Training Report of NBC Bearing

Project report on training in National Bearing Company
ENGINEERING PROJECT
REPORT
ON
INDUSTRIAL TRAINING
IN NATIONAL BEARING COMPANY
FOR THE PARTIAL FULFILLMENT OF
THE REQUIREMENT OF
BACHELOR OF TECHNICAL EDUCATION
SUBMITTED BY
KETAN TOSHNIWAL
IV YEAR, MECHANICAL ENGINEERING
A2 – BATCH, ROLL NO  ME052
GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY
1
JAIPUR
2
TABLE OF CONTENT
➢ Executive Summary
➢ Acknowledgement
➢ Preface
➢ Introduction to Bearings
➢ Bearing industry
 Global Scenario
 Indian Bearing Industry

 Threats and limitation to Indian Market
➢ Organizational Profile
 Introduction
 Mile Stones
 Company Profile
 Research & Development
 Quality Management System
➢ Bearing Manufacturing
 Flow of Material in Bearing Industry
 Classification of Bearing
 Types & Features of Rolling Bearing
 Bearing Designation in NBC
➢ Ball Bearing Manufacturing
 Inner & Outer Ring Manufacturing
 Spherical Ball Manufacturing
 Cage Manufacturing
 Rivet Manufacturing
3
 Ball Bearing Assembly Line
➢ Roller Bearing Manufacturing

 Inner & Outer Manufacturing for Spherical,
Cylindrical & Tapered Roller Bearing
 Roller Manufacturing
 Cage Manufacturing
 Roller Bearing Assembly
➢ Railway Bearing Manufacturing
 Railway Bearing Assembly Line
➢ Heat Treatment
 Heat Treatment Process
 Hardening Procedure for High Carbon Steel
 Hardening Procedure for Low Carbon Steel
 Salt Bath Furnace
 Heat Treatment flow Chart

➢ Conclusion
4
EXECUTIVE SUMMARY
NBC Bearings Limited, a member company of C.K. BIRLA group of Companies - is a
leading player in the Indian Bearing industry.
The company manufactures a very wide range of bearings conforming to the stringent
international quality standards.
NBC manufacturing plants, located at Gunsi (Newai) Rajasthan, Manesar Haryana &
Jaipur - was incorporated in the year 1946. Its feature the most advanced manufacturing
technology. The company is certified to ISO/TS 16949, ISO 9001, and ISO 14001
standards.
NBC India is a leading OEM supplier to the automotive industry, mechanical and
electrical engineering industry, besides the Railways.
Bearings produced at the EOU plant have gained ready acceptance and recognition of
customers located in India & Indian Sub Continent, Europe & Africa.
NBC’s main competitors in bearing are SKF, TIMKEN, NRB, FAG and other local
brands.
OBJECTIVE:
The main objective of this training is to learn different engineering processes and to
develop skills and with that attitude I had done my engineering training with NBC
Bearings Ltd. In this one month training period I had seen different work and key
responsibility of various bearings department.
Training was started with brief introduction program of NBC Bearing Ltd. and plant visit
of different department. It was such a great experience to learn various engineering
production methods used now a days & to better correlate the theoretical knowledge with
practical observations and understandings.
ACKNOWLEDGEMENT
5
As the technologically advancement will enable us to get the environment

we desire. The basic beatitude, bliss, euphoria & our endeavor to achieve
complete and perfect knowledge in the field we choose that accompany the
successful completion of any task would not be complete without the
expression of appreciation of simple virtues to the people who made it
possible. So, with reverence honor I acknowledge all those guidance and
encouragement has made successful completion of training.
I am thankful to Ms. Monika Joshi, H.R.D. Department, for her

constant cooperation and able guidance & without her support this work
would not have been so understandable.
I am also thankful to Mr. R. Jaiswal, HOD Mechanical

Department, G.V.S.E.T. who is always mentor to us.
I am also very thankful to all respected persons who have directly or

indirectly helped me in my earnest effort to accomplish this training.
Submitted By
KETAN TOSHNIWAL
6
PREFACE
The Engineering curriculum is designed in such a way that student can grasp maximum
knowledge and can get practical exposure to the corporate world in minimum possible
time. Engineering schools of today realize the importance of practical knowledge over
the theoretical base.
The research report is necessary for the partial fulfillment of engineering curriculum and
it provides an opportunity to the researcher in understanding the industry with special
emphasis on the development of skills in analyzing and interpreting practical problems
through the application of engineering theories and techniques. It is a new platform of
learning through practical experience. It gives the learner an opportunity to relate the
theory with the practice, to test the validity and applicability of his classroom learning
against real life engineering situations.
7
History & Evolution of Bearing

