How are ball bearings made? Production of bearings: how and from what they are made, a description of the technology

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The perfect shape of the ball in the bearings arouses admiration and justified interest in the production method. The surface of the product is perfectly smooth, the shape is perfectly round. The question of how balls are made for bearings has a detailed answer.

A complex technological process turns the steel wire into a ball of the required diameter. Each stage of production is verified, because the product, on which the stable and reliable operation of complex mechanisms depends, must have precisely specified parameters. The development of technology leads to the gradual replacement of familiar designs, machines with newer and more advanced ones. But bearings remain a popular and relevant part of the design of cars, factory machines, and various devices.

In order to understand how balls are made for bearings, you need to trace all the stages of technological progress.

Steel wire is cut into blanks, which are characterized by a shape close to the ball. A wire is used, which in diameter corresponds to the parameters of the ball. Then, between disk matrices with special grooves, these blanks are rolled, the initially rough shape of the ball becomes more pronounced. Huge pressure is used for processing, up to 20 tons. After such a running-in, the spherical blank has parameters that are only 100 crowns away from the required dimensions.
Forming, which can be cold or hot, is an important step in the production of balls. The wire is passed through a heading machine, in which there are special recesses in the form of a ball. Steel discs are closed around the wire and the result is a workpiece in the form of balls with a rim. Then these balls are heated, hardened. Parts are annealed to ensure high strength and reliability.
The next step is grinding the balls. In order to understand how balls for bearings are made, you need to carefully study all the steps. At the grinding stage, the accuracy of the dimensions of the parts is up to 10 microns from the required one. Those rims that remain after the heading machine are separated from the balls. To do this, the ball is placed between two very thick sheets of metal, one of which is stationary, and the other rotates. Circular movements of the second sheet grind the ball. The polished products are separated from the rest through special holes. They pass through several chutes and are thus sorted by size. A machine is also used, which gives shine to finished products. The main final result is the production of balls of perfectly accurate size and high hardness.
The final stage - the balls are washed, quality controlled, packed.

The process is complex and requires special equipment. Quality bearings should have balls with perfect sliding, which will give a completely smooth shape. The ball is responsible for the operation of the bearing (), any extra micron can affect it. Therefore, it is especially important to control the size of the ball, the smoothness of its surface. Be sure to select high-quality steel wire for production.

The rotation unit is an important part that provides rolling or linear movement, it serves as a support or stop for a movable structure. On the territory of the Russian Federation, more and more bearing manufacturing plants are being built. This becomes a profitable business, since such parts are used in all sectors of the national economy (heavy and light industry, ship and automotive industry, agriculture).

Methods and stages of production

There are two main types: sliding and rolling. We will consider steel products, where the elements that facilitate rotation are balls. This is the most sought after type. They are divided into radial and persistent. The difference lies in the fact that the former compensate for loads directed perpendicular to the shaft, while the latter are responsible for axial displacement.

The part consists of an outer and inner cage, metal elements and a device that ensures their correct distribution along the perimeter. For units operating in conditions of increased pollution, a dust washer is installed on one or both sides. It prevents the ingress of abrasive particles from the outside and limits the space in which the lubricant is located.

Bearing production technology begins with the preparation of the required steel grade. The plant receives metal of a certain grade in the form of round bars.

Initially, consider the issue of making clips:

. Round steel is cut by an automatic line according to the dimensions required for this type.
. A hole is made in a cylindrical billet by a press. The result is a rough puck.
. This is followed by the rolling process. In this case, the part acquires parameters and a shape roughly similar to the final product.
. The next step is turning. On the machine with numerical control, the outer and side surfaces are formed, a groove along which the rolling elements will move.
. Next, the phase of giving the workpiece the necessary physical qualities follows. In most cases, this is done by hardening. First, it is heated to 850 degrees, then abruptly cooled to a temperature of 40 to 50 ° C and tempered. In a special chamber, the part is heated to 170 and allowed to cool slowly.
. Bringing to the required size by grinding. On machines in automatic mode, all parameters are finalized to an accuracy corresponding to GOST.
. The last stage is the polishing of all surfaces to a clarity class of 0.06.

materials

An important question for production is, what steel are the bearing races made of? The most common material has a brand:

. SHH15;
. SHKH15SG;
. SHH20SG;
. ШХ4.

