WO2009064729A2

WO2009064729A2 - A composite outer race for a wheel end and method of manufacturing thereof

Info

Publication number: WO2009064729A2
Application number: PCT/US2008/083132
Authority: WO
Inventors: John D. Dougherty; Brian J. Werner; Timothy J. Krabill
Original assignee: The Timken Company
Priority date: 2007-11-12
Filing date: 2008-11-11
Publication date: 2009-05-22
Also published as: WO2009064729A3

Abstract

Bearing assemblies and methods of manufacturing thereof, having an outer race for a bearing assembly (18) having a body defining a substantial portion of the outer race. The body (12) is configured of a material other than a bearing quality steel. The body includes a cavity defining an inner surface and having an axis for receiving a rotating shaft and a plurality of rolling elements (34) positioned about the rotating shaft. An outer raceway liner (46) is positioned along the inner surface of the cavity of the body and defines an outer raceway (40) presented inwardly towards the axis. The outer raceway liner is configured of bearing quality steel and is fixedly formed with the inner surface of the body for forming a composite outer race.

Description

A COMPOSITE OUTER RACE FOR A WHEEL END AND METHOD OF MANUFACTURING THEREOF

RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No.

60/987,313, entitled A COMPOSITE OUTER RACE FOR A WHEEL END AND METHOD OF MANUFACTURING THEREOF, filed on November 12, 2007. The disclosure of the above application is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to rolling element bearings and, more particularly, to a composite outer race for a wheel end.

BACKGROUND ART The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Wheel ends commonly utilize outer races with integral flanges made by a forging process. These outer races typically have their flanges bolted to a steering knuckle.

SUMMARY OF THE INVENTION

In one aspect, the inventors hereof have succeeded at designing a composite outer race for bearing assemblies having improved features and/or lower manufactured costs. In one aspect an outer race for a bearing assembly includes a body defining a substantial portion of the outer race. The body is configured of a material other than a bearing quality steel. The body includes a cavity defining an inner surface and having an axis for receiving a rotating shaft and a plurality of rolling elements positioned about the rotating shaft. An outer raceway liner is positioned along the inner surface of the cavity of the body and defines an outer raceway presented inwardly towards the axis. The outer raceway liner is configured of bearing quality steel and is fixedly formed with the inner surface of the body for forming a composite outer race.

In another aspect, a bearing assembly for a wheel end having an inner race defining an inner raceway and a plurality of rolling elements, includes an outer race for a bearing assembly having a body defining a substantial portion of the outer race. The body is configured of a material other than a bearing quality steel. The body defines a cavity having an inner surface and having an axis for receiving a rotating shaft and a plurality of rolling elements positioned about the rotating shaft. An outer raceway liner is positioned along the inner surface of the cavity of the body and defines an outer raceway presented inwardly towards the axis. The outer raceway liner is configured of bearing quality steel and is fixedly formed with the inner surface of the body for forming a composite outer race.

In yet another aspect, a bearing assembly for a wheel end having an inner race defining an inner raceway and a plurality of rolling elements, the assembly includes an outer race for a bearing assembly having a body defining a substantial portion of the outer race. The body is configured of a material other than a bearing quality steel. The body defines a cavity having an inner surface and an axis for receiving a rotating shaft. A plurality of rolling elements is positioned about the rotating shaft received within the cavity of the body of the outer race. Means for defining an outer raceway of the outer race along the inner surface of the cavity of the body is provided wherein the outer raceway is presented inwardly towards the axis.

In still another aspect, a method of manufacturing an outer race for a bearing assembly includes configuring an outer raceway liner from a bearing quality steel including defining an outer raceway surface for contacting a rolling element, positioning the outer raceway liner in a mold, casting the outer race in the mold from a casting material, wherein casting includes casting the casting material to and about portions of the outer raceway liner, and machining outer features of the race from the casting material. Additional and further aspects of the present disclosure will be in part apparent and in part pointed out below. It should be understood that various aspects of the disclosure may be implemented individually or in combination with one another. It should also be understood that the detailed description and drawings, while indicating certain exemplary embodiments, are intended for purposes of illustration only and should not be construed as limiting the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional side view of a wheel end assembly having a composite outer race according to one exemplary embodiment. FIG. 2 is a cross sectional side view of a wheel end assembly having a composite outer race according to a second exemplary embodiment.

