The Simulation Analysis On The Forming Of A Tapered Bearing Cage And Design Of The Mould

The tapered roller bearings in the vehicle transmission is one of the important parts of automobile, which directly influences the speed, safety, noise and so on. The precision and quality of the tapered roller bearings will affect roller and bearing clearance, and directly affect the performance of the bearing. Therefore, the mould is a direct equipment of producing tapered roller bearings, and the reasonable design of the mould structure is especially important. According to the low accuracy and low efficiency of traditional processing method, based on the sheet metal stamping theory, the simulation analysis of sheet metal deep drawing is made to design the deep drawing, lateral cage pocket forming, pressure slope mould and so on, to effectively ensure the high quality, high efficiency and low cost of the tapered bearing cage.Firstly, this paper intends to analyze the impact of the process parameters, the mould structure parameters, sheet metal shape and mold clearance on the deep drawing, and to analyze the obstacle (cracking and wrinkling), in order to put forward the effective measures to reduce or control the obstacle to improve the deep drawing forming limit.Secondly, combined with the sheet forming simulation technology, the establishment of the material and the mechanics model, together with the division of the gird and the selection of boundary conditions and analysis, will be described for the detailed analysis of stamping forming of the tapered roller bearings.Thirdly, with the analysis of the structure characteristics of tapered bearing cage, for designing a deep drawing mould which can make good tapered bearing cage, together with the analysis of the sheet deformation process and the defect with DYNAFORM to find out the causes of stamping defects, the mould structure and technological parameters are optimized to reduce or avoid the defects, and to improve the performance and efficiency of the deep drawing.According to the performance requirements of the lateral cage pocket, a new kind of mould will be designed to cut multiple cage pockets on the tapered bearing cage from inside to outside at the same time, to improve forming efficiency, reduce the mould cost, reduce bending beams and parts errors, to achieve punching accuracy.According to the smaller gaps between the outer diameter and outer raceway, there exists radial channeling move between the cage pocket and the rollers, which will cause the bearing failure when the outer diameter is in contact with the outer raceway. When optimizing the tapered bearing cage parameters (pressure slope depth, pressure slope angle), a kind of mould will be designed to finish all pressure slopes of all cage pockets in one-time, for finishing extrusion with high efficiency and high quality and adjusting the bending beams, the parts errors and other defects at the same time.The results show that the above measures can better solve the production quality problems of the tapered bearing cage, in order to improve the efficiency and of the tapered bearing cage forming.