Superfinishing process Development boost in superfinishing of wind turbine main bearings

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Supfina Grieshaber GmbH & Co. KG

SIMTOS (Seoul International Machine Tool Show)

An innovative manufacturing solution from Supfina now makes the fine surface machining of rings for large rolling bearings possible. This results in many advantages, foremost among them the significant extension of bearing life.

Given the increasingly shorter development cycles for wind turbines and the simultaneous shortening of test phases, manufacturers are under enormous pressure. Simulations and complex models are increasingly replacing real tests, which increases the risk of failures, especially in the main bearings. Since the main bearing is the central element of the drive train, the consequences of a failure are particularly severe. It is the heart of the system and must match the lifespan of the entire wind turbine. In addition, the ongoing trend towards larger and more powerful systems and the growing competition in the global market increase the pressure on the industry.

Innovations in the superfinishing of wind turbine main bearings for enhanced safety

The superfinishing process, also known as microfinishing, honing, or short-stroke honing in standards, has been established in the rolling bearing industry for decades. It is used for the production of individual bearing components—inner ring, outer ring, and rolling elements—and produces precisely defined surface characteristics and structures. These ensure an optimal tribological interaction of the bearing components. While the superfinishing process has long been standard in the production of spherical roller bearings and gearbox bearings, it has increasingly gained acceptance for rolling elements such as tapered rollers in recent years. However, its application in the production of bearing rings remains limited.

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In light of this challenge, the superfinishing process is now also relevant for larger tapered roller bearings and has evolved across various industries.

The current market challenges make the continuous development of manufacturing technologies indispensable. For Supfina Grieshaber, a long-standing partner of the rolling bearing industry, this led to the development of the Supfina RacePro 4000. This innovative manufacturing solution transfers proven superfinishing processes to the machining of large rolling bearings and combines stone finishing and tape finishing technologies in one system. The newly developed workpiece drive concept increases efficiency and further optimizes the quality of surface finishing.

Superfinishing increases the lifespan of bearings

The use of qualified superfinishing processes in the production of rolling bearings significantly contributes to extending their lifespan. Therefore, transferring this technology to wind turbine main bearings represents a logical advancement that greatly increases the reliability of these critical components.

The current market challenges have significantly shifted the focus. Safety is now the top priority to remain competitive in the long term—and that, without compromising on economic efficiency.

For Supfina Grieshaber, a reliable supplier and development partner of the international rolling bearing industry for decades, it was therefore obvious to address this topic. After intensive development work, an innovative manufacturing solution for the fine surface finishing of rings for large rolling bearings was created: the Supfina RacePro 4000. This solution allows proven superfinishing processes and the associated high-quality standards from other industries to be transferred to large rolling bearings. This is made possible through the use of stone finishing processes or a combination of stone and tape finishing. The established process units of the Supfina RaceFlex 1600 series are used, supplemented by a newly developed, highly innovative workpiece drive concept.

The implementation of a qualified superfinishing process in the manufacturing of rolling bearings positively impacts numerous aspects of bearing function. A comprehensive description of all the advantages would exceed the scope of a single article. However, one stands out in particular: the significant contribution to extending bearing lifespan.

This correlation is well substantiated across the entire range of standard industrial rolling bearings. Therefore, transferring this proven technology to wind turbine main bearings is the logical step.

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*Thomas Harter is responsible for product and technology at Supfina Grieshaber, with a focus on superfinishing of rolling bearing components.