An early type of linear bearing uses tree trunks laid down under sleds. This technology
may date as far back as the construction of the Pyramids of Giza, though there is no
definitive evidence. Modern linear bearings use a similar principle, sometimes with balls
in place of rollers.
Tapered steering head bearings for a motorcycle
The first plain and rolling-element bearings were wood, but ceramic, sapphire, or
glass were also used, and steel, bronze, other metals, ceramics, and plastic (e.g.,
nylon, polyoxymethylene, Teflon, and UHMWPE) are all common today.
A "jeweled" pocket watch uses stones to reduce friction, and allow more precise time
keeping. Even old materials can have good durability. As examples, wood bearings can
still be seen today in old water mills where the water provides cooling and lubricatio
BEARING
Definition - A bearing is a device to allow constrained relative motion between two or more
parts, typically rotation or linear movement. Bearings may be classified broadly
according to the motions they allow and according to their principle of operation as well
as by the directions of applied loads they can handle.
BEARING FRICTION
8
Plain bearings are very widely used, and use surfaces in rubbing contact. Particularly
with lubrication they often give entirely acceptable life and friction.
On the other hand, low friction bearings are often important for efficiency, to reduce wear
and to facilitate extended use at high speeds. Essentially, a bearing can reduce friction by
virtue of its shape, by its material, or by introducing and containing a fluid between
surfaces or by separating the surfaces with an electromagnetic field.
By shape, gains advantage usually by using spheres or rollers, or by forming flexure
bearings.
By material exploits the nature of the bearing material used. (An example would be
using plastics that have low surface friction.)
By fluid exploits the low viscosity of a layer of fluid, such as a lubricant or as a
pressurized medium to keep the two solid parts from touching, or by reducing the normal
force between them.
By fields exploits electromagnetic fields, such as magnetic fields, to keep solid parts
from touching.
Combinations of these can even be employed within the same bearing. An example of
this is where the cage is made of plastic, and it separates the rollers/balls, which reduce
friction by their shape and finish.
9
Principles of Operation
There are at least six common principles of operation:
• Sliding bearings, usually called "bushes", "bushings", "journal bearings", "sleeve

bearings", "rifle bearings", or "plain bearings”.
• Rolling-element bearings such as ball bearings and roller bearings.
• Jewel bearings, in which the load is carried by rolling the axle slightly off-center.
• Fluid bearings, in which the load is carried by a gas or liquid.
• Magnetic bearings, in which the load is carried by a magnetic field.
• Flexure bearings, in which the motion is supported by a load element which

bends.
Motions
Common motions permitted by bearings are:
• Axial rotation e.g. shaft rotation

• Linear motion e.g. drawer
• Spherical rotation e.g. ball and socket joint
• Hinge motion e.g. door
Loads
Bearings vary greatly over the size and directions of forces that they can support.
Forces can be predominately radial, axial (thrust bearings) or moments perpendicular to
the main axis.
10
Global Scenario
The world Market of quality Bearing is very vast. The Big player of bearing sector are
present in U.S.A, Russia, Japan, China and eastern Europe. Some of leading bearing
manufacturer are : -
- NSK Japan
- NTN Japan
- KOYA Seiko Japan
- FAG Germany
- SKF Sweden
- NRB France
- Timken USA
There are few of leading bearing manufacturer present in India. Most of the big player are
having either technical or financial Collaboration with leading Auto Manufacturer.
International Collaboration gives Access to best technology in the world.
Global Collaboration
COMPANY COLLABORATION
FAG Bearing India FAG Germany
SKF India SKF Sweden
NRB Nadella, France
ABC Bearing Ltd. NSK Japan
TIMKEN India TIMKEN USA
BIMETAL Bearing Ltd. Clevite Corporation USA
GABRIEL India Suspension Italy
11
Indian Bearing Industry
The Indian Bearing Industry is estimated at Rs. 30 Billion approximately. The Industry
has established a highly diversified product range of around 1000 type of Bearing, having
High Volume Demand. As much as 70% of the total Demand for common varieties and
size of bearing is met by the domestic Industry, and the remaining demand of 30% is
Imported essentially for Industrial Application and special purpose. The Indian bearing
Industry can be divided in to the organized sector and un-organized sector. The organized
sector primarily caters to the Original Equipment Manufacturer (OEM) Segment,
which predominantly comprises automotive railway and other Industrial users. The
replacement market is dominated by unorganized Sector.
ORGANISED SECTOR
The organized Sector comprises about 12 big Manufacturer, who contribute to more than
50% of total turn over. Most of the big players are having either technical or financial
with International Manufacturer. International Collaboration gives access to best
technology in the world. SKF Bearing is the major player in the Indian market with the
largest market share followed by National Engineering Industry (NBC) and FAG Bearing
India the two other major players.
UNORGANISED SECTOR
The Unorganized Sector Include the Small Scale Manufacturer and Manufacturer of
Spurious Bearing. The unorganized Sector Contribute to almost 15% of Total Industry
turnover. The Unorganized Sector players have a strong regional presence and mainly
cater to the needs of the replacement market.
The direct employment provided by the above sectors is more than 12000 people. Indirect
employment for Transportation, Tools, Containers, and Packaging etc. further helps in
providing employment.
12
INDUSTRY STRUCTURE
30%
Domestic Organized
Domestic Unorganized
55% Imports
15%
USER SEGMENTS
Automobile
6%
21%
General Engineering
45%
Heavy Industries Including

Railways
28%
D IS T R IB U T IO N O F P R O D U C T IO N
Electical Equipment &
Others
7% 3%
6%
B a ll B e a rin g
M A R K E T D Y N A M IC S T a p e r R o lle r
C y lin d ric a l R o lle r
N e e d le R o lle r
54%
S p h e ric a l R o lle r
30%
40%
O E M M a rk e t
R e p la c e m e n t M a rk e t
60%
13
Threats & Limitations to Indian Market
 Increasing Competition in Domestic market.

