Press-Formed Thrust Race Edges to Cut Roll-Over and Grinding
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Solution Overview
Problem
Conventional thrust rolling bearings experience reduced lifespan due to excessive contact surface pressure at radial end portions, and their manufacturing methods require grinding processes that increase costs and yield loss by generating shavings and roll-overs.
Innovation Solution
A press-formed product manufacturing method that involves punching, depressing, and trimming to reduce roll-overs without grinding, using a transfer or progressive working process to form the thrust race with gentler inclinations on the roll-overs, thereby reducing edge stress and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional punching process is used to manufacture the thrust race, then the manufacturing process is simple and fast, but roll-overs are generated on the inner and outer peripheral edges, requiring additional grinding processes that increase manufacturing complexity and cost
Solution Approach 1:
The punching process parameters are optimized in advance to control and minimize roll-over generation at the edges of the thrust race. By pre-setting the punch geometry, punching speed, and material properties, the roll-overs are reduced to a level that eliminates the need for subsequent grinding operations, thus maintaining high productivity while reducing process complexity
Solution Approach 2:
The punching process parameters such as punch radius, punching speed, and material hardness are adjusted to optimize the cutting process. These parameter changes allow the punching process to produce edges with acceptable roll-overs directly, eliminating the need for additional grinding steps and reducing overall manufacturing complexity
2Manufacturing precision
If a grinding process is performed to remove roll-overs, then the edge quality is improved, but material is removed in the form of shavings, reducing material yield and increasing costs
Solution Approach 1:
The punching process is optimized in advance to produce edges with minimal roll-overs that meet the required quality specifications. By pre-configuring the punch geometry and processing parameters, the material is cut with such precision that no additional material removal is needed, thereby maximizing material yield and eliminating the harmful effect of shaving generation
Solution Approach 2:
Instead of viewing roll-overs as harmful defects that must be removed, the invention converts the punching process itself to produce acceptable edge quality directly. The optimized punching process transforms what would be a harmful effect (roll-over generation) into an acceptable outcome, eliminating the need for material-removing grinding operations and improving material yield
3Volume of moving object
If the thrust raceway surface is positioned at the radial intermediate portion with chamfered portions at radial ends, then the bearing size can be reduced, but excessive contact surface pressure is applied to the radial end portions, shortening bearing life
Solution Approach 1:
The thrust race is designed with asymmetric edge features including roll-overs at the inner and outer peripheral edges. These asymmetric roll-over structures are strategically positioned to distribute contact pressure more evenly across the radial ends of the thrust raceway surface, reducing excessive stress concentration while maintaining the compact bearing size achieved through the radial intermediate portion positioning
Data Source
AI summary
A press-formed product manufacturing method includes obtaining a first piece (19, 55) by punching a metal material, obtaining a second piece (28, 50) by comprising an edge of a second surface (8) of the first piece (19, 53) sandwiching the first piece (19, 55) between a first die (25) and a second die (26), and trimming a second piece (28) by using press working.