ISCAR in the Bearing Industry
If something turns, twists, or moves, it most likely has a bearing in it. Today, the most popular bearing type in the market is the ball bearing, but roller bearings, needle, tapered, spherical, and thrust bearings are also quite common.
The sizes of bearings variously range from very small diameters such as 2mm for electronic systems, up to diameters of 6000mm, mostly for wind power turbines. Linear bearings and bearing housings are also part of the industry, but with different geometrical characteristics.
When talking about bearings, one of the most demanding industries today is the automotive industry. Every car has an average of 100-150 bearings, while motorcycles have between 25-30. With an annual production rate of over 93 million cars and 140 million motorcycles a year, the demand for bearings is higher than ever, and continues to rise.
The need for bearings is also increasing in other industrial sectors such as machine production, electrical appliances, construction and infrastructure machinery, aviation, power generation, etc. Along with the remarkable increase in bearing production, there is a lot of pressure on bearing producers to reduce the cost of bearings. Due to this demand, some of the major players are establishing new production plants in less expensive to produce countries, such as China, India, and East Europe.
In addition, many of the bearing manufacturers are looking for faster machining cycles and more efficient processes to enable them to fulfil market requirements. They are also trying to find options to minimise raw material loss by optimising their machining methods and replacing old tech tools that can no longer withstand the high machining conditions and long tool life requirements.
In the world of bearing production, it is very important to stay well prepared with the most innovative tools, as competition is aggressive and non-efficient machining processes may cause loss of business.
ISCAR’s experienced engineers are capable of supporting any bearing design with advanced machining solutions that can ensure maximum performance, efficiency, and precision.
Most of the small to medium size bearing diameters are produced in mass production methods on multi-spindle machines, or on simple single-task machines. Single-task machines are only able to perform one or two operations on the machined rings, and a few machines of this type are needed to complete an entire part.
ISCAR has the knowledge and experience in providing comprehensive solutions for a variety of these applications with very efficient tools for Parting, Trepanning, Grooving, Profiling, and Turning operations.
Many ISCAR inserts are designed as multi-corner inserts, such as the PENTA, and feature economic advantages due to their 5 cutting edges. These inserts are mostly used for parting-off operations; seal groove machining, raceway grooving…etc.
The unique structure of the PENTA inserts enable grinding unlimited numbers of different shapes and geometries with a very attractive cost per edge; thus assisting ISCAR customers to reduce production costs, and enabling them to easily compete with their products.
PENTA inserts can also be used for Trepanning, which is an axial operation for the separation of one thick forged ring to two separate outer and inner rings. For such operations, ISCAR also offers other types of inserts such as BGR and BGMR for wider rings that dictate deep separation operations.
ISCAR also developed multi-parting systems for customers that feature an assembled set of parting blades or adapters designed for parting a few rings at a time. Such sets are provided with the very popular TANG-GRIP and DO-GRIP insert, and also with the PENTA inserts. Such parting systems dramatically shorten one of the most common operations in bearings production.
ISCAR’s unique parting-off products are provided in very narrow sizes that enable manufacturers to significantly reduce the width of inserts, down to 0.7 and 1.0mm, and therefore save on raw materials. Such savings help produce up to 15% more rings out of existing steel tubes.
ISCAR’s Turning division provides a large variety of latest geometries and carbide grades as well as Ceramic and CBN inserts for finish turning operations of harden bearing rings up to 64 HRc. CBN inserts with chipformers are ISCAR’s ultimate solution for such operations and can easily replace expensive grinding processes.
For wide profiling operations on multi-spindle machines, ISCAR has the V-Lock and FTB inserts that can provide a solution for wide profiles of 10 up to 51mm width.
For large bearing rings, ISCAR has developed unique drills based on the popular SUMOCHAM drills, and the unique FCP inserts that provide outstanding performance and superior surface quality in such heavy-duty drilling operations.
Most bearing manufacturers (excluding specials) require mass production and exact precision when meeting deadlines and quality standards. ISCAR has the knowledge and experience to provide comprehensive solutions for a variety of applications in Parting, Grooving & Profiling, Turning, Drilling, and Milling.