FIG. 3 is a cross sectional side view of a wheel end assembly having a composite outer race having an outer raceway liner according to a third exemplary embodiment. FIG. 4 is a cross sectional side view of a wheel end assembly illustrating two different outer raceway liners for composite outer races according to two other exemplary embodiments.

FIGS. 5A-5G are various views of raceway liners defining outer raceways for use in forming composite outer races according to various embodiments. It should be understood that throughout the drawings, any corresponding reference numerals or text labels indicate like or corresponding parts and features.

BEST MODE FOR CARRYING OUT THE INVENTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure or the disclosure's applications or uses.

Before turning to the figures and the various exemplary embodiments illustrated therein, a detailed overview of various embodiments and aspects is provided for purposes of breadth of scope, context, clarity, and completeness.

One embodiment of a composite outer race for a bearing assembly includes a body defining a substantial portion of the outer race. The body is configured of a material other than a bearing quality steel. For example, this can include cast iron, ductile iron, cast steel, cast aluminum, or a plastic or composite material, by ways of example, of non-bearing quality steel. The body includes a cavity defining an inner surface and having an axis. The cavity is configured for receiving a shaft for rotating about the axis and receiving a plurality of rolling elements positioned about the rotating shaft.

An outer raceway liner is positioned along the inner surface of the cavity of the body and defines an outer raceway presented inwardly towards the axis. The outer raceway liner is configured of bearing quality steel and is fixedly formed with the inner surface of the body for forming a composite outer race. In some embodiments, the outer raceway liner and the body defining the cavity form the composite outer race such that they are substantially monolithic. In some embodiments, the outer raceway liner includes an interlocking feature formed adjacent to and integrated with the material of the body. The interlocking feature can be any suitable feature that provides an improved bond or physical coupling between the raceway liner and the body that is configured from non-bearing quality steel. For example, the interlocking feature can include, by ways of examples, a tab, a knurled surface, a rough surface, a cavity, a protrusion, a curled end, two curled ends, a ridge, a hole, a notch, and/or a slot.

In some embodiments, the outer raceway liner includes induction hardened steel or other material suitable for forming a raceway. The outer raceway liner can be formed by any suitable means such as stamping, ring rolling, or cold forming, by ways of example.

While the outer raceway liner can be a single component defining one or more outer raceways, in some embodiments, the outer raceway liner can include two segments, one segment forming an inboard outer raceway and a second segment forming an outboard outer raceway. The two segments can be positioned next to each other or can be spaced apart from each other forming a gap there between. When a gap is provided, a sensor hole can be provided or formed in the gap for receiving a sensor. The sensor hold can be formed such as by drilling or by molding. As known to those skilled in the art, drilling should be easier in the cast material than in the bearing grade steel of the raceway liner. Of course, as known to those skilled in the art, the outer race liner can have any shape, including an outer peripheral shape of a circle, an elliptical, and a polygon, by ways of examples.

As noted above, a bearing assembly for a wheel end having an inner race having an inner raceway and a plurality of rolling elements, can be manufactured or assembled with the composite outer race as described herein.

