The Conrad-style ball bearing is named after its inventor, Robert Conrad, who was awarded British patent 12,206 in 1903 and U.S. patent 822,723 in 1906. These bearings are assembled by placing the inner ring into an eccentric position relative to the outer ring, with the two rings in contact at one point, resulting in a large gap opposite the point of contact. The balls are inserted through the gap and then evenly distributed around the bearing assembly, causing the rings to become concentric. Assembly is completed by fitting a cage to the balls to maintain their positions relative to each other. Without the cage, the balls would eventually drift out of position during operation, causing the bearing to fail. The cage carries no load and serves only to maintain ball position.
Conrad bearings have the advantage that they are able to withstand both radial and axial loads, but have the disadvantage of lower load capacity due to the limited number of balls that can be loaded into the bearing assembly. Probably the most familiar industrial ball bearing is the deep-groove Conrad style. The bearing is used in most of the mechanical industries.
In a slot-fill radial bearing, the inner and outer races are notched on one face so that when the notches are aligned, balls can be slipped in the resulting slot to assemble the bearing. A slot-fill bearing has the advantage that more balls can be assembled (even allowing a full complement design), resulting in a higher radial load capacity than a Conrad bearing of the same dimensions and material type. However, a slot-fill bearing cannot carry a significant axial load, and the slots cause a discontinuity in the races that can have a small but adverse effect on strength.
Relieved race ball bearings are ‘relieved’ as the name suggests by basically have either the OD of the inner ring reduced on one side, or the OD of the outer ring increased on one side. This allows a greater number of balls to be assembled into either the inner or outer race, and then press fit over the relief. Sometimes the outer ring will be heated to facilitate assembly. Like the slot-fill construction, relieved race construction allows a greater number of balls than Conrad construction, up to and including full complement, and the extra ball count gives extra load capacity. However, a relieved race bearing can support significant axial loads in one direction (‘away from’ the relieved race).
Another way of fitting more balls into a radial ball bearing is by radially ‘fracturing’ (slicing) one of the rings all the way through, loading the balls in, re-assembling the fractured portion, and then using a pair of steel bands hold the fractured ring sections together in alignment. Again, this allows more balls, including full ball complement, however unlike with either slot fill or relieved race constructions, it can support significant axial loading in either direction.
There are two row designs: single-row bearings and double-row bearings. Most ball bearings are a single-row design, which means there is one row of bearing balls. This design works with radial and thrust loads.[4]
A double-row design has two rows of bearing balls. Their disadvantage is they need better alignment than single-row bearings.
Bearings with a flange on the outer ring simplify axial location. The housing for such bearings can consist of a through-hole of uniform diameter, but the entry face of the housing (which may be either the outer or inner face) must be machined truly normal to the hole axis. However such flanges are very expensive to manufacture. A more cost effective arrangement of the bearing outer ring, with similar benefits, is a snap ring groove at either or both ends of the outside diameter. The snap ring assumes the function of a flange.
Cages are typically used to secure the balls in a Conrad-style ball bearing. In other construction types they may decrease the number of balls depending on the specific cage shape, and thus reduce the load capacity. Without cages the tangential position is stabilized by sliding of two convex surfaces on each other. With a cage the tangential position is stabilized by a sliding of a convex surface in a matched concave surface, which avoids dents in the balls and has lower friction. Caged roller bearings were invented by
John Harrison in the mid-18th century as part of his work on chronographs.
[5] Caged bearings were used more frequently during wartime steel shortages for bicycle wheel bearings married to replaceable cups.
Ceramic bearing balls can weigh up to 40% less than steel ones, depending on size and material. This reduces centrifugal loading and skidding, so hybrid ceramic bearings can operate 20% to 40% faster than conventional bearings. This means that the outer race groove exerts less force inward against the ball as the bearing spins. This reduction in force reduces the friction and rolling resistance. The lighter balls allow the bearing to spin faster, and uses less energy to maintain its speed.
While ceramic hybrid bearings use ceramic balls in place of steel ones, they are constructed with steel inner and outer rings; hence the hybrid designation. While the ceramic material itself is stronger than steel, it is also stiffer, which results in increased stresses on the rings, and hence decreased load capacity. Ceramic balls are electrically insulating, which can prevent ‘arcing’ failures if current should be passed through the bearing. Ceramic balls can also be effective in environments where lubrication may not be available (such as in space applications).
Self-aligning ball bearings, such as the
Wingquist bearing shown above, are constructed with the inner ring and ball assembly contained within an outer ring that has a spherical raceway. This construction allows the bearing to tolerate a small angular misalignment resulting from shaft or housing deflections or improper mounting. The bearing was introduced by
SKF in 1907.
[6] The bearing was used mainly in bearing arrangements with very long shafts, such as transmission shafts in textile factories.
[7] One drawback of the self-aligning ball bearings is a limited load rating, as the outer raceway has very low osculation (radius is much larger than ball radius). This lead to the invention of the
spherical roller bearing, which has a similar design, but use rollers instead of balls. Also the
spherical roller thrust bearing is an invention that derives from the findings by
Wingquist.