Stepped Bearing Ring Press Forming With Integrated Chamfer Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing bearing elements, such as outer and inner races for radial rolling bearings, are costly and require a large number of steps and significant cutting and grinding processes, which increase production costs and complexity.
Innovation Solution
A bearing element manufacturing method that involves preparing a first piece with predetermined ring portions of different diameters, using multiple processing tools to deform and separate these portions, thereby reducing the number of steps and cutting/grinding needed, and forming chamfered portions through press forming to minimize post-treatment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for bearing elements, then manufacturing precision can be achieved, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations (forming, chamfering, and separation) into a single integrated press working process. The press working device simultaneously deforms the cylindrical material to create ring portions with different diameters, forms chamfered portions at the ends, and creates separation lines, thereby producing multiple bearing elements in one step. This merging of operations reduces the number of manufacturing steps and eliminates the need for separate cutting and grinding processes, thus lowering production costs while maintaining manufacturing precision.
Solution Approach 2:
The patent performs preliminary forming of the bearing element shape, chamfered portions, and separation lines during the initial press working stage. By pre-forming these features before final separation, the method eliminates the need for subsequent cutting and grinding operations. The chamfered portions are formed at the ends of ring portions during pressing, and separation lines are created in advance, allowing for clean separation without additional machining steps.
2Manufacturing precision
If conventional manufacturing methods with multiple steps are used, then manufacturing precision can be maintained, but the number of processing steps increases
Solution Approach 1:
The patent merges multiple discrete manufacturing steps into a single integrated press working operation. The device performs forming, chamfering, and separation line creation simultaneously during one pressing cycle, reducing the process from multiple sequential steps to a single step. This integration maintains precision by ensuring all features are created in proper registration while eliminating the complexity of coordinating multiple separate operations.
Solution Approach 2:
The press working device is designed with multi-functionality to perform various operations simultaneously: it forms the cylindrical shape, creates ring portions with different diameters, forms chamfered portions at the ends, and creates separation lines. This universal device replaces multiple specialized tools and processes, reducing the number of processing steps while maintaining the ability to achieve precise bearing element geometry.
3Manufacturing precision
If conventional methods with significant cutting and grinding are used, then bearing element quality can be ensured, but production time increases
Solution Approach 1:
The patent performs preliminary formation of all critical features during the press working stage, including the bearing element shape, chamfered portions, and separation lines. By pre-forming these features before separation, the method eliminates the need for time-consuming cutting and grinding operations that would otherwise be required to achieve the final geometry. This preliminary action maintains quality by ensuring precise feature formation while dramatically reducing production time.
Solution Approach 2:
The patent extracts and eliminates unnecessary cutting and grinding steps from the conventional manufacturing process. By using press working to form all required features directly, the method removes the extraction/separation of material through cutting and the subsequent surface finishing through grinding. This extraction of unnecessary steps maintains bearing element quality while improving production efficiency.
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 allows for the cost-effective manufacturing of bearing elements with reduced processing steps and minimized cutting/grinding, resulting in lower production costs and improved efficiency.
Implementation Method 1
a second step of obtaining a second piece by processing the first piece such that the second piece includes a third ring portion corresponding to the first ring portion and a fourth ring portion corresponding to the second ring portion
Implementation Method 2
The floating die 6c includes a stepped cylindrical inner peripheral surface and receives an upward elastic force by the elastic member 6d
Data Source
AI summary
A first piece (13) includes a first ring portion (13b) and a second ring portion (13c) which are arranged side by side in an axial direction and an inner diameter and an outer diameter of the first ring portion (13b) are respectively larger than an inner diameter and an outer diameter of the second ring portion (13c). A second piece (16) is obtained by pressing the first piece (13) while the first piece (13) is disposed between a first set and a second set.