Referring now to the figures, as shown in Fig. 1 a wheel end assembly 10 according to one exemplary embodiment includes an outer race 12 as described above. The wheel end assembly includes a hub 14 to which a road wheel is attached, a suspension system component 16 which is connected to a frame or unified body of the vehicle such that it can shift relative to the frame or body, usually under the influence of a suspension spring. An antifriction bearing assembly 18 that is fitted between the hub 14 and the suspension system component 16, enabling the hub 14 and the attached wheel (not shown) to rotate relative to that suspension system component 16 about a generally horizontal axis X. The bearing assembly 18 prevents the hub 14 and the attached wheel from otherwise being displaced. The suspension system component 16 typically takes the form of a steering knuckle that rotates about an axis that is perpendicular or nearly perpendicular to the axis X. Additionally, in other embodiments (such as in Fig. 2), the hub 14 can be connected to a constant velocity (CV) joint (not shown) that is driven by a drive shaft so as to transfer torque to the hub 14 and attached wheel.

The hub 14 includes a spindle 20 and a flange 22 that projects from the spindle 20 at a shoulder 24 located along the inboard face of the flange 22. The flange 22 is adapted for receiving and securing a plurality of lug bolts 26 for attaching a wheel (not shown).

The bearing assembly 18 includes an inner race 28 in the form of two inner races, an outboard inner race 30 and an inboard inner race 32, that fit around the spindle 20 with interference fits, wherein the outer race 12 is embedded within the suspension system component 16, and rolling elements 34 or rollers 34 such as those arranged in two rows between the inner races 30 and 32 and the outer race

12.

Each inner race 30 and 32 has an inner raceway 36, that is presented outwardly away from the axis X, a thrust rib 38 at the large end of its raceway 36, and a back face 42, which is squared off with respect to the axis X on the end of the thrust rib 38. The back face 42 of the outboard inner race 30 abuts the shoulder

24 that lies along the flange 22. The back face 42 of the inboard inner race 32 lies beyond the free end of the spindle 20.

The rollers 34 are arranged in two rows, there being a separate row around each inner race 30, 32. The rollers 34 extend around the inner raceways 36 for the inner races 30, 32, there being essentially line contact between side faces of the rollers 34 and the raceways 36. Each row of rollers 34 has a cage to maintain the proper spacing between the rollers 34 in that row.

The outer race 12 surrounds the spindle 20 as well as the two inner races 30, 32 and the two rows of rollers 34. It has outer raceways 40 that are presented inwardly toward the axis X. The rollers 34 likewise lie along the outer raceways

40 with there being essentially line contact between the outer raceways 40 and the side faces of the rollers 34.

As shown in Fig. 1, the outer race 12 can be configured with an integrated or attached integral flange 43 that can be bolted to a steering knuckle 16 or other suspension system component. The outer race 12 has a body generally formed from a non-bearing quality material. A liner 46 is formed on an inner surface of the outer race 12 as described above. The liner 46 defines the outer raceways 40.

The liner 46 can be integrally formed with the outer race 12 or can initially exist as a separate component that acquires its basic shape through hot forging or by ring rolling, or otherwise, and fixedly coupled to form the outer race 12.

The liner 46 and in particular the outer raceways 40 are formed from bearing quality steel or similarly suitable raceway material for engaging with rolling elements 34. For example, the outer race 12, such as a cup utilized with spherical or tapered rolling bearings or rolling elements 34 by way of example and not intending to be limiting, can be, in part formed by bearing quality steel metal liners 46 forming outer raceways 40. The outer race 12 can thereby be configured from outer race 12 being composed of a non-bearing quality steel as a backing infrastructure with the outer raceways 40 being formed as a composite of the outer race 12 and the liners 46. In one embodiment, the liners 46 can be composed or manufactured by a material conversion process, such as stamping, ring rolling, or cold forming of a bearing quality steel. The bearing infrastructure backing or outer race 12 can be formed from a cast material such as cast iron, ductile iron, cast steel, cast aluminum, or a plastic or composite material, as described above. As shown in Fig. 1, the wheel end assembly 10 is that adapted as a front

4x2 embodiment by way of example. However, it should be known to those skilled in the art that this same concept can be applied to a front 4x4 wheel end embodiment by using a hub that has inner diameter splines for fitting on the outer diameter splines on a CV joint shaft. In some embodiments, an end cap 48 can be positioned on the inboard side or in other embodiments a seal (not shown) can be positioned on the inboard side.

