Powder Forged Composite Bearing Ring with Ferrous Raceway
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Solution Overview
Problem
Existing methods for manufacturing bearing rings fail to securely and integrally form raceway surfaces with excellent abrasion resistance using lightweight materials, limiting the production of durable and lightweight bearing rings.
Innovation Solution
A method involving powder forging, where a raceway surface formation ring made from a high-abrasion-resistant material is integrated with a lightweight material ring body using a forging die, allowing for precise positioning and forming of the raceway surface on the outer or inner peripheral surface, and subsequent surface finishing treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a bearing ring is manufactured using lightweight materials, then the weight is reduced, but the abrasion resistance of the raceway surface deteriorates
Solution Approach 1:
The patent applies composite materials by combining a lightweight base material (aluminum alloy or other light alloy) with a ferrous material layer that has superior abrasion resistance. The raceway surface formation portion is made from ferrous material while the remaining portion is made from lightweight material, creating a composite structure that achieves both weight reduction and maintained abrasion resistance.
Solution Approach 2:
The patent applies local quality by providing different material properties in different regions of the bearing ring. Specifically, the raceway surface formation portion (where rolling elements contact) is made from ferrous material with high abrasion resistance, while the remaining portion of the bearing ring is made from lightweight material. This localized material assignment optimizes both weight and performance.
2Weight of moving object
If a composite bearing ring is manufactured by integrating different materials, then weight is reduced and abrasion resistance is maintained, but the manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining the formation of the lightweight base material and the ferrous material raceway surface portion into a single integrated manufacturing process. The powder forging process simultaneously forms both materials in one operation, eliminating the need for separate manufacturing and assembly steps that would increase complexity.
Solution Approach 2:
The patent uses composite materials approach to integrate different materials (lightweight alloy and ferrous material) into a single composite bearing ring structure that can be manufactured in one process, reducing the need for multiple manufacturing steps and assembly operations.
3Reliability
If a raceway surface formation portion is made from ferrous material with high abrasion resistance, then durability is improved, but the overall weight of the bearing ring increases
Solution Approach 1:
The patent applies local quality by restricting the ferrous material with high abrasion resistance only to the raceway surface formation portion where it is most needed for durability, while the remaining portion of the bearing ring is made from lightweight material to minimize weight. This localized application of high-performance material optimizes the durability-to-weight ratio.
Solution Approach 2:
The patent uses composite materials to combine ferrous material in the raceway surface portion with lightweight material in the remaining portion, creating a structure that achieves high durability where needed while maintaining overall light weight through the strategic use of different materials in different regions.
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 enables the creation of highly durable and lightweight bearing rings by effectively combining materials with superior abrasion resistance and hardness, enhancing the bearing's performance and reducing weight.
Implementation Method 1
manufacturing an annular composite member in which the raceway ring main body portion is formed integrally with the raceway surface formation ring by performing powder forging using a powder of the first material while the raceway surface formation ring is fixed in a forging die
Data Source
AI summary
An outer ring of a cross roller bearing is a composite component having an outer ring main body portion constructed of a lightweight metal alloy and a raceway surface formation portion linked to an inner side thereof and constructed of a ferrous material. A ring for forming the raceway surface formation portion is preformed, and is inserted into a forging die, powder forging is performed using a metal powder for manufacturing the outer ring main body portion, a composite component is manufactured in which a ringshaped portion for forming the outer ring main body portion is integrally formed with the raceway surface formation ring, and an after-treatment is performed on the product.