They differ in the content of technological additives. The composition includes magnesium, silicon, carbon, chromium in sizes up to 2 percent and impurities of sulfur, phosphorus, nickel, copper in a very limited amount. Hardness is acquired by heat treatment.

For products that can withstand heavy loads, it is necessary to have a strong contact surface and a plastic middle. In this case, steel grades are used:

. 15G1;
. 18HGT;
. 20X2H4A.

The planes are cemented. This achieves strength from 59 to 66 HRCe. The core remains softer at about 36. The production process is slightly different from the previous one.

The industry requires nodes to work in aggressive environments. In this case, steel grades 95X18Sh and 110X18MShD are used for production.

In foundries, in heat treatment units, products from heat-resistant material are needed. In Russia, they use 8X4V9F2Sh and 8X4M4V2F1Sh.

How balls for bearings are made at the factory, video

The production of such material is a high-precision production. It is necessary to achieve certain parameters at which friction will be minimized. This is usually a separate industry that provides assembly shops with rolling elements. It should be noted that the material is not only steel of different grades, but also ceramics, Si3N4. This is a completely different industrial cycle. They are used in units with high rotational speeds, because they have a lower mass, are not subject to deformation at high temperatures, and a pair (steel, silicon nitride) have better slip performance.

Manufacturing technology of balls for bearings:

. A bar of larger diameter is taken and cut into cylinders of the required length.
. In the cold exhibition machine, the shape of a ball with a characteristic belt is given. The workpiece has dimensions that are slightly larger than required. The surface has a rather rough configuration.
. The next stage is a run-in between two rotating disks. The future rolling element takes on an almost perfect shape with some allowance.
. Then the parts are processed in a cutter. With the help of abrasive materials scales and burrs are removed from the surface.
. Further, there is a rolling between two cast-iron faceplates. In this case, dimensions close to the required ones are achieved.
. While soft elements require hardening. They are subjected to heat treatment or cementation. It depends on what metal they are made of.
. The final stage of production is grinding. Workpieces are continuously rolled between two discs, automatically mixing. The output is a product with a tolerance of 10 microns. If necessary, the accuracy can be increased even higher.
. The final phase is washing with special solvents, automatic quality control, in which culling and sorting by accuracy class takes place.
. The product is packed and labeled in accordance with GOST, and sent to consumers. Part of the goods goes to the manufacture of rolling units, and the rest is sold as a finished product.

Raw materials, and how balls for bearings are made: video

A small detail for the whole mechanism is one of the most difficult in a technological sense. After all, it is very difficult to achieve smooth, round balls from a metal bar with exact dimensions up to hundredths of a micron, because an extra indicator can adversely affect the operation of the entire mechanism. The factories use special high-quality steel, regulated by GOST 3722-81:

. Chromium carbon, type ШХ15. For indicators with higher hardness, SHKh4, SHKH20, 15 G 1, 12X18, 95X18, 18XGT, 110X18, 8X4M4V2F1 are used to order.
. Molybdenum. It is used for the manufacture of shotgun shot and for balls for special purposes. Small amounts of copper, aluminium, brass, polyamides, polymers and cermets are added to the main component.
. Recently, a new alloy of synthetic material has been used - silicon nitride. Special-purpose products capable of self-reinforcing are produced from it.

We have determined what steel bearings are made of. Steel balls are used for the production of rolling units. Separately, they are used in various sectors of the national economy. They are also indispensable in the automotive, paint and varnish, defense, cement, confectionery, chemical and agricultural industries. In addition, they can act as separate parts for deodorants and pen refills.

These devices are an integral part in the manufacture of wheels and rollers for warehouse equipment (hydraulic carts, pallet trucks), for spare parts and furniture fittings. In the catalog of the online store "MPlast" you can find the necessary part. To do this, you need to enter the site and find the required product there, as well as decide on the price and form of payment.

In units operating in an aggressive environment, balls with a high nickel content are used. Environmentally friendly shot is rolled from soft iron (lead does more harm to nature than low-carbon steel) and copper-plated, with a diameter of 4.5 for pneumatic weapons.

The next step in manufacturing was the creation of ceramic rolling elements. They have found their application in extreme operating conditions (jet engines, spindles in metalworking machines, Formula 1 cars.

