Modelling capabilities required for the double nosing process in the assembly of spherical plain bearings

Abstract

Double nosing is a cold forming process used in the assembly of spherical plain bearings. In order that future bearing product introductions are better facilitated using a virtual process model, with the aim of reducing extensive prototyping, testing and costly design and process changes, the modelling capabilities of pertinent analytical and computational approaches should be evaluated. For example, there are several existing analytical approaches that were developed for the prediction of the forming loads, an important consideration when assessing the capacity of the press machines and die design, but these are generally only valid for thin sections in nosing. In this paper, for a specific bearing size on the limit of a thin/thick section, the validity of the forming load predictions is assessed through a comparison with experimental data taken from a forming press, and in comparisons with two-dimensional (2D) and three-dimensional (3D) finite element analysis (FEA) results. The modelling capabilities of the FEA approach are examined, including the evolution of maximum stresses in the bearing components, interface pressures on dies and temperature rises created during the double nosing cycle. The computational time to obtain the solutions and the validity of some key initial assumptions are discussed, including the selection of the coefficient of friction.