ROLLING BEARING AND METHOD FOR PRODUCING SAME

Abstract

In a raceway surface of at least one of an inner ring and an outer ring, a region not affected by machining is set as a first region, and a region, which has (a) a machining amount of 0.03 or more, (b) an amount of residual austenite being 70% or more of an amount of retained austenite in the first region, and (c) a compressive residual stress being higher by 500 MPa or more than a compressive residual stress in the first region, is set as a second region.

Claims

1. A rolling bearing in which a plurality of rolling elements are rollably held between an inner ring and an outer ring. wherein in a raceway surface of at least one of the inn& ring and the outer ring, a region not affected by machining is set as a first region, and a region, which has: (a) a machining amount of 0.03 or more; (b) an amount of retained austenite being 70% or more of an amount of retained austenite in the first region; and (c) a compressive residual stress being higher by 500 MPa or more than a compressive residual stress in the first region, is set as a second region.

2. A method for manufacturing the rolling bearing according to claim 1, wherein after subjecting the inner ring and the outer ring to a quenching and tempering treatment, machining is performed on the raceway surface of at least one of the inner ring and the outer ring under a condition that a maximum contact surface pressure with a machining jig is 7.2 GPa or less, which is calculated assuming that only elastic deformation occurs.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0027] FIG. 1 is a partially cutout perspective view illustrating a radial ball bearing which is an example of a rolling bearing according to the present invention.

[0028] FIG. 2 is a graph illustrating a result of life test of each radial ball bearing of Example 1 and Comparative Example 1.

[0029] FIG. 3A is a graph illustrating a relationship between a depth from a surface of a raceway surface of an inner ring and the number of white structures generated in the radial ball bearing of Comparative Example 1.

[0030] FIG. 3B is a graph illustrating a relationship between a depth from a surface of a raceway surface of an inner ring and the number of white structures generated in the radial ball bearing according to Example 1.

DESCRIPTION OF EMBODIMENTS

[0031] Hereinafter, the present invention will be described in detail with reference to the drawings.

[0032] In the present invention, a type and a configuration of a rolling bearing are not limited, and for example, a radial ball hearing illustrated in FIG. 1 can be exemplified. As illustrated, a radial ball bearing 1 includes an outer ring 3 having an outer ring raceway surface 2 on an inner peripheral surface thereof an inner ring 5 having an inner ring raceway surface 4 on an outer peripheral surface thereof, and a plurality of balls 6 provided between the outer ring raceway surface 2 and the inner ring raceway surface 4 and serving as rolling elements. The balls 6 are rollably held by a cage 7 in a state in which the balls 6 are disposed at equal intervals in a circumferential direction.

[0033] A material of the outer ring 3, the inner ring 5, and the balls 6 is not particularly limited, and SUJ2, SUJ3 or the like which are general steel materials for rolling bearing can be used. Therefore, the raw material cost can be reduced. without adjusting an additive element of the steel material. However, in the present invention, in at least one of the inner ring raceway surface 4 and the outer ring raceway surface 2, preferably, both of the inner ring raceway surface 4 and the outer ring raceway surface 2, a region such as core part which is not affected by machining is defined as a first region, and a region, which has:

[0034] (a) a machining amount of 0.03 or more;

[0035] (b) an amount of retained austenite being 70% or more of an amount of retained austenite in the first region; and

[0036] (c) a compressive residual stress being higher by 500 MPa or more than a compressive residual stress in the first region, is defined as a second region.

[0037] In order to satisfy the physical properties of (a) to (c), in manufacturing the outer ring 3 and the inner ring 5, after subjecting the outer ring 3 and the inner ring 5 to the quenching and tempering treatment, it is important to perform machining on the outer ring 3 and the inner ring 5 under a condition that a maximum contact surface pressure with a machining jig is 7.2 GPa or less, which is calculated assuming that only elastic deformation occurs. The first region such as a core part, which is deeper than the second region and is not affected by machining, is a so-called “machined region”, and a region affected by machining is a “machined region”. The “machined region” includes the second region.

[0038] Here, the first region can be defined as, for example, a region having a depth of 250 μm or more when viewed from a surface (depth of 0 μm) of the raceway surface. The second region can be defined as, for example, a region covering from the surface (depth of 0 μm) to a depth of 150 μm of the raceway surface.

[0039] The machining is not particularly limited as long as the machining adopts a machining method capable of imparting a compressive stress, and is preferably, for example, burnishing or shot peening.

