Offset Thrust Bearing Segments Reduce Embossing Force
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Solution Overview
Problem
Existing thrust bearings in turbochargers face challenges with material deformation and wear during deep embossing, leading to high tool wear and the need for excessive force, limiting material choices and embossing depths due to material hardening when displacing material.
Innovation Solution
The thrust bearing features segments on opposing sides that are at least partly offset, reducing material displacement and hardening, allowing for lower tool wear, reduced embossing force, and increased embossing depths, enabling the use of less formable materials and providing design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep embossing is used to create segments on thrust bearing surfaces, then segment geometry and bearing functionality are improved, but material hardening occurs leading to increased tool wear and higher embossing forces
Solution Approach 1:
The patent applies asymmetry by offsetting the arrangement of segments on opposite sides of the thrust bearing. Instead of symmetric positioning where segments directly oppose each other, the segments are deliberately misaligned so that they do not coincide. This asymmetric configuration reduces the volume of material that must be displaced during embossing, thereby reducing material hardening, tool wear, and required embossing forces while still achieving the desired segment geometry for bearing functionality.
2Manufacturing precision
If greater embossing depth is achieved, then segment definition and load distribution are improved, but more material must be displaced causing increased tool wear and embossing force requirements
Solution Approach 1:
The asymmetric offset arrangement of segments reduces the total material displacement volume during embossing. By positioning segments so they do not directly oppose each other, the embossing tool encounters less resistance and material hardening, enabling greater embossing depths to be achieved with reduced embossing forces and lower tool wear.
3Adaptability or versatility
If materials with lower formability are used, then material selection flexibility is improved, but deep embossing becomes more difficult due to material hardening
Solution Approach 1:
The asymmetric offset segment arrangement reduces material displacement requirements during embossing. This modification to the segment configuration allows materials with lower formability to be successfully embossed to the required depths, expanding material selection flexibility while avoiding the excessive material hardening that would otherwise occur with symmetric segment positioning.
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 offset arrangement reduces material deformation and hardening, enabling deeper embossing with less force, lower tool wear, and greater design freedom, while allowing the use of previously unsuitable materials, enhancing the thrust bearing's performance and versatility.
Implementation Method 1
The solidification of the material by the deformation however presents problems at this point. The more strongly the material must be moved or the more material has to be forced to the side, the harder the material becomes.
Data Source
AI summary
The invention relates to an axial bearing (10) comprising at least one or more segments (18) on each of the front side (22) and the rear side (26) thereof, wherein the segments (18) on the opposite sides (22, 26) each are disposed at least partially offset from each other.