Fig. 1 illustrates one exemplary hub 14 and bearing assembly 18 combination with an outer race 12 and it should be known that other variations are also considered to be within the scope of the present disclosure. In some embodiments, an end of the hub 14 can also be formed for clamping the bearing assembly 18 to the hub 14.

In another exemplary embodiment, the wheel end assembly 50, as shown in Fig. 2, includes a CV joint 52, which lies at the end of a drive shaft (not shown) and has an enlarged body 54 provided with a shoulder 56 presented toward the bearing assembly 18. It also has a stub shaft 58 that projects beyond the shoulder 56 and is provided with a spline 62. The very end of the stub shaft 58 is reduced in diameter and threaded to provide a threaded end 68. The stub shaft 58 fits into a bore 76 of the spindle 20 for the hub 14, where its spline 62 engages a spline in the bore 76. The shoulder 56 bears against the back face 42 of the inboard inner race 32. The hub 14 defines a circular rib 60 that surrounds a clamping surface 64. The spindle 20 contains a splined bore 76 that at one end opens out of the clamping surface 64 and at its other out of the free end of the spindle 20. Outwardly from the shoulder 24, the flange 22 has a sealing surface 72 that faces inwardly as does the shoulder 24. Beyond the sealing surface 72, the flange 22 is fitted with lug bolts 26 that project axially from its outboard face, forming a bolt circle around a circular rib 60. A brake disk 66 fits against the flange 22 and a road wheel 78 against the disk 66, with the lug bolts 26 projecting through each of them. Beyond the wheel 78, lug nuts 80 are threaded over the lug bolts 26 to secure the brake disk 66 and wheel 78 to the hub 14.

The threaded end 68 of the stub shaft 58 projects axially beyond a clamping surface 64 that lies within the circular rib 60 on the hub 14. Here the stub shaft 58 is engaged with a nut 82. When the nut 82 is tightened, it in effect bears against the clamping surface 64 of the hub 14 and forces the shoulder 56 of the CV joint 52 against the back face 42 of the inboard inner race 32. This clamps the two inner races 30, 32 snugly together between the shoulder 24 on the hub 14 and the shoulder 56 on the enlarged body 54 of the CV joint 52. In the alternative, the end of the spindle 20 on the hub 14 can be extended axially beyond the back face 42 of the inboard inner race 32, and there deformed radially outwardly. The suspension system component 16, when in the form of a steering knuckle having an upper arm 84 and a lower arm 86 that meet at an enlarged intermediate portion 88 in which the outer race 12 of the bearing assembly 18 is formed.

The suspension system component arms 84, 86 are offset toward the inboard end of the intermediate portion 88, thus leaving the outboard end of the intermediate portion 88 resembling a collar. The upper arm 84 projects obliquely inwardly well beyond the inboard end of the intermediate portion 88, whereas the lower arm 86 extends directly downwardly. Each arm 84, 86 has a laterally directed end 90 that projects inwardly and contains a tapered socket 94 designed to receive the tapered stem on a conventional ball-and-socket joint. The intermediate portion 88 contains a bore 76 that opens between the two arms 84, 86 and forms a cavity 96 with an inner surface 98. In addition, the suspension system component 16, when in the form of a steering knuckle, has another arm (not shown) that attaches to a tie rod end of the steering system and a bracket (not shown) to which attaches a brake caliper that operates against the brake disk 66. The suspension system component 16 can be formed in a casting operation from a suitable metal such ductile iron or steel, although other metals such as aluminum will suffice as well.

