National Engineering Industries Pvt.Ltd.

A Report on PROCESS PERFORMANCE Cone and cup

Department : Taper Department

Submitted To sanjay

submitted by vaibhav singh

CONTENTS
1) INTRODUCTION -------------------------------------------------------------- 2

2) TAPERED ROLLER BEARING

----------------------------------------------- 6

3) CASE STUDY 1

------------------------------------------------------------- 11

4) CASE STUDY 2

------------------------------------------------------------- 84

5) CASE STUDY 3

------------------------------------------------------------- 120

6) CASE STUDY 4

------------------------------------------------------------- 123

7) CASE STUDY 5

------------------------------------------------------------- 128

8) CASE STUDY 6

------------------------------------------------------------- 132

INTRODUCTION
The first ball and roller bearing manufacturing industry of South Asia was established in India in 1947 at Jaipur under the name of National Bearing Company Ltd., and manufactured the first bearing in 1950 under the trademark NBC. With ever increasing activities and the working of the factory being diversified to other vital industrial products, the company changed its name to National Engineering Industries Ltd., in 1958, but the product trade-mark NBC remained unchanged. National Engineering Industries Ltd. has been pioneer in India for the manufacture of ball and roller bearings, steel balls and roller bearing axle boxes to international standards. NBC bearing are exported to Europe, Egypt and Iran. The Cartridge Tapered Roller Bearings are manufactured under Technical Collaboration and Licence of BRENCO INC., Petersburg, Virginia, USA, which is considered as the world leader for this product. The company has been manufacturing Cartridge Tapered Roller Bearing for the Indian Railway since 1980.

TIMESCALE:

PLANT ESTABLISHMENT
1946 - Company established under the name of NBC 1950 - Ball Bearing Division started 1951 - Railway Bearing Division started 1957 - Tapered Roller Bearing Division started 1981 - Newai Plant Started 2006 - Manesar Plant Started

EVOLUTION OF QUALITY SYSTEMS

1995 - ISO 9001 Certifications 1999 - SAP ERP Implemented 2000 - ISO 14001 & QS 9000 Certification 2003 - TS 16949 Certification & TPM Kick Off 2005 - AAR M 1003 Quality system certification. 2007 - TPM certification Newai Plant 2008 - TPM certification Jaipur Plant 2010 - Won the Deming Award, the Highest Quality Award for Total Quality Management.

PRODUCT PORTFOLIO AND COLLABORATIONS

Ball Bearings in collaboration with NTN since 1985. Spherical Roller in collaboration with NTN since 1985. Cylindrical Roller Bearing in collaboration with NTN since 1985. Cartridge Tapered Roller Bearing in collaboration with BRENCO Inc. since 1982. Tapered Roller in collaboration with NTN since 1997. Large Diameter Bearing in collaboration with NTN since 1997.

Joint venture with NTN for Constant Velocity Joints since 2007.

NEI NETWORK
USA Brazil Peru Germany Italy South Africa Argentina UAE Pakistan Indonesia Sri Lanka Japan Nepal Bangladesh

MAJOR CUSTOMERS (Automotive)

BAJAJ AUTO YAMAHA MOTORS LIMITED KINETIC ENGINEERING KINETIC MOTORS HERO HONDA MOTORS ROYAL ENFIELD TVS MOTOR INDIA PVT. LTD. H.M.S.I.L. (HONDA) MAJESTIC AUTO LIMITED HINDUSTAN MOTORS TATA MOTORS LTD. ESCORTS EICHER MOTORS TAFE NEW HOLLAND V.S.T. TILLERS H.M.T. TRACTORS ASHOK LEYLAND

FORCE MOTORS SCOOTERS INDIA LIMITED MAHINDRA AND MAHINDRA LTD. ATUL AUTO LIMITED MARUTI UDYOG LIMITED PUNJAB TRACTORS (SWARAJ) SONALIKA INTERNATIONAL TRACTORS LTD.

OTHER CUSTOMERS
1. INDIAN RAILWAYS 2. POWER GENERATION PLANTS (a) MAHARASTRA STATE ELECTRICITY BOARD (b) MADHYA PRADESH POWER GENERATION COMPANY LTD. (c) CHATTISGARH STATE ELECTRICITY BOARD (d) INDRAPASTH POWER GENERATION CO. LTD. (e) RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD. (f) TAMIL NADU STATE ELECTRICITY BOARD (g) PUNJAB STATE ELECTRICITY BOARD (h) UTTAR PRADESH VIDYUT UTPADAN NIGAM LTD. (i) TATA POWER, MUMBAI (j) NATIONAL THERMAL POWER CORPORATION

Types of Bearings
There are many types of bearings, each used for different purposes. These include ball bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered roller thrust bearings.

Ball Bearings Ball bearings, as shown below, are probably the most common type of bearing. They are found in everything from inline skates to hard drives. These bearings can handle both radial and thrust loads, and are usually found in applications where the load is relatively small.

Photo courtesy The Timken Company

Cutaway view of a ball bearing

In a ball bearing, the load is transmitted from the outer race to the ball, and from the ball to the inner race. Since the ball is a sphere, it only contacts the inner and outer race at a very small point, which helps it spin very smoothly. But it also means that there is not very much contact area holding that load, so if the bearing is overloaded, the balls can deform or squish, ruining the bearing.