Factories

In Russia, there are more than two dozen large enterprises that produce such products. We will give some examples:

. OAO Moscow Bearing. It specializes in the production of parts for the metro construction and the railway.
. OJSC GPZ-2 is the oldest plant operating since 1916. It produces a huge list of small-sized products from 4 to 6770 grams. It supplies products to 50 countries.
. Saratov has been functioning since 1941. The goods for consumers are balls.
. Samara "ZPON" produces various types of roller mechanisms (4000 items). Has the production of equipment, its own research base.
. Tomsk "ROLTOM" GPZ-5. It produces movements with miniature sizes with a diameter of 2 mm to large ones - 22 cm.
. Ekaterinburg Plant No. 6 specializes in the production of spherical two-row goods with increased radial load.
. Baku GPZ-7.
. Kharkov №8. The production range of products is from 30 g to 45 kg.
. Samara plant number 9 produces roller rolling units.
. GPZ-10 in Rostov-on-Don has been operating since 1938 and manufactures parts for agricultural machinery, processing equipment and metallurgy.

The Russian market receives products from factories in different countries . The most popular bearings are made:

. In the People's Republic of China by AAA. It specializes in the manufacture of parts for the automotive industry.
. And India at the ABC Bearings concern. The company has been successfully operating for over 50 years and imports its products to many countries of the world.
. In Slovakia by AKE. This new brand is not inferior in quality to famous brands . Every year, the range of manufactured products is increasing, which is much lower in cost than other imported analogues.

Kinds

These mechanisms can be divided into groups according to the direction of the load, according to the elements on which the clips rest, according to the presence or absence of a rotating spacer, and according to the material of manufacture.

What are plain bearings made of and how are they made?

The product is radial and supporting, with a full or partial turn. Depending on the operating conditions, it is made in the form of: outer and inner races (lower and upper), sliding sleeve (washer), lubrication system (forced, natural, air).

Polished surfaces, due to the lubricant or due to the physical properties of the gaskets, provide long-lasting easy glide. Raw materials for manufacturing: steel, cast iron, bronze, fluoroplastic, babbitt, aluminum, ceramics. Pairs with a minimum coefficient of friction are selected. What metal the bearing sleeve is made of directly depends on which cage it will rotate in.

rolling

Such nodes are divided into radial, persistent and complex. This determines the direction of the load. The first are divided into three main classes: ball, roller, needle. These species can be with or without restrictive rings, with one or two anthers, and completely open.

The second type is created on the basis of spherical elements, cylindrical and conical rollers. Completely collapsible varieties are produced. The third - combines the qualities of the first and second in terms of perceived effort. There are also open and closed types.

Depending on the materials for the manufacture of rolling bearings, there are several subclasses:

. standard (most common);
. designed for increased loads;
. designed for extreme temperatures;
. resistant to aggressive environments.

For special conditions (ultra-high rotational speeds, strong heating, the need to operate in the presence of acids and alkalis), products made of ceramics, silicon nitride, and plastics are used. There are models where the sliding layer is a gas or a magnetic field.

Device

It is not possible to describe all the diversity. In principle, this mechanism consists of an external and internal support (they can be replaced by a body part), a sliding gasket (grease, a separator with rolling elements, a bushing).

The most common view is done like this:

. two washers with grooves having the required radius of curvature;
. balls fixed with a special device at the same distance from each other around the entire perimeter;
. when the clips move, friction is sharply reduced.

How ball bearings are assembled: video

The process looks like this:

. Clips prepared in an appropriate way are inserted one into the other, touching at a single point. As a result, a space is formed on the side opposite to the contact, through which the balls can be inserted.
. The number of rolling elements in this scheme is limited. The next step is to evenly distribute them around the perimeter. In this case, the inner ring is automatically centered relative to the outer one.
. Specially made halves of the separator are installed from below and from above. The standard product is made from carbon steel. But there are varieties when fixation occurs due to a brass or plastic part. The latter consists of one part and simply snaps into place.
. On a special machine, the two halves of the holding device are connected with rivets made of metal through a pre-prepared hole.
. The product is washed and lubricated (lithol, cyatim, graphite or preservative composition).
. Protective dust covers are installed. They can be metal, plastic or composite.
. Further, the goods are marked according to GOSTs, and packed in boxes.