[0040] The burnishing is a machining method of pressing a machining jig. As an example, there is a machining method in which a device provided with a component, which has a spherical tip and is high in hardness, is pressed against the outer ring raceway surface 2 and the inner ring raceway surface 4, and the outer ring 3 and the inner ring 5 are rotated about their own axes so as to apply a compressive stress. A maximum contact surface pressure with the machining jig, which is calculated assuming that only elastic deformation occurs, is limited to 7.2 GPa or less.

[0041] The shot peening is a machining method of injecting a projection material having a high hardness to the outer ring raceway surface 2 and the inner ring raceway surface 4. Processing conditions such as the size, material, and injection speed of the projection material can be adjusted to adjust the quality to the same quality as obtained by burnishing.

[0042] It is to be noted that previous processes of the above machining can be performed according to a method in the related art. First, the steel material is forged and formed into a substantially annular material This substantially annular raw material is subjected to a cutting process by turning to manufacture an outer ring-dedicated blank material and an inner ring-dedicated blank material that have a predetermined shape. Next, the blank material is subjected to a quenching and tempering treatment, and then the outer ring raceway surface 2 and the inner ring raceway surface 4 are finished with a predetermined precision by polishing. Thereafter, surface layer portions of the outer ring raceway surface 2 and the inner ring raceway surface 4 are subjected to machining such as burnishing described above, and are finally subjected to finishing.

[0043] Here, when the maximum contact surface pressure exceeds 8.2 GPa in a preliminary test, an excessive contact surface pressure is achieved, and the physical properties of the above (a) to (c) cannot be satisfied. As a result, it is considered that an effect of prolonging the life of the rolling bearing is reduced, A lower limit of the maximum contact surface pressure is preferably 5.8 GPa, and when the maximum contact surface pressure is lower than 5.8 GPa, the compressive stress becomes small and shallow. A preferable maximum contact surface pressure is 7.3 GPa.

EXAMPLES

[0044] Hereinafter, the effects of the present invention will be specifically described with reference to Example and Comparative Example, but the present invention is not limited thereto.

[0045] (Preliminary Test)

[0046] In this example, burnishing was employed as the machining, and machining conditions of burnishing were examined. First, a bearing ring having a predetermined shape was manufactured using bearing steel as a raw material, and was subjected to a quenching and tempering treatment. Thereafter, predetermined polishing was performed on the bearing ring, and then burnishing was further performed under three different conditions to manufacture three types of thrust ball bearings having different specifications.

[0047] In a burnishing apparatus, a tip shape of a burnishing tool is φ3 mm, a slip ratio is 100%, a circumferential speed is 100 m/min, a feed rate of the burnishing tool is 0.05 mm/rev, and a pushing amount of the burnishing tool is 0.3 mm. Further, at the time of machining, a filtered machining liquid was supplied. Then, with respect to a contact surface pressure between the burnishing tool and a raceway surface in the burnishing, a maximum contact surface pressure (P) was calculated assuming that only elastic deformation occurred. The maximum contact surface pressures (P) of the rolling bearings manufactured in the preliminary test were P=5.8 GPa, P=7.3 GPa, and P=8.2 GPa, respectively.

[0048] Next, results of measuring a residual stress in a depth direction from the surface of the raceway surface of the bearing ring by the X-ray diffraction method for each maximum contact surface pressure (P) are indicated in Table 1. It can be said that a value of the residual stress in a surface layer of the raceway surface is a negative value, and a compressive stress is imparted. Further, it can be seen that as the maximum contact surface pressure (P) increases, a larger compressive stress can be introduced to a deeper depth.

TABLE-US-00001 TABLE 1 Maximum contact Maximum contact Maximum contact surface surface surface pressure P = pressure P = pressure P = Depth from 5.8 GPa 7.3 GPa 8.2 GPa surface of raceway Residual stress Residual stress Residual stress surface (μm) (MPa) (MPa) (MPa) 0 −861 −797 −724 40 −956 −1153 −1075 80 −404 −1067 −1229 100 −185 −811 −1231 120 −89 −639 −1069 160 −40 −189 −651 200 −32 −43 −288 250 −73 37 −64 300 7 32 −28

[0049] Table 2 indicates results of measuring the amount of retained austenite in the depth direction from the surface of the raceway surface of the bearing ring by the X-ray diffraction method. A region having a depth of 250 μm or more is set as an unmachined region (first region), and is a region which is not affected by burnishing. A region covering from the surface (depth of 0 μm) to a depth less than 250 μm is a machined region, and is a region affected by burnishing. As the maximum contact surface pressure (P) increases, the retained austenite in the machined region undergoes martensitic transformation, and the amount of retained austenite decreases.

