Maintenance free extended life cam follower for a necker machine

A cam follower comprising:

• a shaft extending from an outboard end to an inboard end and having a first bearing ring disposed thereon;
• wherein the shaft has an outboard diameter as measured from an axial center axis of the shaft where the first bearing ring is disposed thereon;
• a flange radially extending from the shaft and disposed between the outboard end and the inboard end;
• and
• a swaged ridge extending radially outward from the shaft proximate the outboard end and terminating at a radially outward facing circumferential surface, the swaged ridge and flange configured to axially retain the first bearing ring therebetween;
• wherein the swaged ridge is defined by a first cylindrical surface extending axially inward from the outboard end and an outboard axial surface extending radially outward from the first cylindrical surface, the outboard axial surface extending radially from the first cylindrical surface to the radially outward facing circumferential surface;
• wherein the outboard end comprises a torque transmission aperture extending axially inward therefrom, the torque transmission aperture having a radially inward facing engagement surface, wherein the first cylindrical surface is spaced apart from the engagement surface by a neutral zone that extends a predetermined radial distance from the engagement surface to the first cylindrical surface, to prevent deformation of the engagement surface when forming the swaged ridge;
• and
• wherein the predetermined radial distance is approximately 25% of the outboard diameter.

A cam follower comprising:

• a shaft extending from an outboard end to an inboard end;
• a first bearing ring and a second bearing ring disposed on the shaft;
• a flange radially extending from the shaft and disposed between the outboard end and the inboard end;
• and
• a swaged ridge extending radially outward from the shaft proximate the outboard end and terminating at a radially outward facing circumferential surface, the swaged ridge and the flange configured to axially retain the first and second bearing rings therebetween;
• wherein the swaged ridge is defined by a first cylindrical surface extending axially inward from the outboard end and an outboard axial surface extending radially outward from the first cylindrical surface, the outboard axial surface extending radially from the first cylindrical surface to the radially outward facing circumferential surface;
• wherein the swaged ridge separates the first bearing ring from the outboard end by an axial distance;
• wherein the axial distance is less than 12% of a combined axial width of the first and second bearing rings.

A method of assembling a cam follower, the method comprising the steps of:

• providing a shaft extending from a first axial end to a second axial end thereof, the shaft having a circumferential shoulder extending radially outward from the shaft and being located between the first axial end and the second axial end;
• providing at least one bearing, the at least one bearing having an inner ring defining a bore, an outer ring coaxially disposed on the inner ring, and a plurality of rolling elements disposed between the inner ring and the outer ring;
• providing a swage die comprising a body having a first end configured to be mounted to a pressing device and a second end opposite the first end, the second end having a cylindrical extension extending from the second end away from the first end, the cylindrical extension having an end surface with a cylindrical punch cavity therein;
• inserting the first axial end of the shaft through the bore of the at least one bearing;
• positioning the at least one bearing on the shaft such that a first axial end of the inner ring abuts the circumferential shoulder of the shaft;
• securing the shaft in a fixture with the first axial end extending outwardly from the fixture;
• placing the punch cavity of the swage die on the first axial end of the shaft;
• pressing the swage die against the first axial end of the shaft;
• and
• swaging a swaged ridge on the shaft with the swage die, the swaged ridge extending radially outward from the shaft at the first axial end of the shaft, the swaged ridge having a first axial surface facing toward the first axial end of the shaft and extending radially outward and terminating at a radially outward facing circumferential surface, the swaged ridge having a second axial surface facing toward the shoulder of the shaft and extending radially outward and terminating at the radially outward facing circumferential surface, the second axial surface of the swaged ridge conforms in shape to and compresses against a second axial end of the inner ring;
• wherein the swaged ridge axially retains the inner ring on the shaft between the swaged ridge and the shoulder.

A method of visually inspecting a cam follower, the method comprising the steps of:

• providing a shaft extending from a first axial end to a second axial end thereof, the shaft having a swaged ridge extending radially and circumferentially outward from the shaft and being located proximate the first axial end, the shaft having a bearing positioned thereon such that a first axial end of the bearing abuts the swaged ridge, the swaged ridge having a first color and the bearing having a second contrasting color;
• scanning the first axial end of the shaft;
• differentiating between the first color of the swaged ridge and the second contrasting color of the bearing;
• and
• measuring a swage diameter of the swaged ridge at a radially outward facing circumferential surface thereof.