Roller Bearings
Roller bearings like the one illustrated below are used in applications like conveyer belt rollers, where they must hold heavy radial loads. In these bearings, the roller is a cylinder, so the contact between the inner and outer race is not a point but a line. This spreads the load out over a larger area, allowing the bearing to handle much greater loads than a ball bearing. However, this type of bearing is not designed to handle much thrust loading.

A variation of this type of bearing, called a needle bearing, uses cylinders with a very small diameter. This allows the bearing to fit into tight places.

Photo courtesy The Timken Company

Cutaway view of a roller bearing

Ball Thrust Bearing

Ball thrust bearings like the one shown below are mostly used for low-speed applications and cannot handle much radial load. Barstools and Lazy Susan turntables use this type of bearing.

Photo courtesy The Timken Company

Ball thrust bearing

Roller Thrust Bearing

Roller thrust bearings like the one illustrated below can support large thrust loads. They are often found in gearsets like car transmissions between gears, and between the housing and the rotating shafts. The helical gears used in most transmissions have angled teeth -- this causes a thrust load that must be supported by a bearing.

Photo courtesy The Timken Company

Roller thrust bearing

Tapered Roller Bearings

Tapered roller bearings can support large radial and large thrust loads.

Photo courtesy The Timken Company

Cutaway view of (left) a spherical roller thrust bearing and (right) a radial tapered roller bearing

Tapered roller bearings are used in car hubs, where they are usually mounted in pairs facing opposite directions so that they can handle thrust in both directions.

Taper Bearings
Products Description

Supplier Information

Industrial Taper Roller Bearing

We manufacture Industrial Taper Roller Bearings in superior grades of steel. They can carry combinations of large radial and thrust loads. In the industrial taper roller bearings there is a difference between the inner and outer raceway contact angles, which causes a force component that drives the tapered rollers against the guide flange. The Industrial Taper Roller Bearings are used in the construction machinery, gear, construction, and vehicle manufacture. These durable industrial taper roller bearings can be customized as per specific requirements of the buyers. They can be availed from us at most competitive prices.Advantages of Taper roller bearings * Dimensional Stability * Long Life Even In Contaminated Lubricant * Durable Steel Cage * Dimensionally Interchangeable With Other Bearing Manufacturers Applications of Taper Roller Bearings * Car and vehicle more...

Taper Roller Bearings

Tapered roller bearings consist of four basic components including the cone (inner ring), the cup (outer ring), tapered rollers, and a cage (roller retainer). Tapered roller bearings are designed such that their conical rollers and raceways are arranged so that all elements of the roller and raceway cones meet at a common apex on the bearing axis. The rollers are guided by the contact between the large end of the roller and the rib on the inner ring (cone). This construction provides a high capacity for radial loads, axial loads, and combined loads. The larger the contact angle, the greater the loading capacity becomes. When a pure radial load is placed on the bearing, an induced load in the axial direction is also generated. So, these bearings are generally used in pairs opposing each other. Tapered roller bearings have the inherent advantage of being adjustable and, they can be set to approach optimum performance in almost any application. These are mainly used in more...

TAPERED ROLLER BEARING

FLOW CHART FOR TAPER ROLLER BEARINGS

Cone(I/R) R.M. Inspection SAE52100 Tube/ Forged ring Complete Finish Turning by Vendor Rec. Inspection Soft face Grinding* Stamping* Heat treatment Face Grinding Track Grinding Large flange Grinding Bore Grinding Track Superfinishing Washing & Oiling Final inspection Final inspection Laser Marking* Laser Marking* Cup(O/R) R.M. Inspection SAE52100 Tube/ Forged ring Complete Finish Turning by Vendor Rec.Inspection Soft face Grinding* Stamping* Heat treatment Face Grinding Semi Finish O.D. Grinding I.D. (Track) Grdg. I.D. (Track) Superfinishing Finish O.D. Grdg. Washing & Oiling Heat treatment Tumbling Rough O.D. grinding Semi finish O.D. Grinding Large End grinding Finish O.D. Grinding Super finishing Washing Visual Inspection Soft Tumbling Headed, Soft Tumbled, H.T., S.F., Finish bought out from vendor Rec.Inspection Finsh bought out from vendor Roller R.M.Inspection SAE52100 WIRE Retainer As per IS:4397/ SPCC-SD / AISI 1008

Rec.Inspection Washing

Send to appropriate station

Retainer & Roller filling in Inner Closing in Free running Inspection Stand height inspection

Washing Oiling Packing Despatch Assurance Delivery to Finish Godown Shipment

PARTS OF TAPERED ROLLER BEARING

Retainer

Cup

ASSEMBLY OF TAPERED ROLLER BEARING

The tapered roller bearings consist of the following parts:
1. 2. 3. 4.

CUP: It has the largest diameter and is the

outermost part of the assembly.

CONE: It has the smallest diameter of the two,

and is in the innermost part.

ROLLERS: These are tapered cylinders that are

sandwiched between the cup and the cone.

CAGE/RETAINERS: These are used to

separate the rollers from one another, hold them, and uniformly divide them along the circumference of the cone.

Common terminologies:
1. 2.

TAPER:

The difference of the size of large face

and small face.

OOR: Stands for out of round. It is the difference

of the maximum and minimum readings of a face diameter.

BORE: The inner surface of the cone or cup. 4. OD: Stands for outer diameter of the cup or cone.
3.

CONE GRINDING

CONE BORE GRINDING

CONE FLANGE GRINDING

CONE TRACK GRINDING

CUP GRINDING

CUP BORE GRINDING

Cone Roller Cup

CUP TRACK HONING