The assembly of the support product consists in creating a cage that holds the rolling elements in certain places. The edges of the device are rolled. The implementation comes in the form of three parts (upper and lower washer, and the assembly itself).

For high loads, more points of contact need to be created. It is impossible to place additional balls in the classical mechanism. Then manufacturers make technological recesses in the disks, through which the number of touch points becomes maximum. In the future, the classic riveting of the separator occurs.

One of the verified suppliers is the MPlast company. It sells products based on bearings produced in Russia by factories with an ideal reputation.

The bearing is an important design detail that provides rotational movements of parts during rolling or linear movement. It is an assembly unit consisting of two round plates: an outer and an inner ring. A separator with several balls is inserted inside the structure, which provide the torsion of the mechanism.

Types of bearings

Bearings differ in type of design and material of manufacture:

Most often found in household appliances and are familiar to consumers bearings with balls. They are placed on devices that do not experience heavy loads. For example, electric motors, woodworking machines, gearboxes. Used in medical equipment.
Spherical bearings have the greatest strength and withstand even extreme loads, so they are installed in mechanisms such as crushers or pumps.
Small parts in home appliances often use needle bearings . In the mechanism of such products, thin cylindrical sticks are inserted, shaped like a needle.
Cylindrical bearings are considered one of the most reliable bearings that can withstand sufficient loads . They are used in mechanical engineering: in automobile, aviation and railway transport.

Ball bearing device

Consider the first version of the product. Such a device consists of two metal plates that have special grooves or so-called raceways in the middle of the planes. On the large outer ring, such a groove is located inside, on the ring of a smaller diameter - on the outside.

A separator with inserted balls is inserted into the center of the structure. Thanks to this system, the rolling is smooth. Bearings when mounted on the mechanism can still be wiped with lubricants for better rotational movement.

The separator consists of two parts - the so-called semi-separators. These two parts are then soldered using spot welding. Sometimes they are attached to mounting antennae or by riveting. Such devices may have one or two rows of balls.

Roller bearing device

Another version of the device for rotating parts consists of rollers. These are metal cylinders or cones of the same size, which are inserted into the separator in the middle between two rings. Such products are much stronger and more reliable than ball bearings. They are used in mechanical engineering: automobile, aviation and railway transport.

There are roller inserts of a cylindrical or conical shape, which are placed in the inner part of the part in one or several rows. Cylindrical rollers, after the bearing is assembled, are installed in guillotines, powerful gearboxes and electric motors, machine tool spindles or pumps.

The conical shape is used in products for helical mechanical gears, in road transport, in the hubs of passenger cars.

Preparing to assemble the bearing

At enterprises, assembly processes are carried out on special equipment, namely shafts. Before assembling the bearings, the quality of the surfaces of both the shaft and the rings of the product is checked. They should not have any damage: scratches, burrs, nicks, drawn marks, metal corrosion spots, cracks.

All surfaces are thoroughly wiped, dried and lubricated with a thin layer of lubricant before assembling the bearings. Only then can assembly operations begin.

mechanical method

This method is used for small parts, the inner diameter of which is up to 60 mm. When assembling, the main thing is to observe one important rule: the force during mechanical coupling of the outer and inner rings should not be transferred to the cage. It appears only on the ends of the rings.

It is also strictly forbidden to knock on the ring. Light blows can only be applied through additional material, such as a sleeve made of soft metal. At enterprises, these tasks are performed by automated machines on conveyor belts.

Step by step assembly sequence

Let's look at how to assemble a disassembled bearing:

It is necessary to put the outer ring in a vertical position and lubricate its groove from the inside with a thick, almost solid lubricant, but not to the end of the circle, but approximately three-quarters of its surface.
After that, you need to insert the balls alternately with thin tweezers, sinking them into the lubricant.
Before assembling the ball bearing, you need to attach the inner ring to the balls, pressing it down a little. Then we carefully begin to scroll in a circle so that they are distributed at equal distances from one another.
Then we insert the separator and turn it so that the balls find their place in the recesses.
When all the balls snap into place, you can wipe the grease with a dry cloth. For a complete laundering, it is desirable to use kerosene.

Bearing repair

There are times when the bearing in the device began to turn poorly. There may be several reasons. For example, dirt got into the grease. In order to give the product a new life, it must be thoroughly cleaned and rinsed. You can use gasoline for this purpose.