 Very Low Volume of Direct Export.
 Weak Marketing Linkages.
 Raw Material Bank is not present.
 Low level of technology used by most of manufacturing Units.
 Quality of Bearing Manufactured in the Small Scale Industry (SSI) Sector
does not meet the International Quality Standard.
 No Recent upgradation in Design, Technology, Process of Manufacturing
and Quality Control.
 Non existence of highly skilled Man Power.
 Stiff Competition from China made Bearing.
 Increase in Illegal Imports.
 No Entry Barrier in the cluster
 Increase in Raw Material Prices.
 Government Rules & Regulations - According to estimate an entrepreneur
need to interact with 14 Govt. departments to get permission for manufacturing &
exporting. Most of their time is spend in filling up forms and submitting paper as
per their requirement. Therefore Govt. rules and regulation have to be liberalized
& the role of Govt. Department should be a facilitator rather than regulator.
14
Introduction
National Engineering Industries Ltd. is the largest manufacturer of Ball and Roller
Bearings, Steel Balls and Axle Boxes complete with Roller bearing in India, which are
being produced in factories at Jaipur and Newai. Bearings are manufactured for every
possible application and requirement of modern engineering industry and we continue to
develop new sizes, keeping pace with rapid advancement in the Indian engineering
industry.
NEI’s technical collaborations with the world’s leading conglomerates in the field of
Bearing technology viz. M/s NTN Corporation of Japan, M/s BRENCO incorporated of
USA have given a whole new dimension to the product range and a quality par
excellence.
NEI has already implemented modern concepts of Total Quality Management and
accredited QS9000 and TS16949 certification, NEI has also been awarded Association of
American Railroads (AAR) for AAR certificate M-1003 for Cartridge Tapered Roller
Bearing in Feb 04-05. NEI has also been awarded ISO-14001 certificate for its concern
and commitment towards a cleaner environment. NEI has successfully implemented
SAP-ERP to re-engineer and integrate business processes to conform to world class
standards.
15
Milestones
Company Established as National Bearing Company (NBC) under

Technical Collaboration with Hoffman, U.K.
Ball Bearing Production Started
Railway Bearing Production Started
Company Name changed to National Engineering Industries Ltd.

(Retaining NBC as trademark).
Tapered Roller Bearing Production Started under Technical

Collaboration with Federal Mogul Corporation, USA
Established Research & Development Division
Established Machine Building Division
Large Diameter Special Bearing Production Started
Spherical Roller Bearing Production Started with Technical know-how

from FAG-SRO
Separate Factory for Ball Bearings at Gunsi
Cartridge Tapered Roller Bearing Production Started in Technical

Collaboration with BRENCO Incorporated, USA
Largest Bearing with Outer Dia. 1300mm & Weight 4.39 Tons Produced
16
Technical Collaboration with NTN Corporation of Japan for Ball,

Cylindrical & Spherical Roller Bearing
Modernization in Three Phases
ISO – 9001 Certificate
Technical Collaboration with M/S Izumi Kogyo Co. Ltd., Japan for
Machine Retrofitting/Remanufacturing & Overhauling
Technical Collaboration with NTN Corporation, Japan for Tapered

Roller Bearing & Hub Bearing
IV-Phase Modernization Started
Implemented Ist Phase of SAP-ERP Solutions
QS-9000 & ISO-14001 Certification
Ts-16949 Certification
AAR Certification M-1003 for Cartridge Tapered Roller Bearing
17
Company Profile
National Engineering Industries Ltd., Jaipur was founded in the year 1946 as a pioneer
industry in the field of bearing manufacture by the renowned industrialist, late Shri B.M.
Birla, under the name of "National Bearing Company Limited." The first bearing was
manufactured in 1950 with a modest start of 30,000 bearings in 19 sizes. The company is
now manufacturing nearly 3.8 million bearings per month in over 500 different sizes
ranging from 6 mm bore to 1300 mm outer diameter and has the capacity to manufacture
bearings upto 2000 mm outer diameter. At NEI, the development of bearings is a never
ending job. With ever increasing activities and grant of industrial licenses for other vital
industries and manufacturing of Roller Bearing Axle Boxes for Railway Rolling Stock,
Steel Balls, Tapered Roller Bearings, Spindle Inserts etc., the name of the company was
changed in 1958 to "National Engineering Industries Ltd." retaining its original trade
mark NBC.
The industry is spread over 118 acres of land in Jaipur and 56 acres in Gunsi (Newai).
This is the only unit in the country manufacturing wide variety and range of bearings
such as Ball Bearings, Steel Balls, Tapered Roller Bearings, and Cylindrical Roller
Bearings & Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings,
Cartridge Tapered Roller Bearings and Large Diameter special Bearings in separate fully
equipped factories. The development of National Engineering Industries Ltd., was
pioneered with a theme "Indigenisation and Self-reliance".
NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors, Electric
Motors, Railway wagon, Coach and Locomotive manufacturers as Original Equipment
and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and Thermal
Power Plants all across the country.
Mission of Company – “Keeping Nation on the Move”
18
 PLANT AT JAIPUR
i) Ball Bearing
Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are manufactured with
in-process and post-process manufacturing facilities and centrally air conditioned
assembly lines with auto gauging in grinding and testing equipments. The latest advanced
techniques of manufacturing and Quality Assurance are implemented to meet the rapid
increase in demand for Quality, diversity of specifications and new types of bearings.
This Division is spread over a covered area of 14,694 Sq. Meters.
ii) Steel Ball
Precision Steel Balls up to 25 mm diameters for NBC Bearings are manufactured on

precision grinding and lapping machines to achieve super finished surface, accuracy and
roundness as per ISO standards.
iii)Tapered Roller Bearing
Tapered Roller Bearings are manufactured in Inch and Metric series from 15.875mm
bore to 95.25mm bore with technology obtained from Federal Mogul Corporation, USA
and NTN Corporation, Japan. These bearings are used by all major Automobile
manufacturers in the country as Original Equipment.
iv)Railway Bearing
(a) Roller Bearing in Axle Box:
With the production of Roller Bearings and Axle Boxes since 1952, the company has
fully met the requirements of the Indian Railways by designing and developing Axle
Boxes and bearings for fitment to Diesel Locomotive, wagon, the ICF broad and
19
meter gauge coaches. Over a million NBC bearings and boxes are in service with the
Indian Railways. The development of Axle Boxes and bearings for the high speed
Rajdhani Locomotive, the Yugoslavian and Egyptian Railway wagons are the
highlights of the completely indigenized design capabilities at NEI.
On date more than 100 types of Axle Boxes & Bearings have been manufactured.
(b)Spherical Roller Bearing:
The manufacturing of Spherical Roller Bearings was started in the year 1975-76 for
fitment to broad gauge and meter gauge passenger coaches.
(c) Cartridge Tapered Roller Bearing:
For fitment to the new BOX-IN Updated Wagons designed by the RDSO, NEI is the
only manufacturer in the country & largest manufacturer in the world. to indigenize
these bearings to a high percentage. Production of these bearings commenced in the
year 1984. These bearings are grease packed and require no field lubrication for a
period of 7 years.
i) Large Diameter Bearing

