Tapered Roller In-Feed Machining Using Truncated Cone Rollers
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Solution Overview
Problem
In the production of tapered rollers for rolling bearings, existing machining apparatuses face challenges with adjusting drums for different sizes, maintaining worn-out drum surfaces, and preventing sudden slips during in-feed machining, which can damage the outer peripheral surface.
Innovation Solution
An in-feed machining apparatus with a rotating mechanism featuring a pair of truncated cone-shaped rollers and a vibrating grinding stone, where the rollers' peripheral velocities are adjusted to match the tapered roller's, reducing the likelihood of sudden slips and facilitating easy adjustment and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the through-feed machining apparatus uses drums to feed tapered rollers, then high productivity is achieved, but the drums are heavy and difficult to adjust when changing workpiece sizes
Solution Approach 1:
The invention replaces static drums with dynamic rollers that can be easily adjusted in position and orientation. The rollers are designed to be movable along the workpiece axis and can be repositioned quickly for different tapered roller sizes, eliminating the heaviness and adjustment difficulty of traditional drums while maintaining continuous feeding capability
Solution Approach 2:
The invention divides the single drum structure into multiple separate rollers. Instead of one large drum that feeds multiple workpieces simultaneously, the invention uses multiple individual rollers that can be independently adjusted and positioned, making the system more flexible and easier to operate for different workpiece sizes
2Productivity
If the through-feed machining apparatus uses drums with spiral grooves, then tapered rollers are fed continuously, but maintenance becomes difficult when grooves wear away
Solution Approach 1:
The invention uses simple cylindrical rollers without complex spiral grooves. These rollers can be easily replaced or reconditioned when worn, as they lack the intricate groove structures that make drum maintenance difficult. The simplicity of the roller design makes them more economical and easier to maintain over time
Solution Approach 2:
The invention extracts the feeding function from the complex drum structure and implements it through simpler rollers. The spiral groove feeding mechanism is replaced by direct contact and friction-based feeding through cylindrical rollers, eliminating the maintenance burden of groove machining while preserving continuous feeding capability
3Device complexity
If the in-feed machining apparatus uses cylindrical rollers, then the apparatus structure is simple, but sudden slips occur between rollers and tapered roller causing surface damage
Solution Approach 1:
The invention uses tapered rollers instead of cylindrical rollers, creating an asymmetric contact geometry. The conical shape provides a larger contact area and better conformal contact with the tapered roller workpiece, increasing friction and preventing sudden slips while maintaining relatively simple apparatus structure
Solution Approach 2:
The invention changes the geometric parameters of the rollers from cylindrical to tapered shapes. This parameter change increases the contact area and improves the mechanical grip on the workpiece, preventing slips that would occur with cylindrical rollers while keeping the overall device complexity manageable
4Manufacturing precision
If different drums are used for different tapered roller sizes, then machining precision is maintained, but adjustment time increases significantly
Solution Approach 1:
The invention designs universal rollers that can accommodate multiple tapered roller sizes through simple repositioning and adjustment, rather than requiring dedicated drums for each size. The rollers can be moved along the workpiece axis and repositioned to maintain proper contact geometry for different dimensions, preserving machining precision while dramatically reducing changeover time
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 apparatus effectively suppresses sudden slips, allows for efficient machining of tapered rollers with varying sizes, and simplifies maintenance, ensuring high-quality surface finishing and reduced defect rates.
Implementation Method 1
a grinding stone that is brought into contact with an outer peripheral surface of the tapered roller mounted on the pair of rollers
Implementation Method 2
when the rotating tapered roller performs an unstable behavior, the grinding stone may damage the outer peripheral surface of the tapered roller. Specifically, when a (sudden) slip occurs between the pair of rollers and the tapered roller
Data Source
AI summary
A machining apparatus is of an in-feed type configured to machine an outer peripheral surface of a rotating tapered roller, and includes a rotating mechanism having a lateral pair of rollers on which the tapered roller is mounted, the rotating mechanism rotating the pair of rollers, and a grinding stone that is brought into contact with the outer peripheral surface of the tapered roller mounted on the pair of rollers. Each roller of the pair of rollers is shaped like a truncated cone. Small-diameter portions of the pair of rollers come into contact with a small-diameter portion of the tapered roller. Large-diameter portions of the pair of rollers come into contact with a large-diameter portion of the tapered roller.