First you need to remove the stuffing box cover, clamp the bearing in a vice and carefully drill the separator rivets with a thin drill. This can only be done if there are several old bearings, and in the event of a separator or one half of it breaking down, it will be possible to assemble a whole from other products.
All rivets on the separator must be carefully cut with a grinder so that the half is intact, not bent.
The next step will be cleaning the rings and shaken out balls from dirt, washing the parts in gasoline. At the same time, you need to check the condition and integrity of each element of the bearing.
Then the most difficult stage of repair work is putting all the balls back into the structure.
Before you properly assemble the bearing, you need to grind the rings. First, the first half of the separator is inserted, then carefully, one at a time, balls must be placed in each groove so that they fill all the holes.
After that, rivets are made. You can use copper wire.
Next, apply a layer of fresh grease and close the stuffing box cover.

It is not recommended to install bearings repaired in this way in units, a motorcycle or a car. You can use them for household purposes in a summer cottage or a child to repair a scooter.

How to assemble a small bearing?

Now a spinning toy called a spinner is very popular among children. But what does it cost a child to drop such a spinning object on the floor? There were times when the baby ran to his parents in tears and lamented that the spinner was broken.

And most often the problem for parents is how to collect a crumbling bearing. Small items are much more difficult to assemble, but quite possible. To do this, you will need to use thin tweezers.

Most often, such toys use simple ball bearings without separators, in which the balls spin along the grooves of the rings. To assemble all the parts together, you need to use the mechanical assembly method described above. If you can’t, then you need to use knowledge about the properties of the metal.

One of the rings must be put in warm water, and the other in the refrigerator. From frost, the metal will become smaller, and after heat treatment it will expand. This way it will be much easier to put them together. Good luck!

The bearing is a functional unit that performs the function of supporting and guiding a rotating shaft and axis. The device is designed to reduce friction between the moving part of the mechanism, as well as its fixed elements.

Bearings reduce energy losses, eliminate heat and reduce wear on parts.

Leading manufacturers

Among the well-known world brands, experts highlight the following manufacturers:

the Swedish industrial group SKF supplies products to 130 countries;
German manufacturer FAG;
Slovak concern Kinex
the French company SNR is considered the largest supplier for Europe;
Japanese companies NSK, NTN and Koyo;
American concern TIMKEN

For the manufacture of high-quality products, strict adherence to technological standards at all stages of production is required. This requirement is usually met only by well - known world brands . The Ukrzakhidpostach company supplies bearings exclusively from leading brands, the quality of which has been tested by time.

Features and stages of production

The production of bearings requires the use of special steel grades. Steel made from iron is selected for rings and rolling elements, while heavy and light metal alloys such as cast iron, bronze, aluminum and brass are required for the cage.

Now a large number of specialized bearings have been developed, each of which has its own technological chains of production. Regardless of this, all products undergo turning, pressure treatment, heat treatment, grinding, and assembly during the manufacturing process.

Ring production

These elements are made according to the following scheme:

From metal pipes and bars, blanks are prepared according to the calculated diameter.
By rolling and pressure, the initial processing takes place.
Turning works are carried out aimed at cutting individual rings and general surface treatment.
Heating rings to 850ºС, then rapid cooling to 40ºС.
Release of details at a temperature of 170ºС.
Grinding of end, internal and external surfaces, raceways.
Finish grinding of raceways to the required roughness values.

Production of rolling elements

The technological chain for the production of these parts is as follows:

Using a special steel wire of a certain diameter, the original blanks are cut.
Parts are compressed by a special press to give them a spherical shape.
A final pressure treatment is carried out, with the help of which an allowance of 100 microns is achieved.
Heat treatment, according to the same method as for the rings.
Grinding and polishing of the product.

Separator production

For the manufacture of the separator, another technological chain will be required:

Preparation of the workpiece - steel sheet.
Punching in the sheet of holes corresponding to the rolling elements.
Rough and finish stamping of a workpiece, aimed at giving it the required shape.
Drilling holes for rivets.
Hole finishing.

Assembly

To assemble the bearing, it is necessary to insert the inner ring into the outer ring and lay the rolling elements between them. Further, a separator is installed in two places with the help of rivets. Before the delivery of finished products for sale, a mandatory performance check, marking and lubrication of the product is required.