Forged Flanged Inner Ring for Wheel Hub Bearings

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Solution Overview

Problem

Existing flanged wheel hubs for wheel hub bearings face challenges in mass production due to difficulties in machining the outer chamfer, which can lead to increased production times and costs, as well as issues with oscillation and burrs during assembly with the brake disk.

Innovation Solution

A flanged inner ring design where the outer chamfer is forged instead of machined, with specific parameters such as a base axial thickness greater than 7 mm, a chamfer length between 1.5 mm and 2.5 mm, and an angle between 25° and 35°, allowing for a single-piece forging of the flange and radial arms, eliminating the need for stock removal machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stock removal machining is used to form the outer chamfer, then the chamfer can be created, but production time increases and machining difficulties arise

Engineering Contradiction:

Improvechamfer formationVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Instead of removing material to create the chamfer (stock removal machining), the patent inverts the approach by forming the chamfer directly through forging during the initial manufacturing process. This eliminates the need for subsequent machining operations, directly resolving the contradiction between ease of manufacture and productivity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The chamfer is formed in advance during the forging process before the bearing is assembled with the brake disk. This preliminary action prevents the need for critical machining operations later, reducing production time and avoiding the harmful effects of burrs and oscillation that occur during post-assembly machining.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If stock removal machining is used to form the outer chamfer, then the chamfer can be created, but machining costs increase

Engineering Contradiction:

Improvechamfer formationVSAvoidmachining complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent inverts the traditional machining approach by using forging to create the chamfer directly. This eliminates complex machining operations, tooling requirements, and associated costs, while simplifying the manufacturing process into a single integrated forging step.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If stock removal machining is used to form the outer chamfer, then the chamfer can be created, but oscillation and burrs are generated

Engineering Contradiction:

Improvechamfer formationVSAvoidburrs and oscillation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The chamfer is formed in advance during the forging process when the material is still pliable and can be shaped without generating burrs. This preliminary action eliminates the harmful effects of burrs and oscillation that occur when machining is performed after the bearing is in contact with the brake disk.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the potential harm of material removal (which causes burrs and oscillation) into a benefit by using the forging process to positively form the chamfer. The forging process shapes the material additively rather than subtractively, eliminating burr generation and oscillation issues.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 production time and costs by avoiding critical machining operations while minimizing oscillation and burr issues, optimizing the weight and mechanical strength of the wheel hub bearing.

Implementation Method 1

the flanged inner ring being forged in one piece together with the flange and the radial arms

Methodology Applied

Scientific EffectForging:

Implementation Method 2

a sector having a forged chamfer along its outer surface

Methodology Applied

Scientific EffectForging:

Data Source

PatentUS10767700B2Flanged inner ring for wheel hub bearings

Publication Date: 2020.09.08 AB SKF SKF PATENT DEPARTMENT

AI summary

A flanged inner ring for wheel hub bearings, the inner ring comprising a tubular body supporting the bearing, the body being coaxial with an axis (A), and a flange, which is transversal to the axis (A), the flange being provided with a plurality of threaded through holes that are distributed around the axis (A) and includes: —an outer annular mounting surface and an inner surface that is axially faced towards an outer ring of the bearing; the flange having a respective base axial thickness (SAF) and comprising for each threaded through hole, a respective radial arm which is arranged on the inner surface of the flange facing the outer ring; the inner ring being forged in one piece together with the flange and the radial arms. Between each pair of adjacent arms there is a flower-shaped sector with a chamfer made by forging along the outer surface thereof.