Customization of automotive bearings involves multiple stages such as design, material selection, processing, assembly, and testing. Each stage must strictly follow safety operating procedures to ensure personnel safety, product quality, and stable equipment operation. The following are safety precautions during the customization process of automotive bearings:
1. Safety precautions during the design phase
Load and speed verification
Accurately calculate the radial load, axial load, and composite load that the bearing can withstand to avoid early failure caused by overload design. Determine the maximum bearing speed based on the engine speed, transmission system speed, and working conditions (such as high temperature and high speed) to prevent lubrication failure or material fatigue caused by excessive speed.
Material and Heat Treatment Selection
Choose high-strength, wear-resistant, and corrosion-resistant bearing steel (such as GCr15) to ensure that the chemical composition of the material meets the standard (such as C content of 0.95% -1.05%).
. The heat treatment process requires strict control of quenching temperature (840 ℃ -860 ℃), tempering temperature (150 ℃ -180 ℃), and cooling rate to avoid uneven hardness caused by quenching cracks or insufficient tempering.Sealing and lubrication design
Choose the sealing form (such as rubber sealing ring, metal dust cover) according to the working environment (such as mud, water) to prevent foreign objects from entering.
. When designing the lubricating oil passage, ensure that the oil hole position is reasonable to avoid lubricating oil leakage or uneven distribution.II. Safety precautions during processing
Equipment safety operation
Lathe/grinder operation:
Before starting, check whether the chuck, tip, and tool are fastened to prevent the workpiece from flying out.
. Maintain a safe distance during processing to avoid clothing or gloves getting caught up in rotating parts. After shutting down, turn off the power and use specialized tools to clean iron filings to prevent scratches.Heat treatment equipment:
The quenching tank should be equipped with temperature control and liquid level alarm devices to prevent high oil temperature from causing fires.
. Operators are required to wear heat-resistant gloves, goggles, and gas masks to avoid burns or poisoning from high-temperature oil mist.Tool and Measuring Tool Management
Tools need to be regularly checked for wear and tear, and passivated tools need to be replaced in a timely manner to avoid workpiece scrap or equipment damage caused by machining vibration.
. Measuring tools (such as micrometers and dial indicators) need to be calibrated regularly to ensure measurement accuracy and prevent bearing assembly failure due to dimensional deviations. Environment and ProtectionThe processing area needs to maintain good ventilation to reduce the accumulation of metal dust and lower the risk of explosion.
. Operators are required to wear safety helmets, protective goggles, dust masks, and anti smashing shoes to prevent splashes or heavy objects from falling and injuring people.III. Safety precautions during assembly
Cleaning and rust prevention
Before assembly, thoroughly clean the bearing parts with gasoline or specialized cleaning agents to remove oil sludge, iron filings, and rust proof oil.
. After cleaning, dry it with compressed air or soak it in rust proof oil and let it air dry naturally to prevent residual moisture from causing rust.Lubrication and pre tightening
When lubricating with grease, the filling amount should be controlled at 1/2-2/3 of the internal cavity of the bearing to avoid excessive heating or leakage.
. The preload force needs to be adjusted according to design requirements, using torque wrenches or hydraulic devices to ensure uniform preload force and prevent bearing jamming caused by insufficient preload leading to vibration or excessive preload.Assembly Tools and Methods
Use specialized press in tools or hot sleeve devices to assemble bearings, avoiding direct tapping that may cause cracking of the inner ring or deformation of the outer ring.
. During assembly, ensure that there is no gap between the inner ring of the bearing and the shoulder of the shaft, and that the outer ring contacts the bearing seat evenly to prevent early failure caused by unbalanced load.IV. Safety precautions during testing stage
Safety of bench test
Before the test, check whether the fixed device of the bench is firm to prevent the bearing specimen from flying out and injuring people.
. During the experiment, personnel should stay away from rotating parts and record speed, temperature, and vibration data through a remote monitoring system. When there is an abnormal shutdown, it is necessary to wait for the equipment to completely stop before checking to avoid mechanical injury caused by sudden start-up.Road test safety
Test vehicles must be equipped with safety officers, and drivers must hold corresponding qualifications and comply with traffic rules.
. The test route should choose closed roads or low traffic flow areas to avoid high-risk testing on highways or in urban areas. After the test, check the temperature, noise, and leakage of the bearings, record the data, and analyze the cause of any abnormalities.Fifth, Storage and Transportation Safety Precautions
Storage Environment
Bearings should be stored in a dry, ventilated, and non corrosive gas warehouse with a temperature controlled between 5 ℃ -35 ℃ and a relative humidity of ≤ 60%.
. Bearings should be placed horizontally or suspended vertically to avoid deformation caused by long-term pressure buildup.Transport protection
Special packing box shall be used during transport, and cushioning materials (such as foam and air cushion) shall be filled inside to prevent collision damage. Transport vehicles must be equipped with anti-skid devices to avoid bearing displacement or collision caused by sudden braking or bumps.
VI. Personnel Training and Emergency Response
Operator Training
Regularly organize safety operation training, covering equipment operation, hazard identification, emergency response, etc. New employees must pass an assessment before they can take up their positions, ensuring that they master safety regulations and operational skills.
Emergency Plan
Develop emergency plans for fires, mechanical injuries, chemical spills, etc., clarify escape routes and rescue procedures.
. Equip emergency supplies such as fire extinguishers, first aid kits, and gas masks, and regularly check their expiration date and integrity.