Roller Bearing Raceway Ring Laser Cladding Hardening
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Solution Overview
Problem
Existing methods for manufacturing rolling bearing rings face challenges in achieving sufficient surface hardness for both the rolling element guide surfaces and other critical areas like fitting and positioning surfaces, while also being cost-effective and environmentally friendly.
Innovation Solution
A rolling bearing ring design that includes a base member with a cladded layer covering the outer and inner circumferential surfaces and side surfaces, along with a hardened layer formed over the entire circumference of the base member's surface layer portions separated from the cladded layer, using laser cladding and laser hardening processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bearing ring is made of hard metal such as high chromium bearing steel that can be made extremely hard by heat treatment, then the rolling element guide surface has excellent peel life and wear resistance, but the material cost of the bearing ring will increase
Solution Approach 1:
The patent applies local quality by forming a hardened layer only on specific surfaces of the base member that require enhanced hardness (rolling element guide surfaces, fitting surfaces, and positioning surfaces) while leaving other portions of the base member with standard material properties. This is achieved through selective laser hardening or cladding processes, allowing the bearing ring to have high reliability where needed without incurring the full material cost of making the entire ring from hard metal.
Solution Approach 2:
The patent uses composite materials by combining a base member made of cost-effective material (such as carbon steel or stainless steel) with a hardened layer made of high-hardness material formed on its surface through laser cladding or laser hardening. This composite structure provides the benefits of both materials: the cost advantage of the base material and the performance advantage of the hardened surface layer, thereby reducing overall material cost while maintaining excellent peel life and wear resistance.
2Reliability
If heat treatment is performed using a heat treatment furnace to make the bearing ring extremely hard, then the rolling element guide surface has excellent peel life and wear resistance, but the equipment and operation costs for performing the heat treatment will increase
Solution Approach 1:
The patent replaces the traditional heat treatment furnace system with a laser-based surface hardening or cladding system. Instead of heating the entire bearing ring in a furnace, the laser process applies localized energy to form or harden only the necessary surfaces. This substitution eliminates the need for expensive heat treatment furnace equipment and reduces operation costs while achieving the same or better hardening效果 on critical surfaces.
Solution Approach 2:
The patent segments the heat treatment process into localized zones, treating only the specific surfaces that require hardness enhancement (rolling element guide surfaces, fitting surfaces, positioning surfaces) rather than heating the entire bearing ring. This is achieved through selective laser application, which divides the treatment into discrete spatial zones, reducing energy consumption and eliminating the need for large-scale furnace equipment.
3Quantity of substance
If a cladded layer made of Ni-based alloy is formed on the base member by laser cladding to ensure sufficient hardness of the raceway surface, then the manufacturing cost of the bearing ring can be suppressed, but the hardness of parts other than the raceway surface is not sufficiently ensured
Solution Approach 1:
The patent applies universality by designing a manufacturing process that performs multiple functions in sequence: first forming a cladded layer on the base member to provide cost-effective raceway surface hardness, then performing additional laser hardening on the cladded layer and/or base member to ensure sufficient hardness on fitting surfaces and positioning side surfaces. This multi-functional approach ensures all critical surfaces achieve the required hardness while maintaining cost efficiency through selective material application.
Solution Approach 2:
The patent applies preliminary action by first forming the cladded layer on the base member to establish a cost-effective foundation with adequate raceway surface properties, then subsequently applying laser hardening to the cladded layer and/or base member to enhance hardness on fitting and positioning surfaces. This sequential approach allows the cheaper cladded layer to serve as the primary material solution, with targeted hardening applied only where additional hardness is required, thereby suppressing overall manufacturing cost while ensuring sufficient hardness across all critical surfaces.
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 ensures sufficient surface hardness for both the rolling element guide surfaces and other critical areas, reducing material and equipment costs while minimizing environmental impact by eliminating the need for heat treatment furnaces.
Implementation Method 1
a cladded layer made of a metal material, which is to be used as a rolling element guide surface, is formed on the base member by laser cladding
Implementation Method 2
a hardened layer is formed over the entire circumference of a surface layer portion that includes at least one part of a surface of the base member that is separated from a section covered by the cladded layer
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3
AI summary
[Problem] To provide a manufacturing method capable of obtaining at low cost a rolling bearing ring in which the hardness of not only of the rolling element guide surface, but also of surfaces of predetermined areas separated from the rolling element guide surface is sufficiently ensured. [Solution] The manufacturing method includes: a step of obtaining a base member 12; a step of forming, by laser cladding, a cladded layer 13a, 13b made of a metal material having a higher hardness than a portion of the base member 12 that is separated from a hardened layer 14, on one surface of the outer circumferential surface, the inner circumferential surface, and side surfaces on both sides in the axial direction of the base member 12; a step of forming a surface layer portion of the rolling element guide surface 8, 9 by finishing the surface of the cladded layer 13a, 13b; and a step of forming, by laser hardening, a hardened layer 14 over the entire circumference of a surface layer portion of the base member 12 including at least one part of a portion that is separated from the section covered by the cladded layer 13a, 13b.