NEI has the distinction of being one of the ten manufacturers of these bearings in the
world, who can manufacture large diameter bearings up to 2000 mm diameter.
The largest bearing manufactured by NEI for fitment to the Plate Mill of Rourkela Steel
Plant was 4-Row Tapered Roller Bearing measures 1300 mm diameter and weigh 4.39
tons.
The large diameter bearings are mainly manufactured out of case carburizing steel, heat
treated on special equipment and furnaces developed by NEI & grinding is done to close
tolerances on CNC machines with electronic sizing and numerical display.
20
Production of these bearings started in 1975 and to date over 100 different types of
special large diameter bearings have been manufactured and successfully used, saving
considerable foreign exchange for the country.
The Large Diameter Bearings Division is spread over a covered area of 2,508 Sq. Meters.
 PLANT AT GUNSI (NEWAI)
Established in the year 1980-81, as an expansion project of NEI Ltd., The factory is
equipped with fully automated grinding lines with electronic in-process & post- process
gauging and centrally air-conditioned assembly lines with auto gauging and test
equipments for quality and reliability of the products.
The plant is spread over a covered area of 7,200 Sq. Meters.
 PLANT AT MANESAR
NEI has set up its third Ball Bearing manufacturing plant in Manesar, the fastest growing
industrial town of Haryana with the most advanced and sophisticated machines imported
from reputed manufacturers from Europe and Japan. This plant is equipped with state of
the art fully automated grinding lines, assembly lines and inspection equipments.
The plant is spread over a covered area of 5200 Sq. Meters.
21
Research & Development
 Design & Development
The design of all types of bearings is done on Pro-Engineer 3D Modeling & Analysis
Software.
Complete engineering and research with in-house facility for design development of all
types of bearings and tooling with expert advice on design, development, manufacturing,
installation and maintenance of bearings facility is available. With the signing of the
technical collaboration agreement with NTN Corporation, Japan & BRENCO Inc of
USA, the capability to offer finest engineering services in the bearing industry has
enhanced. Services of team of experienced engineers are available for selection of
bearing as per application.
 Machine Building
NEI has the capability of machine building to design, develop and manufacture special
purpose CNC Grinding Lines, HT Lines, Material Handling Equipments and other
special purpose machines which have been made for its captive use to keep pace with
latest technology.
A well equipped electronic design, development laboratory with all testing facilities
supports the Machine Building Division.
Machine Building has the capability and supports the Manufacturing Divisions by
overhauling and retrofitting of the existing equipments, resulting in upgraded quality and
improved productivity.
R&D Division is spread over a covered area of 2,007 Sq. Meters.
 SAP – ERP
In order to reengineer and integrate the Business processes for sales, production,
materials and finance, NEI has successfully implemented SAP- ERP. By use of this
Package, their processes now conform to international standard.
22
Quality Management System
 ISO / TS 16949:2002
NEI has been awarded TS 16949: 2002 on 17th October, 2003- THE MARK OF
EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by BVQI for design,
development, manufacture & supply of Ball Bearing, Tapered Roller Bearing and
Cylindrical Roller Bearings. NEI Ltd. is the first bearing industry in India to have been
recommended for TS 16949: 2002.
This certificate is awarded only to suppliers of automobile manufacturers.
TS 16949: 2002 quality management system is based on ISO 9001: 2000 in which many
supplementary and additional requirements of automobile industries have been
incorporated.
Simplicity, effectiveness & efficiency of processes, error proofing and continuous

improvement in processes thus become the highlight of TS quality management system.
 ISO 9001:2000
NEI’s Large dia. bearing division and railway bearing division which are manufacturing
Cylindrical Roller Bearings, Spherical Roller Bearings, Cartridge Tapered Roller
Bearings, Railway Rolling Stock and Spares has also been awarded to ISO 9001: 2000 on
9th October, 2003 by BVQI.
 ISO 14001:1996
NEI was awarded ISO -14001 certificates by BVQI in the month of March 2000 for
Environmental Management System. NEI has done tremendous efforts in resource
conservation, recycling and thick plantation. The efforts at NEI have saved precious
natural resources like water, oil and power etc.
23
Collaboration
 BRENCO Incorporated , U.S.A.
Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and locomotives.
 NTN Corporation , Japan

Since 1985-For Ball Bearings, Cylindrical & Spherical Roller Bearings. Since 1997-For
Tapered Roller Bearings.
 Izumi Kinzoku Kogyo Co. Ltd., Japan
Since 1996 - For re-manufacturing, retrofitting and overhauling of grinding and super
finishing machines for bearing races.
24
25
Flow of Material in Bering Industry
Material from Outside Vendor

such as Races (Inner & Outer), Cages, Retainers etc

Store House for Size Inspection

Laboratory
For Metallurgical inspection based on the norms set by R & D Department
No  Material is send
back to vendor
Yes

