 |
|
Races
wear at needle bearing contact points
only, small angular rotations
cause
uneven hill-and-valley wear |
|

|
|
Hill-and-valley
race wear pattern detail |
 |
|
Bronze
bearing wears evenly, full contact on race |
We are sometimes asked why
PolyBronze incorporates bronze bearings
instead of needle or roller bearings. One might conclude that
if a bronze bearing is good, a needle must be better. But a
quick look at the facts shows that for automotive suspensions needle
bearings are a poor choice.
Both
types of bearings deliver very low friction when new and properly
fitted. But wear issues and misalignment cause
serious problems with needle bearings. For these reasons
bronze bearings prove superior in automotive suspension
applications.
Angular
rotation and wear
Needle
bearing races wear only at the contact points of the rollers. For
large angular rotations (shafts that spin round-and-round), the races
wear evenly.
But suspension components
oscillate back and forth, rotating just a few degrees. Small angular rotations
displace lubricant from the needle contact points, accelerating race
wear in a hill-and-valley pattern. This process is known as false
brinelling or fretting.
Once
false brinelling develops, friction of the roller bearing goes up.
In
contrast, bronze
bearings maintain full contact with the race and deliver even wear
for small and large angular rotations. Friction is consistently
low over the bearing life.
Misalignment
and bearing compliance
Control
arms and spring plates are each supported by two bearings that pivot
on a common axis. Any misalignment of the bearings can cause binding. Broad manufacturing tolerance of factory
suspension mounts yield
mount alignment that is less-than-precise even in static unloaded
conditions. This is no problem with soft rubber OEM bushings, but is
a problem with incompressible bearings. This misalignment is
compounded as the
chassis flexes under load.
The
relatively small profile of bronze bearings allows the patent
pending fitment of a
polyurethane jacket in PolyBronze bearings. This elastomer
layer compresses slightly as needed, keeping mounts in alignment (even as the chassis flexes)
without pinching and binding.
In
contrast, the physical size of needle bearings makes the inclusion of
an effective elastomer layer difficult/impossible within factory
mounts that were not designed for their large size.
With no elastomer layer, any misalignment
pinches and binds the metal needles. The condition gets worse when the chassis
flexes under load in turns, braking, bumps and acceleration - just
when suspension performance is most critical.
Summary
In
closing our PolyBronze Bearings (for 911,
914
and 944
series) use bronze bearings because they show
superior wear characteristics for small angular rotations seen in automotive suspensions. Their
small profile
facilitates packaging with the polyurethane jacket that is so
critical to fitment and maintaining proper alignment.
Chuck
Moreland - November 2004
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