Details
| Original language | English |
|---|---|
| Pages (from-to) | 893–905 |
| Number of pages | 13 |
| Journal | Production Engineering |
| Volume | 17 |
| Issue number | 6 |
| Early online date | 9 Jun 2023 |
| Publication status | Published - Dec 2023 |
Abstract
Frictional losses occur in tapered roller bearings, particularly at low rolling speeds, which pose a risk of wear. The increased friction losses are a result of insufficient lubricant film thicknesses in the rolling and rib contact. Micro-lubrication dimples can be used to induce additional lubricant into the contact zone and minimize friction. The aim of this paper is therefore to implement a suitable machining strategy for the production of defined microstructures for tribologically optimized applications and to identify relationships between geometry formation and process parameters. For this purpose, the microstructure milling process was first modelled with a material removal simulation, including tool displacement. Additionally the kinematic limits of the machine tool were determined. The tool displacement was determined experimentally for this purpose. Subsequently, the findings from the simulation were used to induce microstructures in a defined manner on tapered roller bearings made of hardened 100 Cr6 steel. The investigations showed that the defined generation of lubrication dimples is possible with the developed machining strategy. Due to the inclination of the inboard bearing, there is a deviating depth of engagement when the tool penetrates, which also increases the tool displacement. As a result of the microstructure milling process, burr formation occurs, which shows a dependence on cutting speed and structure alignment. Increased burr formation and tool wear at structure orientations of 45° and 70° were found.
Keywords
- 100Cr6, Flycutting, Hard machining, Microstructure milling, Tapered roller bearings
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 17, No. 6, 12.2023, p. 893–905.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Process strategies for milling of dimples on tapered roller bearings
AU - Denkena, Berend
AU - Bergmann, Benjamin
AU - Keitel, Michael
AU - Wege, Christian
AU - Poll, Gerhard
AU - Kelley, Josephine
AU - Pape, Florian
N1 - Funding Information: The authors gratefully acknowledge the German Research Foundation (DFG) for the founding of the project DE 447/165-1 “Hartfräsen von Mikroschmiernäpfen zur Reibungs- und Verschleißreduktion in hochbelasteten Wälzkontakten”.
PY - 2023/12
Y1 - 2023/12
N2 - Frictional losses occur in tapered roller bearings, particularly at low rolling speeds, which pose a risk of wear. The increased friction losses are a result of insufficient lubricant film thicknesses in the rolling and rib contact. Micro-lubrication dimples can be used to induce additional lubricant into the contact zone and minimize friction. The aim of this paper is therefore to implement a suitable machining strategy for the production of defined microstructures for tribologically optimized applications and to identify relationships between geometry formation and process parameters. For this purpose, the microstructure milling process was first modelled with a material removal simulation, including tool displacement. Additionally the kinematic limits of the machine tool were determined. The tool displacement was determined experimentally for this purpose. Subsequently, the findings from the simulation were used to induce microstructures in a defined manner on tapered roller bearings made of hardened 100 Cr6 steel. The investigations showed that the defined generation of lubrication dimples is possible with the developed machining strategy. Due to the inclination of the inboard bearing, there is a deviating depth of engagement when the tool penetrates, which also increases the tool displacement. As a result of the microstructure milling process, burr formation occurs, which shows a dependence on cutting speed and structure alignment. Increased burr formation and tool wear at structure orientations of 45° and 70° were found.
AB - Frictional losses occur in tapered roller bearings, particularly at low rolling speeds, which pose a risk of wear. The increased friction losses are a result of insufficient lubricant film thicknesses in the rolling and rib contact. Micro-lubrication dimples can be used to induce additional lubricant into the contact zone and minimize friction. The aim of this paper is therefore to implement a suitable machining strategy for the production of defined microstructures for tribologically optimized applications and to identify relationships between geometry formation and process parameters. For this purpose, the microstructure milling process was first modelled with a material removal simulation, including tool displacement. Additionally the kinematic limits of the machine tool were determined. The tool displacement was determined experimentally for this purpose. Subsequently, the findings from the simulation were used to induce microstructures in a defined manner on tapered roller bearings made of hardened 100 Cr6 steel. The investigations showed that the defined generation of lubrication dimples is possible with the developed machining strategy. Due to the inclination of the inboard bearing, there is a deviating depth of engagement when the tool penetrates, which also increases the tool displacement. As a result of the microstructure milling process, burr formation occurs, which shows a dependence on cutting speed and structure alignment. Increased burr formation and tool wear at structure orientations of 45° and 70° were found.
KW - 100Cr6
KW - Flycutting
KW - Hard machining
KW - Microstructure milling
KW - Tapered roller bearings
UR - http://www.scopus.com/inward/record.url?scp=85161457850&partnerID=8YFLogxK
U2 - 10.1007/s11740-023-01208-4
DO - 10.1007/s11740-023-01208-4
M3 - Article
AN - SCOPUS:85161457850
VL - 17
SP - 893
EP - 905
JO - Production Engineering
JF - Production Engineering
SN - 0944-6524
IS - 6
ER -