Hitesh NBC Report

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ACKNOWLEDGEMENT
As a part of our graduation degree in engineering, I underwent training from 1june 2012 to 30june 2012 at NATIONAL ENGINEEERING INDUSTRIES LIMITED, JAIPUR for a period of 30 days.
I shall in my duties if I do not acknowledge thanks to Ms. Monika Joshi , Assistant Manager(HR) of National Engineering Industries Limited, Jaipur with whose permission my training in the factory was made possible.
I wish to express appreciation for taken keen interest taken by the engineers, workers of different Departments in explaining of various machines and for important valuable information regarding their operations etc.
I also acknowledge thanks to my fellow student for discussing various points during the course of training which proved very useful in preparing this project.
GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
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PREFACE
A very important element in curriculum of an Engineering student is the Practical Training.
We underwent practical training at NATIONAL ENGINEERING INDUSTIES LIMITED, JAIPUR from 1-06-2012 to 30-06-2012. This is a part of total 30 days training program incorporated in the curriculum of the Gyan Vihar College of Engineering & Technology for B.Tech. course.
As we are the students of Mechanical Engineering so the training at NBC has been particularly beneficial for us. We saw the various procedures, processes and equipment used in production of railway bearing which were studied in books. The student wishing that private sector undertaking success so that it may flourish and serve the nation which has reached 61 years of its independence and has to achieve many goals.
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CONTENT
1. INTRODUCTION 2. COMPANY PROFILE 3. INTRODUCTION OF PRODUCTS 4. MANUFACTURING PROCESS OF BEARING 5. BALL BEARING DIVISION 6. BEARING DESIGNATION 7. ABOUT THE QUALITY IN NEL 8. MY OBSERVATION 9. CONCLUSION 10. REFERENCES
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INTRODUCTION
THE GROUP C.K.Birla group is a diversified conglomerate with interests spanning across industries such as Cement, Consumer Electricals, Precision Bearings, Heavy Engineering Products, Paper, Building products, Automobiles, Auto components, Healthcare, Education & ITES. With a combined turnover of over US $ 1.8 billion and over 20,000 employees, manufacturing and service footprint across India, and track record of successful partnerships with global leaders; the CK Birla group strives to deliver enduring value to stakeholders. The group extends social welfare activities to communities, especially, around its industrial units while strengthening the social infrastructure through education and healthcare initiatives as part of its social responsibility.
The group companies include

AVTEC Limited Birlasoft Limited GMMCO Limited Hindustan Motors Limited Hyderabad Industries Limited Indian Smelting & Refineries Limited Orient Paper and Industries Limited Special Engineering Services Limited Nigeria Engineering Works Limited Rivers Vegetable Oil Company Limited
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Education Institutions

Birla Institute of Technology Modern High School for Girls Rukmani Birla Modern High School
Healthcare Institutions

The Calcutta Medical Research Institute B. M. Birla Heart Research Centre
Arts and Science Centers

The CK Birla Groups not-for-profit initiatives cover Science, Temples, Art and Archaeology and are aimed at building the social infrastructure in the communities we serve. The B.M. Birla Science & Technology Centre, Jaipur, The B.M.Birla Planetariums at Jaipur, Chennai and Hyderabad, B.M. Birla Museum, Ujjain, B.M. Birla Science Museum and the G.P. Birla Observatory & Astronomical Research Centre, Hyderabad are institutions that seek to get the mysteries of science and astronomy within the reach of the common man. The Birla Temples at Hyderabad, Jaipur and Bhopal are archaeological marvels. The Birla Archaeological & Cultural Research Institute, Hyderabad, Birla Institute of Art & Music, Bhopal, The B.M.Birla Archaeological Museum and Modern Art Gallery, Hyderabad and the many renovation initiatives at renowned religious and historical places are a testimony of the CK Birla Groups commitment to Art and Architecture.
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COMPANY PROFILE
NEI manufactures a wide range of bearings namely ball and cylindrical roller bearings, double row angular contact bearings, tapered roller bearings for automobiles, railways and industrial applications and large diameter bearings for steel plants and rolling mills. The three plants situated at Jaipur, Newai and Manesar manufacture these products with approx. 2300-strong team, supported by a well-equipped R&D with bearing life testing facility. NEI Ltd. has been awarded the coveted 2010 Deming Application Prize, by the Union of Japanese Scientists and Engineers (JUSE), Japan, for achieving distinctive performance improvement through the application of Total Quality Management (TQM).The Deming medal confirms that our quality management systems are one of the best ,globally .For our customers, this means enjoying consistently superior products and assurance of highest quality National Engineering Industries Ltd., part of the 150 year old, multibillion dollar C.K. Birla group manufactures a wide range of bearings for automotive and railway industry as well as for general industrial applications under the brand name nbc . NEI, founded in the year 1946 as a pioneer industry in the field of bearing manufacture, now manufactures nearly 80 Million Bearings per annum in over 500 different sizes ranging from 6 mm bore to 1300 mm outer diameter having capability to manufacture bearing upto 2000 mm. diameter. NEI is one of the largest domestic bearing manufactures with gross annual turnover of Rs. 1051 crore in 2010-11. The company exports bearings to more than 20 countries and is also exporting to OEMs in Europe and USA. NEI has grown at a CAGR of 19% since 2007-08.
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The company having three plants situated in India these plants with their specialties are:
(I) PLANT AT JAIPUR