As shown by way of example, Fig. 2 illustrates a steering knuckle of a wheel end having a outer race 12 configured by casting around the liner 46 for forming the outer race 12 with the outer raceways 40 of bearing assembly 18. These liners 46 can be made by a material conversion process, such as stamping, ring rolling, or cold forming, by ways of example. The cast material can be similar to those as described above. Fig. 2 illustrates a front 4x4 wheel end embodiment, but the same concept can be applied to a front 4x2 wheel end embodiment. Fig. 2 illustrates a non-formed hub and bearing embodiment, but it should be understood to those skilled in the art that this concept can also be applied to other non-formed or formed hub and bearing embodiments.

Fig. 3 illustrates a wheel end assembly 100 having an outer race 12 configured by casting around a metal liner 46 that only forms the outer raceways 40. This exemplary embodiment provides that the flange 22 is axially centered over the outer raceways 40 of the outer race and a sensor 102 is oriented perpendicular to a centerline of the bearing assembly 18. The flange 22 can also be shifted in either axial direction with respect to the bearing raceways 40 as may be adapted for the particular wheel end requirements. In these embodiments, the sensor 102 can enter the outer race at an angle to avoid interference with the steering knuckle 16. Generally, a hole 104 for the sensor 102 can be made by any suitable manufacturing means and can include forming during casting or by drilling after the casting process by ways of example. In some embodiments, a hole 106 or slot can be placed in the metal liner 46 before casting using either a drilling or a punch piercing process as additional examples wherein the hole 106 aligns with the hole 104 in the outer race 12 During the casting process, the cast material fills the hole 106 in the metal liner 46 providing a mechanical interlocking of the metal liner 46 with the outer race 12. The sensor hole 104 is then drilled in the outer race 12 for connecting with the hole 106 in the liner 46. In this manner, the drill bit only passes through the cast material of the outer race 12 and not the hardened material of the liner 46 thereby making it easier to drill the hole 104. In some cases, additional mechanical interlocking between the outer race 12 and the liner 46 may be desired. In such embodiments, additional holes or slots can be drilled or punched or other protrusions, cavities or similar features can be added to the back of the liners 46 before casting for providing additional mechanical interlocking with the outer race 12, or at least an inner surface 98 of the outer race 12 defining the boar 76.

Fig. 4 illustrates two alternative embodiments for the metal liners for a composite outer race, one on the top portion and the other on the lower portion, for brevity. The top portion of the figure shows a one-piece liner 46A that has extensions at both ends for providing one or more seats 108 for one or more seals 110. Integrating the seal seat 108 with the metal liner 46A, results in the press fit between a case of the seal 110 and the seal seat 108 being between two steel components instead of between one steel component and one cast material component. In this embodiment, the hole 106 for the sensor 102 can be formed in the metal liner 46 A before or after the casting process.

In the bottom portion of Fig. 4 a two-piece liner 46B configuration is shown wherein with both portions of the two-piece liner 46B have identical geometry and also have, by way of example, the integrated seat 108 for a seal 110 on each end. For this two-piece liner embodiment, the two liner portions 46B can abut each other at the axial center of the inner diameter flat or they can be spaced apart to form a gap 112 therebetween, such as during the molding or casting of the outer race 12. In this embodiment, any space or the gap 112 between the two liner portions 46B is filled with cast material during the casting process of the outer race 12. This filled cast material provides a mechanical interlocking between the metal liner portions 46B and the cast outer race 12. Additionally, the space or gap 112 between the liner portions 46B that is composed of cast material enables easier drilling of the hole 104 for the sensor 102, because no drilling of the hardened steel of the liner portions 46B would be required.

As with the embodiments of Fig. 3, the embodiments of Fig. 4 can also include additional mechanical interlocking by including additional holes, slots, protrusions, cavities, for example, in the liner portions 46B before casting of the outer race 12.