Material is send to specific departments for further Operations

The following Operations are done:
1. Hardening Or Heat Treatment
2. Rough Grinding (Face, O.D., Inner & Track)
3. Finish Grinding (Face, O.D., Inner & Track)
4. Inspection
5. Assembly
26
Classification of Bearing
27
Types & Features of Rolling Bearing
Name Application
1. In addition to Radial Loads, Axial Loads can be imposed in either direction.
Single Row Radial Ball 2. Highly Suitable for applications where High Speed & Low Power loss are
Bearing required.
1. They are capable of taking Radial Load & also the Axial Load in one
direction.
Single Row Angular
2. 4 contact angles 15°, 25°, 30° & 40° are available. Higher the contact angle,
Contact Ball Bearing
higher is the Axial Load carrying capacity.
3. For Higher Speed lower contact angles are preferred.
1. They are 2 single Row Angular Contact Ball Bearing mounted back to
Double Row Angular back.
Contact Ball Bearing 2. They have only one inner and one outer ring.
3. They can take axial load in either direction.
1. The Inner Ring has 2 Raceways & Outer Ring has a single Spherical
Self Aligning Ball Raceway with its centre of curvature coincident with bearing axis.
Bearing 2. This has an advantage of correcting minor angular misalignment of Shaft
and Housing caused by Machining or Mounting Error.
1. They have High Radial Load capacity and are suitable for High Speed.
Cylindrical Roller
2. Double Row bearing have high Radial Rigidity and are used primarily for
Bearing
high Precision Instruments.
1. They are capable of taking high Radial Loads & also Axial Load in one
Direction.
Tapered Roller Bearing
2. Depending upon the contact angle they are divided into 3 types, Normal,
Medium & Steep Angle.
1. Due to coincide of the centre of curvature of the outer ring raceway surface
Spherical Roller with the bearing axis, they are also called as Self Aligning Bearing.
Bearing 2. They can take Heavy Radial Load & some Axial Load in either direction.
3. They are suitable for the use where there are Heavy or Impact Load.
1. They are capable of taking High Axial Load and some amount of Radial
Load.
Thrust Bearing
2. Outer & Inner Rings are called as Washer because they seems to be as
Washer in Structure.
Bearing Designation In NBC

Rolling bearing part numbers indicate Bearing type, Dimensions, Tolerance, Internal
Construction & other related specifications.
28
The Digits & Indications are:-
➢ 1st Digit – Bearing Type

➢ 2nd Digit – Width or Height Series
➢ 3rd Digit – Diamete Series
➢ Last 2 Digits – Bore Diameter
29
Inner & Outer Ring Manufacturing
Flow Chart
Forged Ring ( De-Scaled) as Raw Material

(SAE 52100 Steel)
Turning Operation

Heat Treatment

Hardness Testing

Rough Grinding (Face, Outer Diameter, Bore or Track)

Finish Grinding (Face, Outer Diameter, Bore or Track)

Honing & Super Finishing

Washing

Application of Rust Preventive

Ready for Dispatch to Assembly
30
Theory
Ball Bearings are generally made of High Carbon Steels, such as AISI 52100 because the
life of the bearing steel is determined by the purity of cleanliness of steel. The 52100
steel are subjected to a rigorous purification process with stringent controls in order to
meet the ever-increasing standard of cleanliness & eliminating non-metallic inclusions &
impurities. The impurities are removed through various processes such as vacuum
degassing & consumable electrode vacuum melting (CEVM). The Chemical composition
of the SAE 52100:
Element C Si Mn S P Cr
Minimum 0.98 0.15 0.25 ---- ---- 1.30
Maximum 1.10 0.35 0.45 0.025 0.025 1.60
Oxygen Content – Not more than 15 ppm
The Turning operations are divided into various lathe Operations viz. O.D., face, track &
Bore. All these operations are done on production lathe machines.
The Hardening of steel is achieved by heat treatment process in which the steel
microstructure is manipulated by cycles of heating & quick cooling to obtain the
optimum hardness range for steel – usually on the order of 60 to 64 on Rockwell C
Hardness Scale. When slowly quenched it would form Austenite & Pearlite which is a
partly hard and partly soft structure respectively. Hardening of steel requires a change in
structure from Body Centered Cubic Structure found at room temperature to Face
Centered Cubic Structure found in Austenite Region. When Steel is suddenly Quenched
Martensite is formed which is extremely strong and If steel is Quenched slowly then
Pearlite is formed which is extremely Soft.
31
32
The Next stage is grinding, in order to give the rings the right form and dimension. The
operations occur in following Order:
 Face Grinding – It is the first operation for both inner & outer rings. Both faces
are ground simultaneously to give the final width.
 Outside / Center less Grinding – Outside diameter of inner ring is ground to final
dimension in center less grinding machine.
 The final machining operations are carried out on parallel lines of grinding and
finishing machines. Inner Rings have the bores & raceways ground while Outer
Rings have the only the raceway ground. These operations are carried away by
form dressed grinding wheels.
After grinding Operation, Honing is done.
After Honing the rings are thoroughly washed with water based cleaning medium so
Rings get perfectly cleaned before Assembly is done.
33
Spherical Ball Manufacturing
Flow Chart
Input Wire Rod as Raw Material

(SAE 52100 Steel)

Shearing & Handling Operation
On Ball Header Machine

Deburring on Vibro Benz Machine

Lushing of excess material after the Ball forged in Cold Header

Heat Treatment of Ball

Grinding of Ball in Rotary Grinding Machine (Flashing Machine)

