperature conditions, transforming the material rather than removing it. This eliminates material loss while maintaining manufacturing feasibility through controlled parameter adjustment.
Solution Approach 2:
The patent replaces traditional mechanical machining systems (lathes, honing machines) with a flow forming system that uses controlled plastic deformation. The forming rollers and molds create the bearing ring geometry through material flow rather than chip removal, substituting a fundamentally different mechanical approach that eliminates material waste.
2Productivity
If multiple work steps including soft machining are used, then bearing rings can be produced with required precision, but the number of work steps increases and production time increases
Solution Approach 1:
The patent merges multiple separate work steps (blank preparation, forming, and finishing) into a single integrated flow forming process. The forming rollers and molds perform multiple functions simultaneously - shaping the blank, creating surface structures, and achieving final dimensions in one continuous operation, thereby eliminating sequential processing steps and reducing production time.
Solution Approach 2:
The patent incorporates preliminary action by pre-heating the blank to optimal temperature before forming. This preliminary thermal treatment prepares the material for plastic deformation, allowing the subsequent forming operation to proceed efficiently without requiring additional heating steps during the actual forming process, thus reducing total production time.
3Device complexity
If traditional machining methods are used, then bearing rings can be produced, but the number of tools and machines required increases and tool costs increase
Solution Approach 1:
The patent implements universality through the flow forming system where a single set of forming rollers and molds can produce different bearing ring geometries by changing the mold configuration or forming parameters. This multi-functional system replaces multiple specialized machining tools, reducing the total number of tools required while maintaining manufacturing flexibility and simplicity.
4Reliability
If bearing rings are machined by turning or honing, then bearing rings can be produced with required dimensions, but crack formation occurs at stress-concentrated points
Solution Approach 1:
The patent changes the manufacturing process from high-stress machining operations to controlled plastic deformation at elevated temperatures. This parameter change allows the material to flow into the final geometry without the localized stress concentrations that cause cracking during machining, while still achieving precise dimensional control through the constrained forming process between rollers and molds.
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 results in a cost-effective, simplified production process with reduced tool requirements, increased strength, and the ability to form complex structures like spiral lubricant channels, which were previously difficult to achieve, while minimizing material loss and crack formation at stress-concentrated points.
Implementation Method 1
pressure rolling means forming a blank by means of at least one forming roller, with the blank being pressed at least once against at least one spinning mold having a negative structure
Implementation Method 2
bearing rings can be realized with a higher strength, which results from the strain hardening of the near-surface bearing ring areas, since the flow-forming process takes place without additional heating of the blank
Data Source
Figure 1A~1E
Figure 2~3
Figure 4~5
AI summary
A method for manufacturing a bearing ring (26) of a rolling or sliding bearing having an inner surface (44) and an outer surface (50) by means of flow forming is disclosed, wherein the inner surface (44) and/or the outer surface (50) of the bearing ring (26) has at least one structure, and wherein the method comprises the following steps: a) inserting a blank (6) made of bearing steel into a flow forming machine; b) flow forming the blank (6) in a circumferential, axial and/or radial direction against a die (8) by means of at least one forming roll (32), wherein the die (8) has at least one negative structure (10); and c) forming a positive structure (36) complementary to the negative structure (10) of the die (8) on the inner surface (44) and/or outer surface (50) of the bearing ring (26) by forming the negative structure (10) during flow forming.