Sheet Metal Bearing Raceway with Recesses for Low-Waste Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of raceway elements for rolling-element bearings is uneconomical, particularly for small quantities, due to the requirement of multiple machines and process steps, resulting in high costs and material wastage, and the use of thin-walled metal can lead to heavy and expensive components.
Innovation Solution
A raceway element is manufactured from a sheet metal panel using laser cutting and/or punching, which allows for the formation of recesses and surface treatments to reduce material and manufacturing costs, with the option of forming the raceway element as an inner or outer ring, and incorporating features like chamfers and alignment elements to facilitate assembly and minimize contact with rolling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deep drawing and multiple processing steps are used to manufacture raceway elements, then the raceway elements can achieve desired surface properties and material characteristics, but the manufacturing process becomes complex, time-consuming, and uneconomical particularly for small quantities
Solution Approach 1:
The raceway element is segmented into a base body and a separately attachable surface treatment layer or coating. This allows the surface properties to be applied independently from the base material formation, simplifying the manufacturing process while maintaining desired surface characteristics.
Solution Approach 2:
Surface treatment layers or coatings are applied in advance during the manufacturing process, or pre-treatment is performed on the sheet metal panel before forming. This eliminates the need for separate post-processing steps to achieve desired surface properties, reducing overall manufacturing complexity.
2Manufacturing precision
If traditional manufacturing methods with multiple machines and process steps are used, then comprehensive surface treatment can be achieved, but manufacturing time and production costs increase significantly
Solution Approach 1:
Multiple manufacturing operations are merged into a single integrated process. The sheet metal panel is formed and surface treated in one continuous operation, eliminating the need for separate deep drawing, cutting, and surface treatment machines. This significantly improves productivity while maintaining surface treatment quality.
Solution Approach 2:
The manufacturing system uses universal sheet metal forming and treatment processes that can handle various raceway element geometries and surface requirements through software control and adjustable parameters, rather than requiring dedicated equipment for each specific task.
3Quantity of substance
If thin-walled metal is used for raceway elements, then material usage and cost are reduced, but the components become heavier and more expensive
Solution Approach 1:
The raceway element uses composite construction with a lightweight base material combined with functional surface layers or coatings. This allows reduced material usage in the base structure while maintaining or enhancing performance characteristics through the surface treatments, achieving weight reduction without sacrificing strength or functionality.
Solution Approach 2:
Material thickness and surface treatment are optimized locally rather than uniformly throughout the entire raceway element. Thinner sections are used where full strength is not required, while localized reinforcement or enhanced surface treatment is applied only where needed for performance, reducing overall material usage and weight.
4Quantity of substance
If conventional manufacturing processes are used, then standard raceway elements can be produced, but material wastage and manufacturing costs increase
Solution Approach 1:
Traditional mechanical cutting and forming processes are replaced with laser-based technologies for cutting and surface treatment. Laser processing allows for more precise material removal and forming with minimal waste, enabling near-net-shape manufacturing that significantly reduces material wastage compared to conventional mechanical methods.
Solution Approach 2:
The manufacturing process utilizes controllable parameters such as laser power, speed, and focal position to optimize material utilization. By adjusting these parameters, the process achieves precise material transformation with minimal excess material generation, reducing wastage while maintaining product quality.
Data Source
AI summary
A raceway element for a rolling-element bearing, the rolling-element bearing having an inner ring, an outer ring, and a plurality of rolling elements that are disposed between the inner ring and the outer ring. The raceway element is configured as an inner ring or as an outer ring, or is configured to be attachable to an inner ring or outer ring of the bearing, wherein at least one surface of the raceway element is configured as a raceway for the rolling elements. The raceway element is formed from a sheet metal panel having at least one recess formed in the surface configured as the raceway.