Fig. 5 illustrates a plurality of exemplary embodiments of outer race liners 46 consistent with some embodiments of an outer race 12 as described herein. As shown, one or more of these embodiments of liners 46 can provide additional retention and anti-rotation of the liner 46 relative to the outer race 12 of which the liner 46 is a part for providing bearing quality outer raceways 40 to the outer race 12 of the bearing assembly 18. As shown in Fig. 5 A, a curled end 116 can be formed into a large end of the outer raceways 40. Although not shown in Fig. 5A, this can also include an outward curl at the small end of the liner 46C. Another embodiment is illustrated in Fig. 5B that can be utilized with two portion raceway liners 46B or one double raceway liner 46A. As shown, these liners 46A and 46B can include the curled end 116 that can provide for increased surface area being in contact with the outer race 12 such as in the cast material thereby enhancing retention and the resistance to rotation of the liners 46A and 46B to their respective outer race 12. The curl 116 of the liners 46 can also provide structural support for retaining the liners 46 and thereby the outer raceway 40 relative to the other components of the outer race 12.

Fig. 5C illustrates an additional embodiment of a curled liner 46 that can provide improved resistance to rotation. It should be understood to those skilled in the art after reviewing this disclosure that the curled formations of the liners 46 as described here can be of a circular shape or can be any non-circular outer shape and still be within the scope of the present invention. For example, this can include an elliptical shape, a polygon shape, or otherwise.

Fig. 5D illustrates another exemplary embodiment configured for resisting rotation of a liner 46D relative to the outer race 12. The outer diameter 118 can include irregularities 120 and 122 that will interface with the cast material of the outer race 12 for resisting rotation relative thereto. These irregularities 120 and 122 could be obtained from a high surface roughness or from shapes formed, cut or trimmed into the part. Of course, one or more shapes can be used. The pattern of the shapes may be symmetric or non-symmetric. The shapes may project into or out of the liner 46D.

Fig. 5E illustrates yet another exemplary embodiment of a liner 46 configured enhance retention and resist rotation of the outer raceway 40 defined by a liner 46E relative to the outer race 12. As shown, a plurality of indentations 124 can be formed axially on the face of the curled edge of the liner 46E. In this manner, during casting or forming of the outer race 12, any casting material will enter these indentations 124 for providing retention and resistance to rotation of the liner 46E relative to the outer race 12. For stamped liners 46, the features shown in Figs. 5A, 5B, 5C, 5D, and 5E can all be formed during the stamping process with little to no additional manufacturing time or cost. Fig. 5F illustrates an additional embodiment of a liner 46 adapted for use in the outer race 12. As shown in this exemplary embodiment, the outer raceway liner 46F can include a plurality of tabs 126 formed along a periphery for embedding in the cast material during formation of the outer composite race 12. The tabs 126, once cast within the cast material of the outer race 12, provide for securing the outer raceway liner 46F thereto.

Similarly, as shown Fig. 5G a plurality of ridges 128 or knurls can be formed on the outer diameter of a surface of an end of the outer raceway liner 46G for providing a securing feature or formation with the cast material of the outer race 12. The present disclosure also includes methods of manufacturing a composite outer race and/or a bearing assembly containing such a composite outer race. The methods can include, configuring an outer raceway liner from a bearing quality steel including defining an outer raceway surface for contacting a rolling element. This can include stamping, ring rolling, and cold forming, by ways of examples. The outer raceway liner is positioned in a casting mold (such as in a cavity of the mold) and the outer race is cast in the casting mold utilizing a casting material such that the casting material casts to and about the outer raceway liner. The outer features of the race are then machined or otherwise formed from the casting material.

Additionally, the method can also include machining one or more holes for a sensor and/or sensor mounting bolt.

In other embodiments, the method can include finishing the outer raceway surface to achieve a predetermined surface finish for contacting a rolling element.

In yet other embodiments, the method can include induction hardening the outer raceway liner along the outer raceway surface. Such induction hardening can be before the casting or can be following the casting of the outer race.