(i). Ball Bearing
Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are manufactured on state of the art manufacturing facilities with in-process and post-process gauging in grinding and centrally air conditioned assembly lines with auto gauging and testing equipments. The latest advanced techniques for 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. This Division is spread over a covered area of 4,700 Sq. Meters.
(iii). Tapered Roller Bearing

Precision Tapered Roller Bearings are manufactured in Inch and Metric series from 15.875mm bore to 95.25mm bore with technology obtained from our earlier collaborator, Federal Mogul Corporation, USA and now with NTN Corporation, Japan. These bearings are used by all major Automobile manufacturers in the country as Original Equipment. This Division is spread over a covered area of 11,652 Sq. Meters.
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(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 (one of the largest systems of the world) by designing and developing Axle Boxes and bearings for fitment to Locomotives manufactured by Diesel Locomotive Works , Chittaranjan Locomotive Works, various wagon builders, the ICF broad and meter gauge coaches. Over a million NBC bearings and boxes are in service with the Indian Railways. The development of completely indigenised Axle Boxes and bearings for the high speed Rajdhani Locomotive, the Yugoslavian and Egyptian Railway wagons are the highlights of the 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 with designs, technology, machines and equipment procured from the collaborators. (c) Cartridge Tapered Roller Bearing For fitment to the new BOX-IN Uprated Wagons designed by the RDSO, NEI is the only manufacturer in the country to indigenise these bearings to a high percentage under collaboration with the largest manufacturer of these bearings in the world. 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. This Division is spread over a covered area of 4,855 Sq. Meters.
(v). Large Diameter Bearing

Self-sufficiency in steel is the call of the day, so is the importance of bearings in Steel Mills Equipment. 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 released by Mr. G.P. Birla in September 1985. This 4-Row Tapered Roller Bearing measures 1300 mm dia and weigh 4.39 tons. The large diameter bearings are mainly manufactured out of case carburising steel, heat treated on special equipment and furnaces developed by NEI. Precision grinding is done to close tolerances on CNC Twin Spindle Programmable Berthiez Machine for bearings ranging from 500 to 2000 mm diameter with electronic sizing and numerical display. 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.
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(II) 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 airconditioned 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.
(III) PLANT AT MANESAR

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 . This plant is equipped with state of the art fully automated grinding lines, assembly lines and inspection equipments.
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COMPANY DEFINITION
Industry can be defined as: Any type of Economic Activity producing GOODs or SERVICES It is part of a chain from raw materials to finished product, finished product to service sector, and service sector to research and development. It includes AGRICULTURE, MANUFACTURING and SERVICES Industry varies over time and between different countries
Industrial linkage: When one Industry depends on the output of another This can cause problems if one industry has production problems or closes down
The CAR INDUSTRY is a good example each component (engine parts, lights, body etc.) may be produced by a different company before it goes to the ASSEMBLY PLANT.
BEARING INDUSTRY GLOBAL SCENERIO