[0050] The reason why the amount of retained austenite at the surface (depth of 0 was small is that the amount of retained austenite was reduced to about 5% in the polishing before burnishing.

TABLE-US-00002 TABLE 2 Maximum contact surface Maximum contact surface Maximum contact surface Depth pressure P = 5.8 GPa pressure P = 7.3 GPa pressure P = 8.2 GPa from Residual ratio of Residual ratio of Residual ratio of surface of Retained retained austenite Retained retained austenite Retained retained austenite raceway austenite to that in austenite to that in austenite to that in surface amount unmachined amount unmachined amount unmachined Range of (μm) (%) region (%) (%) region (%) (%) region (%) burnishing   0 4.9  45 4.6 37 4.6 40 Machined  40 9.7  89 7.9 63 4.7 41 region  80 9.6  88 9.9 79 5 44 100 11.2 102 10.8 86 6.1 54 120 11.4 104 11.4 91 7.3 64 160 11 100 11.8 94 8.8 77 200 11.6 106 12.2 98 8.9 78 250 11.2 100 12.6 100 12 100 Unmachined 300 10.7 12.4 10.8 region

[0051] From Table 1 and Table 2, when the maximum contact surface pressure calculated assuming that only the elastic deformation occurs is 7.3 GPa or less, it is possible to secure 63% or more of the amount of retained austenite in the machined region with respect to the amount of retained austenite in the unmachined region while imparting the compressive residual stress in the machined region.

Example 1

[0052] An inner ring, an outer ring, and a rolling element were manufactured using bearing steel as a raw material, and were quenched and tempered. In order to allow a large number of inclusions to exist at different internal depths from a surface layer portion of a raceway surface of the inner ring, a raw material in which a large number of inclusions were present was used.

[0053] For the outer ring and the rolling element, a raw material having an extremely small amount of inclusions was used. Thereafter, burnishing was performed on the raceway surface of the inner ring, and raceway surfaces of the inner ring and the outer ring were further finished to manufacture a deep groove ball bearing having a bearing number of 6206. Here, the maximum contact surface pressure (P) in burnishing was set as 7.2 GPa, which was calculated assuming that only elastic deformation occurred, based on the results of the preliminary test. Other machining conditions in burnishing were the same as those in the preliminary test.

Comparative Example 1

[0054] A 6206 deep groove ball bearing was manufactured in the same manner as in Example 1 except that burnishing was not performed on the raceway surface of the inner ring after quenching and tempering.

[0055] Using the 6206 deep groove ball bearings of Example 1 and Comparative Example 1, a rolling fatigue life test was carried out under the following conditions. A lubrication condition is a good condition in which an oil film is sufficiently secured and there is almost no mixing-in of a foreign matter, and it can be said that flak* occurs from inclusions present in the surface layer or the inside. Regarding test results, a state of a flaked surface in the test is confirmed, and it is confirmed that there is no occurrence of flaking starting from an indentation caused by biting of a foreign matter. [0056] Test load: 1410 kgf [0057] Rotation speed: 3900 min.sup.−1 [0058] Discontinuation: 1000 h

[0059] The results are indicated in FIG. 2. It can be seen that Example 1 has a longer life than Comparative Example 1.

[0060] After the rolling fatigue life test or after the life test was interrupted at an arbitrary time, a cross-section of the inner ring raceway surface was observed, and the number of white structures (portions where the structures were changed) generated per visual field area was obtained for each depth from the surface of the raceway surface. The result of the 6206 deep groove ball bearing of Comparative Example 1 is illustrated in FIG. 3A, and the result of the 6206 deep groove ball bearing of Example 1 is illustrated in FIG. 3B. As illustrated in FIG. 3A, in the 6206 deep groove ball bearing of Comparative Example 1, it is understood that the number of white structures generated in a region from the surface of the raceway surface to a depth of 150 μm is large. In contrast, as illustrated in FIG. 3B, in the 6206 deep groove ball bearing of Example 1, it is understood that the number of white structures in a region from the surface of the raceway surface to a depth of 150 μm is significantly reduced. Note that a dynamic shear stress indicated by a dotted line in FIG. 3A is obtained by calculation, and indicates a state of a load on the raceway surface portion under the above-described test conditions.