Lapping in Ball Lapping Machine

Inspection for checking Hairline Cracks

Lapping of Balls in Tumbling Barrel

Magnetic Crack Testing

Washing


Packing & Dispatch to Assembly Line
Theory
34
The Raw Material used (SAE 52100) for manufacturing of balls is a specially formulated
grade of Steel Wire. The Material is Supplies either by wire or rod. It is then cut to length
& width.
The wire or rod is then fed through a header. This cold forged process produce “slugs” at
an incredibly high speed. Wire is fed from decoilers into cold heading machines where it
is cut into blanks and then pressed into balls between hemispherical dies.
The flash around the balls produced during pressing is removed by filing plates in
deburring machines.
These rough shaped balls have a ring around the middle. The next process is to remove
this ring by machining in rill-filing machine, equipped with one fixed and one rotating
cast iron rill-plate. Concentric grooves in the plate ensure that the whole ball surface is
machined to same extent and thus a spherical form is achieved
Final inspection for size, form and surface finish is carried out on a sample basis by
means of high resolution microscopes and other precision equipment because a tiniest
deviation even of the order of 1 Å (10-10 m) in the roundness of bearing element can have
an impact on bearing quality.
The balls are then cleaned and packed ready for bearing assembly operation
35
Cage Manufacturing
Flow Chart
Raw Material
(Narrow width Cold Rolled Sheet IS 4397)

Blanking & Punching

Forming (Pocketing)

Inspection & Batch Checking

Shot Blasting/Vibro

Assembly Line
Theory
The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & Cold
Annealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in Press
Machine in Successive Operations:
Blanking, Punching, Forming (Pocketing) rivet holes and visual inspection is carried for
any deformity.
36
Rivet Manufacturing
Flow Chart
Raw Material
(Wire EN 8 or EN 9)

Heading in Ball Header

Deburring in Vibro Benz Machine

Rust Preventive Oiling

Assembly Line
Theory
The Rivets are manufactured from wire rods. The Wires are cut in requires sizes in Rivet
Header machine, then in Vibro Machine it is Super – Finished.
There is no Grinding operation involved.
37
Ball Bearing Assembly Line

Flow Chart
Cage Rivet Outer Inner Ball
Put Inner in Outer


Insert Balls

Put Retainers

Put under Riveting Machine

Riveting

Washing

De-Magnetizing

Inner & Outer Diameter Inspection Machine

Radial Clearance Testing Machine

Washing

Double side Vibration (Noise) Testing Machine

Laser Aching Machine

Application of Anti Rust

Packaging of Bearing in Pillow Wrapping Machine & Ready to Dispatch
Theory
38
Finally the rings, balls & Cage which have been manufactured in different locations come
together for semi – Automatic or Automatic Assembly.
Raceways & Rings are Optically Inspected separately prior to assembly. By selecting
suitable combinations of ring & ball sizes the required internal clearance is obtained.
Balls are fed between the rings and spaced equally before the two cage halves are fitted
and riveted together.
After washing, the final inspection sequence starts which consist of number of checks
such as running accuracy, vibration level, outside and bore diameters and radial clearance
of bearings.
The bearings are then automatically washed, coated with preservative, greased and fitted
with seals or shields before being packed.
39
40
Inner & Outer Ring Manufacturing for

Spherical, Cylindrical & Tapered Roller Bearing
Flow Chart
Forged Ring (De-Scaled) as Raw Material

(SUJ 2 Steel or SC/SCM/SNCM Steel)
Turning Operation

Heat Treatment

Hardness Testing

Rough Grinding (Face, Outer Diameter, Bore or Track)

Finish Grinding (Face, Outer Diameter, Bore or Track)

Honing & Super Finishing

Washing


Ready for Dispatch to Assembly
41
Theory
The contact surfaces of the bearing rings and rolling elements are subjected to repeated
heavy stresses, so they must maintain high precision and rotational accuracy. To
accomplish this, the rings and rolling elements must be made of a material that has high
hardness, resistant to rolling fatigue, wear resistant and has good dimensional stability.
High carbon chromium bearing steel (SUJ 2) deep hardened by the hardening method &
case hardening steel (SC/SCM/SNCM) with a hardened carburized outer layer are used
for the rings and rolling elements of standard bearings.
The most widely used and most suitable materials for rolling bearings are high carbon
steels. The most commonly used of these steels is SUJ2. For bearings with large cross
section dimensions SUJ3 or SUJ5 having good hardening properties are used. NBC uses
high carbon steel for almost all of spherical roller & cylindrical roller bearings.
For case hardening steel; Chrome Steel (SCr), Chrome Molybdenum Steel (SCM) and
Nickel Chrome Molybdenum Steel (SNCM) are used because of its combination of a
hard surface layer which has been carburized and hardened to an appropriate depth, and a
relatively pliable inner core, case hardening steel has excellent efficiency against shock
load. NBC uses case hardening steel for almost all of tapered roller bearings.
Since the life of the bearing steel is determined by the purity of cleanliness of steel the
above grade steels are low in non-metallic impurities & low in oxygen content because
they are refined by a vacuum degassing process & outside hearth smelting process.
The Chemical compositions of above steels are:
Specification Elements C Si Mn P S Ni Cr Mo
42
Minimum 0.95 0.15 ---- ---- ---- ---- 1.30 ----

