Roller Bearing Surface Treatment With Oscillating Overlap Tracks
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Solution Overview
Problem
Conventional surface treatment methods for roller bearing components, which involve hard turning followed by ball calendering, are inefficient in achieving improved surface quality with reduced manufacturing effort, as they often result in longer, uninterrupted groove-shaped structures and require additional time.
Innovation Solution
A method that combines material removal and rolling in the same clamping setup with overlapping machining tracks, where the distance between the material removal and rolling tools is varied oscillationally, ensuring no unprocessed surface areas remain and minimizing unnecessary tool traversal, using a device with independently controllable and oscillating feed rates and directions for both tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hard turning followed by ball calendering is used, then surface treatment is achieved, but manufacturing time increases and surface quality is limited due to uninterrupted groove structures
Solution Approach 1:
The patent combines hard turning and ball calendering into a single simultaneous operation where both the material removal tool and rolling tool act on the workpiece at the same time during one clamping setup, eliminating sequential processing time while achieving both material removal and surface rolling
Solution Approach 2:
The patent segments the continuous machining track into overlapping discrete tracks by using oscillating feed rates for the rolling tool, creating multiple intersection points that break up long uninterrupted grooves into shorter segmented structures with improved surface quality
2Manufacturing precision
If conventional sequential hard turning and ball calendering are used, then surface rolling is achieved, but additional tool traversal and manufacturing effort increase
Solution Approach 1:
The patent merges material removal and surface rolling into a single simultaneous operation within one clamping setup, eliminating the need for separate sequential operations and reducing manufacturing effort while achieving both functions in one process
Solution Approach 2:
The patent ensures continuous useful action by having both tools operate simultaneously during one clamping setup, eliminating idle time and unnecessary tool re-traversal associated with sequential operations, maintaining productive action throughout the entire machining cycle
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 significantly reduces manufacturing time while achieving improved surface quality by generating numerous intersection points between machining tracks, preventing uninterrupted grooves and ensuring comprehensive processing without excessive tool re-traversal.
Implementation Method 1
A pressure medium with a hydrostatic pressure in the range from 50 bar to 400 bar acts on the ball
Implementation Method 2
a rolling process, in order to level the ridges of the roughness profile
Implementation Method 3
The subsequent rolling is also referred to as roller burnishing
Data Source
AI summary
A method for surface treatment of a workpiece includes providing the workpiece with hardened workpiece surface, clamping the workpiece, removing material from the hardened workpiece surface with a material removal tool to produce a machined surface with first machining tracks, and rolling the machined surface with a rolling tool by overlapping the first machining tracks to produce a rolled surface with second machining tracks. A distance between the material removal tool and the rolling tool measured in an axial direction of the workpiece is varied in an oscillating manner. The material removal tool may be advanced in the axial direction at a constant speed and the rolling tool may be advanced in the axial direction at an oscillating speed, or the rolling tool may be advanced in the axial direction at a constant speed and the material removal tool may be advanced in the axial direction at an oscillating speed.