[0061] Table 3 indicates results of measuring the amount of retained austenite and the residual stress in the depth direction from the surface of the raceway surface of the inner ring of the 6206 deep groove ball bearing of Example 1 by the X-ray diffraction method. A region which is not affected by burnishing, such as a core part of the inner ring, is defined as an unmachined region, that is, a first region. On the other hand, a region affected by burnishing is defined as an machined region, and in Example 1, when a region where generation of a white structure is prevented, that is, a region from the surface of the raceway surface to a depth of 150 μm is defined as a second region, the second region is also included in the machined region. The residual stress in the region (second region) covering from the surface of the raceway surface to the depth of 150 μm is 500 MPa or more as compared with that in the unmachined region, that is, the first region. In addition, the amount of retained austenite in the region (second region) covering from the surface of the raceway surface to the depth of 150 μm is secured to be 70% or more as compared with that in the unmachined region (first region).

TABLE-US-00003 TABLE 3 Residual ratio of retained Depth from austenite to surface of Retained that in raceway austenite unmachined Residual stress Range of surface (μm) amount (%) region (%) (MPa) burnishing 0 10.3 72 −853 Machined region 50 14.7 102 −645 (second region) 100 13.3 93 −832 150 14.5 101 −532 200 14.7 102 −166 Machined region 250 14.6 100 16 Unmachined 300 14.5 31 region (first 350 14 33 region) 400 14.3 18

[0062] In addition, a strain amount (machining amount) introduced into a metal structure inside the raceway surface by burnishing was measured. First, the inner ring of'the 6206 deep groove ball bearing manufactured m the same manner as the 6206 deep groove ball bearing of Example 1 was subjected to burnishing, and thereafter subjected to mechanical polishing on the cross-section of the raceway surface thereof and subjected to chemical polishing using colloidal silica. An electron backscatter diffraction analysis was performed on a plurality of measurement points in the cross-section of the polished raceway surface by using an electron backscatter diffraction analyzer manufactured by TSL Solutions Inc., and a microstructure analysis was performed with respect to the analysis result by using orientation imaging microscopy (OIM) analysis software developed by TSL Solutions Inc.

[0063] That is, sharpness of the Kikuchi line for each measurement point which was obtained in the electron backscatter diffraction analysis was Hough transformed (Hough transform), and a Hough transform value (hereinafter also referred to as “IQ value”) for each measurement point was obtained. With respect to each of pixels constituting an image obtained by photographing the cross-section of the raceway surface, an IQ value for a measurement point at a position corresponding to the pixel was applied, and a color corresponding to a magnitude of the IQ value was displayed on each pixel of the image, thereby creating map data of the cross-section of the raceway surface. Thereafter, the map data is subjected to image analysis, and a distribution curve indicating the distribution of the IQ values in the map data is created on the orthogonal coordinates having the IQ value as the X axis and a frequency of the IQ value as the Y axis. A machining amount of a non-overlapping region not overlapping a region surrounded by the distribution curve of a non-fatigued part which is not fatigued due to the burnishing and the X axis, among a region in the orthogonal coordinates surrounded by the distribution curve of a part which is fatigued due to burnishing and the X axis, is calculated. That is, by subtracting a strain amount of the non-fatigued part from a strain amount of the part fatigued due to burnishing, the strain amount (machining amount) introduced into the cross-section of the raceway surface by burnishing can be evaluated.

[0064] Table 4 shows the strain amount (machining amount) in the depth direction from the surface of the raceway surface of the inner ring of the 6206 deep groove ball bearing of Example 1. It can be seen that a strain amount (machining amount) from the surface of the raceway surface to a depth of 150 μm is 0.03 or more, and a strain amount (machining amount) in the second region is suitably 0.03 or more.

TABLE-US-00004 TABLE 4 Strain amount Depth from surface of raceway surface (machining amount) 0 μm to 50 μm or less 0.10 Over 50 μm to 100 μm or less 0.05 Over 100 μm to 150 μm or less 0.03 Over 150 μm to 200 μm or less 0.02

[0065] Although the embodiments are described above with reference to the drawings, it is needless to say that the present invention is not limited to such examples. It will be apparent to those skilled in the art which various changes and modifications may be conceived within the scope of the claims. It is also understood that the various changes and modifications belong to the technical scope of the present invention. Components in the embodiments described above may be combined freely within a range not departing from the spirit of the present invention.

[0066] The present application is based on Japanese Patent Application No. 2020-024705 filed on Feb. 17, 2020, the contents which are incorporated herein by reference.

REFERENCE SIGNS LIST

[0067] 1 radial ball bearing

[0068] 2 outer ring raceway surface

[0069] 3 outer ring

[0070] 4 inner ring raceway surface

[0071] 5 inner ring

[0072] 6 ball

[0073] 7 cage