The world Market of quality Bearing is very vast. The Big players of bearing sector are present in U.S.A, Russia, Japan, China and Eastern Europe. Some of leading bearing Manufacturers are: - NSK Japan - NTN Japan - KOYA Seiko Japan - FAG Germany - SKF Sweden There are few of leading bearing manufacturer present in India. Most of the big player is having either technical or financial Collaboration with leading Auto Manufacturer. International Collaboration gives Access to best technology in the world.
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BEARING INDUSTRY INDIAN SCENERIO

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 to the tune 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 industries and other mechanical Industrial users. The replacement market is dominated by unorganized Sector.
NATIONAL ENGINEERING INDUSTRY LIMITED(NEI)

Bearing in India started with the setting up of manufacturing unit in JAIPUR by the Birla Group in 1946 under the name of "National Bearing Company Ltd." The 1st Bearing was manufactured in 1950 with a modest start of 30 thousand bearing in 19 Sizes. The Bearing Races (Soft) was Manufactured by the Tiny Unit in the Small Scale Sector at Jaipur during 1970 on Job Work basis. It is a view to utilize the end piece of the Stainless steel tube which could not be fed to the Multi operation of National Engineering Industries Jaipur. There after there is a continuous growth of this Industry and now it has grown to a level that Almost All the Leading Manufacturer of the country are procuring Soft Bearing Races from JAIPUR. The National Engineering Industries procure lakhs of Ring every month from these Bearing Race Manufacturing Unit. The other leading manufacturer like S.K.F., FAG, TATA Bearing, NBC are also procuring the Bearing races from Jaipur. In addition to above, the Small Scale Units manufacturing Bearing in the state of Rajasthan, Delhi, Gujarat and Punjab also purchasing Bearing Races and components from Jaipur.
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QUALITY MANAGEMENT
ISO / TS 16949
NEI extensively embarked upon system improvement and implemented modern concepts of Total Quality Management. NEI has been awarded TS 16949: 2002 on 17th October, 2003THE 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 to only suppliers of automobile manufacturers. NBC bearings are used by all major auto OE customers in India like Maruti Udyog, Hero Honda, Bajaj Auto, Bajaj Tempo, TVS Motors, Ashok Leyland, Tata Motors, Hindustan Motors, Yamaha Motors, Eicher Limited, Eicher Motors, Mahindra & Mahindra Auto & Kinetic Motors etc. In addition customers like Eicher Tractors, Punjab Tractor, Escort Tractor, International Tractors, New Holland Tractors, Electric & Pump Motors, Crompton & Orient Fans and many more in Automobile, Electric Motors & Pump, Fans, Conveyors, Steel Plants, Thermal Plants also use NBC bearing regularly. The recommendation was made by BVQI after 15 days of detailed audit in all areas of NEI including our Gunsi plant. TS 16949 quality management system is based on ISO 9001 in which many supplementary and additional requirements of automobile industries have been incorporated. TS quality management system in NEI starts with identification of all customer requirements and ends with ensuring that all customer requirements have been fulfilled. This also requires continuous improvement in all areas. Every process is critically studied and performance indicators for measuring output of those processes defined. Measurement of efficiency and effectiveness of every process only decides how ably the process has been performed. Simplicity, effectiveness & efficiency of processes, error proofing and continuous improvement in processes thus become the highlight of TS quality management system. NEI is complying latest version of ISO/TS16949 standard.
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ISO 9001
NEIs 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. NEI is complying latest version of ISO 9001 standard.
ISO 14001
NEIs everlasting concern for cleaner, pollution free environment has made the NEI to go on the path of Environmental management System. NEI was awarded ISO -14001 certificate 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. NEI is complying latest version of ISO 14001 standard.
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AWARDS
NEI has been awarded with many Biz-awards in its tenure till date. Some of recent awards won by the company are : 1. Winner of DEMING PRIZE 2010. 2. Grand Award for Cost in 2009-10 from Honda Motorcycle & Scooter India Pvt. Ltd. 3. Award for TPM Excellence Category-A in 2009. 4. Vendor Performance Award in 2008-09 for Overall Commendation. 5. Certificate of Appreciation in 2008 from Maruti Suzuki India ltd. 6. Award for Challenge India Support (Engine Group) in 2003-04 from 7. Excellence Award in 2003 from IES. 8. The 4India Pro User Award 2002 9. Award for Excellence in 2001-02 from MICO Bosch Group. 10. Excellence in Performance in 2001-02 from Motors industries Co. ltd. 11. The 3India Pro User Award 2001. 12. Indian Pro User Award 1999. 13. Winner of Certificate of Excellence in Industrial Equipment Category from PTC.
The company is now preparing for the INDIAN MANUFACTURING EXCELLENCE AWARD 2011(IMEA).
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RESEARCH & DEVELOPMENT