As one example of the manufacturing of a wheel end assembly having a composite outer race, the following processes are illustrative thereof:

1) configure one or more bearing quality steel raceway liner by a stamping, ring rolling, or cold forming process; 2) position the metal raceway liners in the casting mold, such as within a cavity of the mold;

3) cast the outer race such as a steering knuckle around the metal liner;

4) induction harden the metal liner along the raceway surfaces;

5) machine the finished geometry of the race; 6) machine any required holes for any sensor or sensor mounting bolt; and

7) finish the outer raceway surfaces to achieve proper surface finish and geometry.

Additionally, following completion of processes 1-3, or possibly additional processes, the outer race and bearing assembly can be assembled with the other components in the final bearing assembly and a wheel end as desired. Of course, as known to one skilled in the art after reviewing this disclosure, one or more processes and steps are also possible and within the scope of the present disclosure.

Current wheel end embodiments can provide a formed or unformed hub and bearing assembly that is bolted to the steering knuckle. These assemblies feature an outer race that has two raceways, a cylindrical shaped body, and an integral flange for bolting the assembly to the steering knuckle. Prior to the conception of various embodiments of the present disclosure, the practice was to have the flanged double outer race hot forged, cold formed, or ring rolled out of bearing quality steel. However, this resulted in the entire component being made of bearing quality steel. Bearing quality steel is more expensive than standard steel types or cast materials, such as cast steel, cast iron, ductile iron, and cast aluminum. As such, one of the advantages of some of the embodiments of the present disclosure over the prior practices and systems is the reduction in the quantity of bearing quality steel required, such that it is only that required for the outer race metal liners for forming the outer raceways. The remainder portion of the outer race can be made of less expensive cast material.

The composite structure as described herein (steel and cast material) can be achieved by casting the flanged outer race, such as a flanged double outer race or a steering knuckle, by ways of examples, around the metal outer race liner. The metal outer race liner can be formed by stamping, ring rolling, or cold forming processes. The formed outer race liner can be placed in the casting mold and the cast material is poured into the mold to create the insert cast component.

Various embodiments of the present disclosure solves problems that had previously been attempted to be solved. For example, previously, a cast steering knuckle required hot forging of a flanged insert and the substantial manufacturing cost. In contrast, some embodiments of the present disclosure addresses casting a steering knuckle around an insert that featured a non-circular flange portion that resulted in mechanical interlocking of the casting and the insert. As described herein the outer race liner can be produced by stamping for example which enables the cost of the insert to be substantially reduced over the prior systems.

Similarly, wheel hubs have been made by molding a polymer material around a metal insert. However, these structures had fatigue and stiffness problems that limited their practical use. Similarly, a part has been cast around finished single outer or inner race. However, due to high temperature associated with the casting process, these previous metal liners had to be pressed over the outer race or into the inner race to protect them. This added complexity and cost to the assembly by increasing the number of components required. In contrast, as described herein the outer liners are formed first from bearing quality steel and then placed within a mold wherein the outer race infrastructure is formed by molding or casting.

When describing elements or features and/or embodiments thereof, the articles "a", "an", "the", and "said" are intended to mean that there are one or more of the elements or features. The terms "comprising", "including", and "having" are intended to be inclusive and mean that there may be additional elements or features beyond those specifically described.

Those skilled in the art will recognize that various changes can be made to the exemplary embodiments and implementations described above without departing from the scope of the disclosure. Accordingly, all matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense.

It is further to be understood that the processes or steps described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated. It is also to be understood that additional or alternative processes or steps may be employed.

Claims

CLAIMSWhat is claimed is:

1. An outer race for a bearing assembly comprising: a body defining a substantial portion of the outer race, the body being configured of a material other than a bearing quality steel, the body including a cavity defining an inner surface and having an axis for receiving a rotating shaft, and a plurality of rolling elements positioned about the rotating shaft; and an outer raceway liner positioned along the inner surface of the cavity of the body and defining an outer raceway presented inwardly towards the axis, the outer raceway liner being configured of bearing quality steel, wherein the outer raceway liner is fixedly formed with the inner surface of the cavity of the body for forming a composite outer race.

