The examples and perspective in this article deal primarily with the United States and do not represent a worldwide view of the subject.(October 2014) |
Bearing balls are special highly spherical and smooth balls, most commonly used in ball bearings, but also used as components in things like freewheel mechanisms. The balls themselves are commonly referred to as ball bearings. [1] This is an example of a synecdoche. The balls come in many different grades. These grades are defined by bodies such as the American Bearing Manufacturers Association (ABMA), a body which sets standards for the precision of bearing balls. They are manufactured in machines designed specially for the job.
In 2008, the United States produced 5.778 billion bearing balls. [2]
Bearing balls are manufactured to a specific grade, which defines its geometric tolerances. The grades range from 2000 to 3, where the smaller the number the higher the precision. Grades are written "GXXXX", i.e. grade 100 would be "G100". [3] [4] Lower grades also have fewer defects, such as flats, pits, soft spots, and cuts. The surface smoothness is measured in two ways: surface roughness and waviness. [4]
Size refers to the farthest possible distance between two points on the ball's surface, as measured by two parallel plates in contact with the surface. The starting size is the nominal ball diameter, which is the nominal, or theoretical, ball diameter. The ball size is then determined by measuring the ball diameter variation, which is the difference between the largest and smallest diameter measurement. For a given lot there is a lot diameter variation, which is the difference between the mean diameter of the largest ball and the smallest ball of the lot. [4]
Sphericity refers to the amount of deviation from a true spherical form (out of roundness). [4] This is measured by rotating a ball against a linear transducer with a gauge force of less than 4 grams (0.14 oz). The resulting polar graph is then circumscribed with the smallest circle possible and the difference between this circumscribed circle and the nominal ball diameter is the variation. [4]
Grade | Size range [in] | Sphericity [in] | Lot diameter variation [in] | Nominal ball diameter tolerance [in] | Maximum surface roughness (Ra) [μin] |
---|---|---|---|---|---|
3 | 0.006–2 | 0.000003 | 0.000003 | ±0.00003 | 0.5 |
5 | 0.006–6 | 0.000005 | 0.000005 | ±0.00005 | 0.8 |
10 | 0.006–10 | 0.00001 | 0.00001 | ±0.0001 | 1.0 |
25 | 0.006–10 | 0.000025 | 0.000025 | ±0.0001 | 2.0 |
50 | 0.006–10 | 0.00005 | 0.00005 | ±0.0003 | 3.0 |
100 | 0.006–10 | 0.0001 | 0.0001 | ±0.0005 | 5.0 |
200 | 0.006–10 | 0.0002 | 0.0002 | ±0.001 | 8.0 |
1000 | 0.006–10 | 0.001 | 0.001 | ±0.005 |
Grade | Sphericity [mm] | Lot diameter variation [mm] | Nominal ball diameter tolerance [mm] | Maximum surface roughness (Ra) [μm] |
---|---|---|---|---|
3 | 0.00008 | 0.00008 | ±0.0008 | 0.012 |
5 | 0.00013 | 0.00013 | ±0.0013 | 0.02 |
10 | 0.00025 | 0.00025 | ±0.0013 | 0.025 |
25 | 0.0006 | 0.0006 | ±0.0025 | 0.051 |
50 | 0.0012 | 0.0012 | ±0.0051 | 0.076 |
100 | 0.0025 | 0.0025 | ±0.0127 | 0.127 |
200 | 0.005 | 0.005 | ±0.025 | 0.203 |
1000 | 0.025 | 0.025 | ±0.127 |
The manufacture of bearing balls depends on the type of material the balls are being made from.
