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Bearing Blanking Techniques

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Blanking is the first step in the casting process. The quality of the blank directly affects the precision, shape, and size of the final component. Poor blanking can lead to issues in both casting and forging processes. In foreign bearing manufacturing, advanced production lines such as high-speed upsetting machines, flat forging presses, and multi-station eccentric presses are commonly used. These systems produce bearing rings directly from bar stock, resulting in fewer blanks and higher precision. In these systems, the cutting process involves progressive material shaping. One method is radial compaction of the bar, while another focuses on increasing the shearing speed. Foreign cutting equipment is highly automated, often including loading/unloading, feeding, cleaning, monitoring, and other functions. Traditional shearing methods, however, are mostly open-cut, leading to poor blank quality. The variation in component dimensions can be as high as 5%, and the end face tilt may exceed 3°. To address this, many domestic manufacturers have been exploring new techniques. Most Chinese manufacturers use a single-point press with a grinding tool for shearing. Improvements in abrasive tools have helped enhance blanking quality. However, the main issue remains the axial turbulence and warping of the bar during shearing. To solve this, a sleeve-type shearing die has been introduced. Even if the blade shapes match the cross-section of the bar, the warping during shearing is reduced, and the bar is flattened during cutting, significantly improving the shear quality. In practical applications, cold material differences can be controlled within 1%, the cutting depth is around 0.5 mm, and the end face tilt is less than 2°30'. For hot materials, the difference is within 2%, and the end face tilt is under 3°. This technique, known as "restrictive shearing," uses radial rushing to control warping, axial turbulence, and severing of the bar. Some methods apply pressure at the fixed end, others at both ends, and some use cylinder or linkage mechanisms. Blades are shaped to match the bar's cross-section, and active feeding equipment can also be added. The use of hot bar cutting machines is becoming more widespread, typically operating in a production line setup. These machines use medium-frequency induction heating, automatic feeding, and real-time detection, offering a high level of automation. They include radial rushing devices, strong structural rigidity, and material adjustment features. Compared to older shearing machines, the cutting accuracy has improved significantly, with component errors not exceeding 1.5% and end face tilt within 3°. Band saw blanking, a technique widely used abroad, is now also adopted in China. Band saws offer a rigid structure, stable guiding rails, and controlled feeding that ensures smooth operation and strong cutting force. This results in accurate blanks, high-quality end faces, and a wide range of cutting sizes.

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