SUJ 2 0.02 ----
Maximum 1.10 0.35 0.50 0.025 1.60 ----
5
Minimum 0.95 0.40 0.90 ---- ---- ---- 0.90 0.10
SUJ 3 / SUJ 5 0.02 ----
Maximum 1.10 0.70 1.15 0.025 1.20 0.25
5
Minimum 0.18 0.15 0.60 ---- ---- ---- 0.90 ----
SCr 420 0.03 ----
Maximum 0.23 0.35 0.85 0.030 1.20 ----
0
Minimum 0.18 0.15 0.60 ---- ---- ---- 0.90 0.15
SCM 420 0.03 ----
Maximum 0.23 0.35 0.85 0.030 1.20 0.30
0
2.0
Minimum 0.15 0.15 0.35 ---- ---- 0.50 0.15
SCNM 420 / 0
SCNM 815 0.03 4.0
Maximum 0.21 0.35 0.65 0.030 0.90 0.30
0 0
The Turning operations are divided into various lathe Operations viz. O.D., face, track &
Bore. All these operations are done on production lathe machines.
The Hardening of steel is achieved by heat treatment process in which the steel
microstructure is manipulated by cycles of heating & quick cooling to obtain the
optimum hardness range for steel – usually on the order of 60 to 64 on Rockwell C
Hardness Scale. When slowly quenched it would form Austenite & Pearlite which is a
partly hard and partly soft structure respectively. Hardening of steel requires a change in
structure from Body Centered Cubic Structure found at room temperature to Face
Centered Cubic Structure found in Austenite Region. When Steel is suddenly Quenched
Martensite is formed which is extremely strong and If steel is Quenched slowly then
Pearlite is formed which is extremely Soft.
43
The Next stage is grinding, in order to give the rings the right form and dimension. The
operations occur in following Order:
 Face Grinding – It is the first operation for both inner & outer rings. Both faces
are ground simultaneously to give the final width.
 Outside / Center less Grinding – Outside diameter of inner ring is ground to final
dimension in center less grinding machine.
 The final machining operations are carried out on parallel lines of grinding and
finishing machines. Inner Rings have the bores & raceways ground while Outer
Rings have the only the raceway ground. These operations are carried away by
form dressed grinding wheels.
After grinding Operation, Honing is done.
After Honing the rings are thoroughly washed with water based cleaning medium so
Rings get perfectly cleaned before Assembly is done.
44
Roller Manufacturing
Flow Chart
Input Bar as Raw Material

(SUJ 2 Steel)

Turning Operation on Production Lathe

Deburring

Lushing of excess material

Rough Grinding of Rollers

Heat Treatment of Rollers

Finish Grinding of Rollers

Lapping in Roller Lapping Machine

Inspection for checking Hairline Cracks

Lapping of Rollers in Tumbling Barrel

Magnetic Crack Testing

Washing


Dispatch to Assembly Line
Theory
45
The Raw Material used (SUJ 2 Steel) for manufacturing of rollers is a specially
formulated grade of Steel. The Material is Supplies by rod. It is then cut to length &
width on Production Lathe.
For Spherical Rollers or Tapered Rollers, The rod is then fed through a header. This cold
forged process produce “slugs” at an incredibly high speed. Rod is fed from decoilers
into cold heading machines where it is cut into blanks and then pressed between
hemispherical dies or conical dies. For Cylindrical Rollers the above procedure is not
done.
The flash around the rollers produced during pressing is removed by filing plates in
deburring machines.
These rough shaped spherical rollers have a ring around the middle. The next process is
to remove this ring by machining in rill-filing machine, equipped with one fixed and one
rotating cast iron rill-plate. Concentric grooves in the plate ensure that the whole roller
surface is machined to same extent and thus a spherical form is achieved
The next process for Rollers is grinding in which rollers are grind in the order: Face, O.D,
and I.D. The grinding process is done in two phases; one prior to Heat Treatment (Rough
Grinding) & one after the heat treatment process (Finish Grinding).
Final inspection for size, form and surface finish is carried out on a sample basis by
means of high resolution microscopes and other precision equipment because a tiniest
deviation even of the order of 1 Å (10-10 m) in the roundness of bearing element can have
an impact on bearing quality. The rollers are then cleaned and dispatched for bearing
assembly operation
Cage Manufacturing
46
Flow Chart
Raw Material
(Narrow width Cold Rolled Sheet IS 4397)

Blanking & Punching

Forming (Pocketing)

Inspection & Batch Checking

Shot Blasting/Vibro

Assembly Line
Theory
The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & Cold
Annealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in Press
Machine in Successive Operations:
Blanking, Punching, Forming (Pocketing) rivet holes and visual inspection is carried for
any deformity.
47
Roller Bearing Assembly Line

Flow Chart
Cage Outer Inner Rollers
Put Inner in Outer


Insert Rollers & Cage

Put under Pressing Machine

Pressing

Washing

De-Magnetizing



Washing




Theory
48
Finally the rings, Rollers & Cage which have been manufactured in different locations
come together for semi – Automatic or Automatic Assembly.
suitable combinations of ring & Rollers sizes the required internal clearance is obtained.
Rollers are fed into the cage which are together fed in between the Outer & Inner
Raceway & are fitted together through pressing.
of bearings.
The bearings are then automatically washed, coated with preservative, greased and fitted
with seals or shields before being packed.
49
Railway Bearing Assembly Line

Flow Chart
Put Spacer Ring in Outer


Insert Cage & Rollers Assembly

Washing

Insert Seal Ring or Seal Caps

Put End Caps

De-Magnetizing



Washing




Assembly with Sealing Rings
Assembly with Lamellar Rings
50
Theory
Finally the Outer rings, Spacer Rings & Rollers & Cage Assembly which have been
manufactured in different locations come together for semi – Automatic or Automatic
Assembly.
suitable combinations of Outer & Inner rings, the required internal clearance is obtained.
Spacer Ring is inserted between the Rollers & Cage Assembly to avoid interaction
between them.
of bearings.
The bearings are then automatically washed, coated with preservative, greased before
being packed.
Cylindrical roller bearings are used on wagons, BEML coaches and engines.
Spherical roller bearings are used on ICF coaches, some wagons and engines.
Tapered roller bearings are only used on engines.
51
Heat Treatment Process
Chugai – Ro Heat Treatment Furnance

Hardening Procedure for High Carbon Steel ( C – 0.9%
to 1.10%)
Air
Process Hardening Quenching Tempering Cooling
Heat the Fast cooling Furnace Cool at