Metal balls start as a wire. The wire is sheared to give a pellet with a volume approximately that of the ball with the desired outer diameter (OD). This pellet is then headed into a rough spherical shape. Next, the balls are fed into a machine that de-flashes them. The machine does this by feeding the balls between two heavy cast iron [5] or hardened steel plates, called rill plates. One of the plates is held stationary while the other rotates. The top plate has an opening to allow balls to enter and exit the rill plates. These plates have fine circumferential grooves that the balls track in. The balls are run through the machine long enough so that each ball passes through many of these grooves, which ensures each ball is the same size, even if a particular groove is out of specification. The controllable machine variables are the amount of pressure applied, the speed of the plates, and how long the balls are left in the machine. [6]
During the operation coolant is pumped between the rill plates because the high pressure between the plates and friction creates considerable heat. The high pressure applied to the balls also induces cold working, which strengthens the balls. [6]
Sometimes the balls are then run through a soft grinding process afterward to improve precision. This is done in the same type of machine, but the rill plates are replaced with grinding stones. [5]
If the balls are steel they are then heat treated. After heat treatment they are descaled to remove any residue or by-products. [5]
The balls are then hard ground. They are ground in the same type of machine as used before, but either an abrasive is introduced into the coolant or the rotating plate is replaced with a very hard fine-grain grinding wheel. This step can get the balls within ±0.0001 in (0.0025 mm). If the balls need more precision, then they are lapped, again in the same type of machine. However, this time the rill plates are made of a softer material, usually cast iron, less pressure is applied, the plate is rotated slowly. This step is what gives bearing balls their shiny appearance and can bring the balls between grades 10 and 48. [5] [6] [7]
If even more precision is needed, then proprietary chemical and mechanical processes are usually used. [5]
The inspection of bearing balls was one of the case studies in Frederick Winslow Taylor's classic Principles of Scientific Management.
Plastic bearing balls are made in the same manner as described above. [6]
Ceramic bearing balls are made of sintered materials that are then ground to size and shape as above. Common materials include: silicon nitride (Si
3N
4) and zirconium dioxide (ZrO
2). [8]
Common materials include carbon steel, stainless steel, chrome steel, brass, aluminium, tungsten carbide, platinum, gold, titanium, plastic. Other less common materials include copper, monel, k-monel, lead, silver, glass, and niobium. [9]
Material | UNS 52100 | Stainless steel 440C | M50 | BG-42 | REX-20 | 440NDUR | Haynes 25 | Si3N4 | BeCu | 455 | C276 |
---|---|---|---|---|---|---|---|---|---|---|---|
Hardness [HRC] | 60 | 58 | 62 | 62 | 66 | 60 | 50 | 70 | 40 | 50 | 40 |
Temperature limit [°F] | 300 | 300 | 400 | 400 | 600 | 300 | 1200 | 1500 | 400 | 500 | 1000 |
Corrosion resistance [m 1] | 1 | 3 | 1 | 2 | 1 | 4 | 5 | 5 | 1 | 4 | 5 |
Cost [m 1] | 1 | 1 | 1 | 2 | 3 | 1 | 5 | 5 | 3 | 2 | 4 |
Availability [m 1] [ clarification needed ] | 1 | 1 | 2 | 2 | 2 | 4 | 5 | 3 | 3 | 2 | 4 |
Magnetic | Magnetic | Magnetic | Magnetic | Magnetic | Magnetic | Magnetic | Non-magnetic | Non-magnetic | Non-magnetic | Magnetic | Magnetic |
Electrical Conductivity | Conductive | Conductive | Conductive | Conductive | Conductive | Conductive | Conductive | Non-conductive | Conductive | Conductive | Conductive |
Size limit | None | None | None | None | None | None | 1.5 in (38 mm) | No Torque Tube[ clarification needed ] | None | None | 5 in (130 mm) |
Relative load capacity [m 1] | 3 | 2 | 4 | 4 | 5 | 3 | 1 | 5 | 1 | 1 | 1 |
Relative fatigue life [m 1] | 3 | 2 | 4 | 4 | 5 | 3 | 1 | 5 | 1 | 1 | 1 |
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings. Thus, it is possible for some fluid bearings to have near-zero wear if operated correctly.
A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.
A plain bearing, or more commonly sliding contact bearing and slide bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore, the journal slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.
In mechanical engineering, a rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing rolling elements between two concentric, grooved rings called races. The relative motion of the races causes the rolling elements to roll with very little rolling resistance and with little sliding.