2. The outer race of claim 1 wherein the outer raceway liner and the body are fixedly formed to have a monolithic body.

3. The outer race of claim 1 wherein the body is formed from a material selected from the group consisting of cast iron, ductile iron, cast steel, cast aluminum, or a plastic or composite material.

4. The outer race of claim 1 wherein the outer raceway liner includes an interlocking feature formed adjacent to and integrated with the material of the body selected from the group consisting of a tab, a knurled surface, a rough surface, a cavity, a protrusion, a curled end, two curled ends, a ridge, a hole, a notch, and a slot.

5. The outer race of claim 1 wherein the outer race liner induction hardened steel and is configured includes a method selected from the group consisting of stamping, ring rolling, and cold forming.

6. The outer race of claim 1 wherein an outer raceway liner includes two segments, one segment forming an inboard outer raceway and a second segment forming an outboard outer raceway, wherein the first segment is spaced apart from the second segment forming a gap therebetween.

7. The outer race of claim 6 wherein a sensor hole is formed in the gap formed between the first second and the second segment.

8. The outer race of claim 1 wherein the outer race liner has an outer peripheral shape selected from the group consisting of a circle, an elliptical, and a polygon.

9. The outer race of claim 1 wherein outer raceway liner includes an outwardly extended portion configured as a mounting seat for a seal.

10. The outer race of claim 1 wherein the outer raceway liner has a monolithic body defining an inboard outer raceway and an outboard outer raceway and a gap therebetween and wherein the gap includes a hole for receiving a portion of a sensor.

11. The outer race of claim 1 wherein the outer raceway liner defines an inboard outer raceway and an outboard outer raceway and wherein the body includes a hole for receiving a sensor positioned between the inboard outer raceway and the outboard outer raceway.

12. A bearing assembly for a wheel end having an inner race defining an inner raceway and a plurality of rolling elements, the improvement comprising: an outer race for a bearing assembly having a body defining a substantial portion of the outer race, the body being configured of a material other than a bearing quality steel, the body including a cavity defining an inner surface and having an axis for receiving a rotating shaft, and a plurality of rolling elements positioned about the rotating shaft, and an outer raceway liner positioned along the inner surface of the cavity of the body and defining an outer raceway presented inwardly towards the axis, the outer raceway liner being configured of bearing quality steel, wherein the outer raceway liner is fixedly formed with the inner surface of the cavity of the body for forming a composite outer race.

13. A bearing assembly for a wheel end having an inner race defining an inner raceway and a plurality of rolling elements, the assembly comprising: an outer race for a bearing assembly having a body defining a substantial portion of the outer race, the body being configured of a material other than a bearing quality steel and the body including a cavity defining an inner surface and having an axis for receiving a rotating shaft; a plurality of rolling elements positioned about the rotating shaft received within the cavity of the body of the outer race, and means for defining an outer raceway of the outer race along the inner surface of the cavity of the body wherein the outer raceway is presented inwardly towards the axis.

14. The bearing assembly of claim 13, further comprising means for fixedly coupling the means for defining the outer raceway to the body of the outer race.

15. A method of manufacturing an outer race for a bearing assembly comprising: configuring an outer raceway liner from a bearing quality steel including defining an outer raceway surface for contacting a rolling element; positioning the outer raceway liner in a mold; casting the outer race in the mold from a casting material, wherein casting includes casting the casting material to and about portions of the outer raceway liner; and machining outer features of the race from the casting material.

16. The method of claim 15 wherein configuring the outer raceway liner includes a method selected from the group consisting of stamping, ring rolling, and cold forming.

17. The method of claim 15, further comprising machining one or more holes for a sensor and/or sensor mounting bolt.

18. The method of claim 15, further comprising finishing the outer raceway surface to achieve a predetermined surface finish for contacting a rolling element.

19. The method of claim 15, further comprising induction hardening the outer raceway liner along the outer raceway surface.

20. The method of claim 19 wherein induction hardening is following the casting of the outer race.