The following are the core processes and precautions for customizing non-standard bearing seats, combined with mechanical design specifications and engineering practice experience:

1、 Customized core process

1. Requirement analysis

Determination of key parameters:

Load characteristics: static load/dynamic load (direction and distribution should be specified)

Speed range: High speed and start stop frequency

Installation conditions: matching shaft diameter tolerance (such as H7/k6), installation space dimension chain

Environmental factors: temperature (-40 ℃~+200 ℃), humidity, corrosive media

2. Design confirmation

Structural scheme:

Split/integral structure selection (split is easy to maintain)

Bearing type adaptation (deep groove ball/tapered roller/self-aligning roller, etc.)

Finite element analysis: stress verification for high load scenarios (allowable stress ≤ 60% of material yield strength)

3. Material selection

Common materials:

Cast iron (HT200-HT300): Low cost, good vibration damping performance

Cast steel (ZG270-500): high strength, impact resistance

Aluminum alloy (ZL104): lightweight, suitable for high-speed scenarios

Surface Treatment

Blackening treatment (salt spray test ≥ 72 hours)

Spray coating/electrophoresis (film thickness ≥ 80 μ m)

4. Processing technology

Key process control:

Bearing hole machining: roundness ≤ 0.01mm, cylindricity ≤ 0.02mm

Joint surface flatness: ≤ 0.05mm/100mm

Thread hole accuracy: 6H level (GB/T 197)

5. Testing and verification

No load test run: 30 minutes of running in and out, temperature rise ≤ 30 ℃

Load test: Load to 1.5 times the rated load for 2 hours without deformation

Sealing test: IP65 waterproof (no leakage after 10 minutes of water spray test)

2、 Key precautions

1. Design specifications follow

Standard reference:

ISO 113:2019 (Dimensions of sliding bearing seats)

JB/T 2560-2014 (Split Bearing Seat)

Safety factor: Dynamic load safety factor ≥ 1.8, static load ≥ 2.5

2. Cooperate with precision control

Bearing and seat hole fit:

Interference fit: 0.01~0.03mm (adjusted according to bearing type)

Transition fit: Gap ≤ 0.01mm (for scenarios requiring slight adjustment)

3. Lubrication and sealing design

Lubrication system:

Lubricating with grease: equipped with an oil nozzle (M8 × 1.25), with a grease storage capacity of ≥ 1/3 of the bearing seat cavity

Oil lubrication: Set the oil level window (the low oil level is higher than the center of the ball under the bearing)

Sealing structure:

Double lip skeleton oil seal (lip fit 0.15~0.25mm)

Maze seal (gap ≤ 0.5mm)

4. Key points for installation and debugging

Central requirements:

Coupling alignment deviation ≤ 0.05mm (detected by laser alignment instrument)

The flatness of the bottom surface of the bearing seat is ≤ 0.02mm/m

Tightening torque:

Tighten high-strength bolts (grade 10.9) at 110% of the standard torque value

5. Cost control strategy

Material optimization: Adopting hollow structure for weight reduction (wall thickness ≥ 8mm)

Modular design: Reserve expansion interfaces (such as temperature measuring hole M10 × 1)

Processing economy: Avoid deep hole machining (L/D ≤ 5)

3、 Supplier selection suggestions

Technical Capability Verification:

Request to provide finite element analysis report for similar products

Confirm whether it has the capability of three coordinate detection (accuracy ≤ 0.005mm)

Process stability:

Examine the sand hole control of casting blanks (X-ray inspection)

Confirm the heat treatment process (such as quenching and tempering hardness HB220-250)

After-sales service

Request for installation and debugging guidance (including torque parameter table)

Warranty period ≥ 18 months (excluding vulnerable parts)

summary

Customization of non-standard bearing seats should follow the principles of "functional priority, controllable accuracy, and reasonable cost". It is recommended to use three-dimensional parametric design (such as SolidWorks) and establish a digital twin model for pre validation. During the production process, critical dimensions require First Article Full Scale Inspection (FSI) to ensure compliance with the drawing requirements.