R&D is equipped to introduce new technology in the field of bearings and related products .All functions from concept design to product launch are an integral part of R&D . The activity begins from customer interaction by Application Engineering and QFD approach is used to understand customer requirements to translate into a useful product . It has a full fledged test centre for endurance as well as application testing .The test lab is being expanded to double the capacity in next four years. Advanced functions like Tribology ,Simulation ,Materials Technology and Lubrication technology have been added .The centre relies on the associate strength that has vast experience in the bearing industry . Academics excellence is being promoted by inclusion of specialists from IITs and RECs .The centre will be a leading technology centre in next 4 to 5 years. NEI stands committed to an endless journey of continuous improvement through TQM.
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CLIENTS
1. 2 wheelers
BAJAJ AUTO
YAMAHA MOTORS LIMITED
KINETIC ENGINEERING KINETIC MOTORS
HERO MOTOCORPS
ENFIELD INDIA
TVS MOTOR INDIA(P)LTD
HMSIL
MAJESTIC AUTO LIMITED
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2. 3wheelers
BAJAJ AUTO
FORCE MOTORS SCOOTERS INDIA LIMITED MAHINDRA & MAHINDRA LTD. ATUL AUTO LIMITED
3. Cars, jeeps
MARUTI UDYOG LIMITED
HINDUSTAN MOTORS
FORCE MOTORS
MAHINDRA & MAHINDRA LTD.
ASHOK LEYLAND
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FORCE MOTORS
EICHER MOTORS
HINDUSTAN MOTORS
TATA MOTORS LTD
4. TRACTORS
ESCORTS
FORCE MOTORS
EICHER MOTORS
PUNJAB TRACTORS
TAFE
NEW HOLLAND
VST TILLERS
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HMT TRACTORS
SONALIKA International Tractors Ltd
5. RAILWAYS
INDIAN RAILWAYS I.Production Units for Locomotive and passenger coaches: Chittaranjan Locomotive Works Diesel Locomotive Works Diesel Loco Modernization Works Intergral Coach Factory Rail Coach Factory II.All Zonal Railways III.Wagon Builders BESCO Ltd. Bharat Wagon and Engg.Ltd. Bharat Wagon and Engg.Ltd. Braithwarte & Compay Limited Bridge & Roof Burn Std. Company Limited Hindustan Engineering Industries JESSOP & Co. Ltd. Modern Industries Ltd. Texmaco Limited Titagarh Wagon Ltd.
BRENCO INC., USA
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6. LARGE DIAMETER BEARING