A thrust bearing is a particular type of rotary bearing. Like other bearings they permanently rotate between parts, but they are designed to support a predominantly axial load.
A mill is a device, often a structure, machine or kitchen appliance, that breaks solid materials into smaller pieces by grinding, crushing, or cutting. Such comminution is an important unit operation in many processes. There are many different types of mills and many types of materials processed in them. Historically mills were powered by hand or by animals, working animal, wind (windmill) or water (watermill). In modern era, they are usually powered by electricity.
The ABEC scale is an industry accepted standard for the tolerances of a ball bearing. The ABEC scale is designed to provide bearing manufacturers dimensional specifications that meet the standards of precision bearings in a specified class. The scale is also used by manufacturers who produce equipment that require bearings must also know the dimensional tolerances to design parts that will accommodate a bearing.
A linear-motion bearing or linear slide is a bearing designed to provide free motion in one direction. There are many different types of linear motion bearings.
A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with little friction. A threaded shaft provides a helical raceway for ball bearings which act as a precision screw. As well as being able to apply or withstand high thrust loads, they can do so with minimum internal friction. They are made to close tolerances and are therefore suitable for high-precision applications. The ball assembly acts as the nut while the threaded shaft is the screw.
A pulverizer or grinder is a mechanical device for the grinding of many different types of materials. For example, a pulverizer mill is used to pulverize coal for combustion in the steam-generating furnaces of coal power plants.
Grinding is a type of abrasive machining process which uses a grinding wheel as cutting tool.
Burnishing is the plastic deformation of a surface due to sliding contact with another object. It smooths the surface and makes it shinier. Burnishing may occur on any sliding surface if the contact stress locally exceeds the yield strength of the material. The phenomenon can occur both unintentionally as a failure mode, and intentionally as part of a metalworking or manufacturing process. It is a squeezing operation under cold working.
The rolling-elements of a rolling-element bearing ride on races. The large race that goes into a bore is called the outer race, and the small race that the shaft rides in is called the inner race.
Brinelling is the permanent indentation of a hard surface. It is named after the Brinell scale of hardness, in which a small ball is pushed against a hard surface at a preset level of force, and the depth and diameter of the mark indicates the Brinell hardness of the surface. Brinelling is permanent plastic deformation of a surface, and usually occurs while two surfaces in contact are stationary and the material yield strength has been exceeded.
The yaw bearing is the most crucial and cost intensive component of a yaw system found on modern horizontal axis wind turbines. The yaw bearing must cope with enormous static and dynamic loads and moments during the wind turbine operation, and provide smooth rotation characteristics for the orientation of the nacelle under all weather conditions. It has also to be corrosion and wear resistant and extremely long lasting. It should last for the service life of the wind turbine) while being cost effective.
Barden Corporation is a ball bearing manufacturer based in Danbury, Connecticut, USA with factories in Danbury, Winsted, Connecticut and in Plymouth, England. It previously had factories in Bridgeport, Connecticut and Haverhill, Massachusetts.
Self-lubricating chains, also referred to as lube-free chains, are commonly found in both roller chain and conveyor chain varieties, with specialty self-lubricating chains also available. These chains utilize a bush made of an oil-impregnated sintered metal or plastic to provide continuous lubrication to the chain during drive, eliminating the need for further lubrication.
Air bearings are bearings that use a thin film of pressurized gas to provide a low friction load-bearing interface between surfaces. The two surfaces do not touch, thus avoiding the traditional bearing-related problems of friction, wear, particulates, and lubricant handling, and offer distinct advantages in precision positioning, such as lacking backlash and static friction, as well as in high-speed applications. Space craft simulators now most often use air bearings and 3-D printers are now used to make air-bearing-based attitude simulators for CubeSat satellites.
Lewis Rasmus Heim was an American machinist and businessman who was the inventor of the Centerless Cylindrical Grinder, the Heim Joint Rod End Bearing and a pioneer of modern spherical, ball and roller bearings.