SAE 52100 Steel, adhering to global quality benchmarks, serves as the foundational raw material for crafting AVB bearings. This steel variant is consistently employed in the production of bearing elements such as races and rolling components. Additionally, all cages are exclusively composed of CRC material and brass, while rollers are crafted from SAE 52100 / EN31 Steel, in strict accordance with international standard specifications.
Forging, a transformative metalworking technique, utilizes heat and force to achieve the desired metal shape. This method is meticulously applied to SAE 52100 Steel, ensuring precision in shaping. Annealing, a thermal process, is employed to heighten the ductility of bearings, enhancing their malleability for achieving various desired forms.
The forged material undergoes precision turning facilitated by automated CNC Machines. Renowned globally for their dependable performance, these machines significantly enhance productivity in the production of intricate components, ensuring the highest levels of accuracy and perfection.
Every element of the bearing, encompassing the Inner and Outer races, rings, and rollers, undergoes a rigorous heat treatment process to bolster its resilience against wear and tear. Both the inner and outer races are precisely hardened to 60 ± 2 HRC in accordance with international standards. Subsequently, the hardness levels of both races and rolling elements are meticulously examined and verified utilizing a specialized hardness tester.
The transformation of steel wires into rollers involves a precision die-cutting process, shaping them into cylinders. Subsequently, the rollers undergo a series of meticulous surface finishing and heat treatment procedures.
Initially, steel plates undergo precision press cutting to create circular shapes, which are subsequently molded into conical forms. The bottom section is then carefully trimmed. Following this, a turning process is applied. Finally, rectangular sections are meticulously cut for the roller assembly.
The grinding process is meticulously conducted through multiple stages. An automated grinding cycle with diamond size control ensures seamless, consistent grinding at elevated cutting speeds. Furthermore, an automatic wheel dressing cycle, coupled with wheel wear compensation, minimizes the dependency on operator expertise and vigilance. The system rigorously assesses size accuracy, examining factors such as ovality, roughness, roundness, and other potential errors.
Internal clearance, the minute gaps between inner and outer rings and taper rollers, is carefully addressed during assembly. By selecting taper rollers of varying sizes, the clearance is finely adjusted. The assembly machine then expertly positions the precise number of taper rollers between the rings, securing them in place with retainers above and below, skillfully riveted. Post-assembly, meticulous cleaning ensues, followed by the uniform distribution of grease. If required, the bearings are then sealed. Finally, a comprehensive battery of tests is conducted to assess durability, performance, and noise levels prior to shipping.