Furnace 600 C – Oil Heating Room
Procedure 850-870O C Quenching 1650-1800C Temperatu
1800C – Salt re
Bath
Hardness ------ 62 – 66 HRC 60 – 64 HRC ------
Time 35-60 min. 5-15 min. 150 min. ------

According to
the job
Hardening Procedure for LC Steel (Low Carbon Steel)
52
Process Carburizing Hardening Quenching Temperin

g
Carbon Furnace Fast cooling Heat the

Furnace temperature 600 C –for oil Furnace at
Procedure heating at at 8500 C – quenching 1650 C-
9400 C - 9500 C 8700 C only 1800 C
Hardness .200 - .250 ------ 60 – 64 HRC 52 – 62

HRC
Time 8 – 10 hours 35-60 min. 5-15 min. 120-180

According to min.
the job.
Salt Bath Furnace
Heat Treatment
53
Raw Material
(Carbon Steel)

Carburizing
(Carbon Shield Layer increases Hardness)
(10 – 12 hrs.) (940 0C) (GC Furnace)

Hardness I
(Revolving Furnace)
(920 0C) (Time Dependent on Job)

Annealing
(6 hrs.) (650 0C)

Shot Blasting

Hardening II
(Revolving Furnace)
(820 0C) (Time Dependent on Job)

Sub-Zero Treatment
(-60 0C) (Increases Toughness)

Tempering
(160 0C) (4 hrs.)

Shot Blasting
(Wheel Abrator)

Hardness Inspection
(60 HRC)
54
Conclusion
This report describes the NBC bearing industry and its technology. The industry is spread
over 118 acres of land in Jaipur and 56 acres in Gunsi (Newai).
This is the only unit in the country manufacturing wide variety and range of bearings
such as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical Roller Bearings
& Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings, Cartridge
Tapered Roller Bearings and Large diameter special Bearings in separate fully equipped
factories.
NEI has set up its third Ball Bearing manufacturing plant in the fastest growing industrial
town of Manesar in Haryana. The plant is having a covered area of 5200 sq. meters. with
the most advanced and sophisticated machines imported from reputed manufacturers
from Europe and Japan .
It has been long pursued policy and commitment of National Engineering Industries
Limited (NEI) to adhere to highest standards of integrity – professional and financial –
and business ethics in the operation of its business. We believe that this organization has
been handed to us by the various stakeholders in "trust” and we as professional managers
are the "trustees" of those stakeholders. It is therefore our responsibility to ensure that the
organization is managed in a manner that protects and furthers the interests of our
stakeholders.
55

Training Report of NBC Bearing

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Training Report of NBC Bearing

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Project report on training in National Bearing Company

IN NATIONAL BEARING COMPANY

FOR THE PARTIAL FULFILLMENT OF

BACHELOR OF TECHNICAL EDUCATION

IV YEAR, MECHANICAL ENGINEERING

A2 – BATCH, ROLL NO  ME052

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY

 Indian Bearing Industry

 Ball Bearing Assembly Line

➢ Roller Bearing Manufacturing

 Heat Treatment flow Chart

As the technologically advancement will enable us to get the environment

I am thankful to Ms. Monika Joshi, H.R.D. Department, for her

I am also thankful to Mr. R. Jaiswal, HOD Mechanical

I am also very thankful to all respected persons who have directly or

History & Evolution of Bearing

Tapered steering head bearings for a motorcycle

There are at least six common principles of operation:

• Sliding bearings, usually called "bushes", "bushings", "journal bearings", "sleeve

• Rolling-element bearings such as ball bearings and roller bearings.

• Magnetic bearings, in which the load is carried by a magnetic field.

• Flexure bearings, in which the motion is supported by a load element which

Common motions permitted by bearings are:

• Axial rotation e.g. shaft rotation

GABRIEL India Suspension Italy

Indian Bearing Industry

Heavy Industries Including

Threats & Limitations to Indian Market

 Increasing Competition in Domestic market.

Company Established as National Bearing Company (NBC) under

Ball Bearing Production Started

Railway Bearing Production Started

Company Name changed to National Engineering Industries Ltd.

Tapered Roller Bearing Production Started under Technical

Established Research & Development Division

Established Machine Building Division

Large Diameter Special Bearing Production Started

Spherical Roller Bearing Production Started with Technical know-how

Separate Factory for Ball Bearings at Gunsi

Cartridge Tapered Roller Bearing Production Started in Technical

Technical Collaboration with NTN Corporation of Japan for Ball,

Modernization in Three Phases

ISO – 9001 Certificate

Technical Collaboration with NTN Corporation, Japan for Tapered

IV-Phase Modernization Started

Implemented Ist Phase of SAP-ERP Solutions

QS-9000 & ISO-14001 Certification

AAR Certification M-1003 for Cartridge Tapered Roller Bearing

Mission of Company – “Keeping Nation on the Move”

This Division is spread over a covered area of 14,694 Sq. Meters.

ii) Steel Ball

Precision Steel Balls up to 25 mm diameters for NBC Bearings are manufactured on

This Division is spread over a covered area of 4,700 Sq. Meters.

iii)Tapered Roller Bearing

This Division is spread over a covered area of 11,652 Sq. Meters.

(a) Roller Bearing in Axle Box:

(b)Spherical Roller Bearing:

(c) Cartridge Tapered Roller Bearing:

This Division is spread over a covered area of 4,855 Sq. Meters.

i) Large Diameter Bearing

 PLANT AT GUNSI (NEWAI)

The plant is spread over a covered area of 7,200 Sq. Meters.

The plant is spread over a covered area of 5200 Sq. Meters.

Research & Development