Ring-Shaped Bearing Part Forming With a Thin Drawn Cup Base
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Solution Overview
Problem
Existing methods for producing rolling bearing rings result in excessive waste material due to the restriction of material flow by stepped forming tools, leading to thicker cup bases that require additional processing and increased energy consumption.
Innovation Solution
A method and device that utilize stepless forming tools to create a cup with a drawn-out cup base and adjoining stepless cup wall, allowing for simultaneous or separate separation of inner and outer ring-shaped sections, reducing material hindrance and waste material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stepped forming tools are used to produce ring-shaped sections, then the forming process can create separated inner and outer rings, but the material flow is restricted and the cup base cannot be drawn out thinly enough
Solution Approach 1:
The forming process is divided into two distinct stages: first forming a cup with a thin drawn-out base using a stepless punch, then subsequently forming the ring-shaped sections by introducing a stepped punch. This segmentation allows the cup base to be drawn out thinly without material flow restriction, minimizing waste material while still enabling proper ring separation in the second stage.
Solution Approach 2:
The cup base is drawn out to its final thin shape in the first forming stage before the ring-shaped sections are formed. This preliminary action ensures the cup base achieves maximum thinness without interfering with subsequent ring formation, as the stepped punch is introduced only after the thin base is already in place.
2Manufacturing precision
If stepped forming tools are used, then ring-shaped sections can be formed, but additional processing steps are required and energy consumption increases
Solution Approach 1:
The invention merges the formation of the thin cup base and the ring-shaped sections into a single integrated forming process using a combined punch design. The punch has both a stepless portion (for forming the thin base) and a stepped portion (for forming the rings), allowing both features to be created in one operation rather than requiring separate processing steps, thereby reducing energy consumption.
3Shape
If stepped forming tools are used, then the forming process can create the required geometry, but the material flow is hindered and the cup base thickness cannot be minimized
Solution Approach 1:
The punch is segmented into a stepless portion and a stepped portion. The stepless portion allows unrestricted material flow during the initial cup formation, enabling the material to flow smoothly and form a thin drawn-out base without hindrance. The stepped portion is then introduced to form the ring-shaped sections, achieving both free material flow for thin base formation and proper ring geometry.
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
The method achieves a thinner cup base, minimizing waste and energy consumption while enabling efficient further processing into rolling bearing rings.
Implementation Method 1
a shaped blank is produced from a blank by cup extrusion... the two ring-shaped sections and the cup base are shaped from the blank in one forming step
Data Source
AI summary
A method for producing an inner and an outer ring-shaped formed part from a blank includes the step of cup extrusion of the blank to form a cup having a drawn-out cup base and an adjoining stepless cup wall and the step of forming the cup wall in such a way that the formed cup wall includes an inner ring-shaped section and an adjoining outer ring-shaped section which is partly offset in an axial direction. The method further includes the step of separating the outer ring-shaped section from the inner ring-shaped section and separating the inner ring-shaped section from the drawn-out cup base, the detached outer ring-shaped section constituting the outer ring-shaped formed part and the detached inner ring-shaped section constituting the inner ring-shaped formed part.