MAHARASHTRA STATE ELECTRICITY BOARD
MADHYA PRADESH POWER GENERATION COMPANY LTD.
CHATTISGARH STATE ELECTRICITY BOARD INDRAPRASTH POWER GENERATION CO. LTD. RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD
TAMILNADU STATE ELECTRICITY BOARD
PUNJAB STATE ELECTRICITY BOARD
UTTAR PRADESH VIDYUT UTPADAN NIGAM LTD.
TATA POWER, MUMBAI
NATIONAL THERMAL POWER CORPORATION STEEL PLANTS: SAIL, BOKARO STEEL PLANT,BOKARO SAIL,ROUERKELA STEEL PLANT, ROUERKELA SAIL,DURGAPUR STEEL PLANT, DURGAPUR SAIL,BHILAI STEEL PLANT, BHILAI
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INTRODUCTION OF PRODUCT
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.
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TYPES OF BEARING
There are many different types of bearings. Type Description Friction Stiffness Speed Life Notes
Widely used, relatively high friction, Depends on Rubbing suffers from materials surfaces, Good, stiction in and usually with provided some construction, lubricant; some wear is Low to very high - applications. PTFE has Plain bearings use low, but Low to depends upon Depending coefficient of bearing pumped some very high application and upon the friction lubrication and slack is lubrication application, ~0.05-0.35, behave similarly normally lifetime can depending to fluid present be higher or upon fillers bearings. lower than added rolling element bearings. Rolling coefficient of friction with steel can be ~0.005 (adding resistance due to seals, packed grease, preload and misalignment can increase friction to as much as 0.125)
Ball or rollers Rolling are used to element prevent or bearing minimize rubbing
Good, but some slack is usually present
Moderate to high (often requires cooling)
Moderate to high (depends on lubrication, often requires maintenance)
Used for higher moment loads than plain bearings with lower friction
Off-center Jewel bearing rolls in Low bearing seating
Low due Low to flexing
Adequate (requires maintenance)
Mainly used in low-load, high precision work such as clocks. Jewel bearings may
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be very small. Can fail quickly due to Very high grit or dust or Virtually infinite (usually other in some limited to contaminants. Fluid is forced applications, may Zero friction a few Maintenance Fluid between two wear at at zero Very high hundred free in bearing faces and held startup/shutdown speed, low feet per continuous in by edge seal in some cases. second use. Can Often negligible at/by handle very maintenance. seal) large loads with low friction. Zero friction at zero speed, but constant power for levitation, Faces of bearing eddy are kept currents are separate by Magnetic often magnets Low bearings induced (electromagnets when or eddy movement currents) occurs, but may be negligible if magnetic field is quasistatic
Indefinite. No Maintenance practical free. (with limit electromagnets)
Active magnetic bearings (AMB) need considerable power. Electro dynamic bearings (EDB) do not require external power.
Material flexes Flexure to give and Very low bearing constrain movement
Low
Very high.
Very high or low depending on materials and strain in application. Usually maintenance free.
Limited range of movement, no backlash, extremely smooth motion
Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct from the friction of the bearing. Table 1: Types of bearing
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PRODUCT RANGE
A BROAD RANGE BORN OF PRECISION
From a few mms to thousands of mms, from a few grammes to a few tonnes, the NBC range is hard at work in some of the most critical areas of Indian industry. BALL BEARINGS The initial technology was from Hoffman Manufacturing Company Ltd., U.K. a collaboration, which continued for 20 years. We offer a wide range of both metric and inch series deep groove ball bearings, angular contact ball bearings, self-aligning ball bearings etc. With our tie up with the world's leading bearing manufacturing company NTN Corporation, JAPAN, we have gained access to the most advanced ball bearing technology i.e. thermo mechanical bearings (TMB) and tensioner bearings available today and our wide range of ball bearings is increasing under this collaboration.
TAPERED ROLLER BEARINGS

Manufactured at an ultra modern plant, with technology obtained from our earlier collaborators, Federal Mogul Corporation, USA and now with NTN Corporation, JAPAN, these bearings are used by all major automobiles, truck and tractor manufacturers in the country as original equipment. SPECIFICATION M244249A/N1060 (Bore 220.662 mm x OD 314.325 mm x Width 61.912 mm) Suspension Bearing developed for Indian Railways for GM Locomotive WDG-4 N1059/M244210 (Bore 221.17 mm x OD 314.325 mm x Width 61.912 mm) Suspension Bearing developed for Indian Railways GM Locomotive WDG-4.
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SPHERICAL ROLLER BEARINGS

Originally developed in collaboration with Swiss leaders FAG-SRO. Vital for broad gauge and meter gauge coaches manufactured by ICF, Chennai and RCF, Kapoorthala for the Indian Railways. Now new sizes are being developed with the help of NTN Corporation, JAPAN. SPECIFICATION
22312D1
(Bore 60 mm x OD 130 mm x Width 46 mm)
22312KD1
22314D1
(Bore 70 mm x OD 150 mm x Width 51 mm}
22314KD1
22222
22222KD1
(Bore 110mm x OD 200 mm x Width 53mm)
ROLLER BEARING AXLE BOXES

Developed by NBC for the Indian Railways for use in rolling stocks. Excellent performance even in the high speed Rajdhani locomotives, the Yugoslavian and Egyptian Railway wagons. A total of 34 different types of the axle boxes are turned out at the
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NEI plant in Jaipur. Designs for high speed railway application are being developed together with NTN. More than one million NBC axle boxes and roller bearings are in operation with Indian Railways. We have the privilege of being the single largest source of bearings to Indian Railways, which is one of the largest networks of its kind in the world.
CARTRIDGE TAPERED ROLLER BEARINGS

Successful Track record in the Railways for the past 30 years, these require no field lubrication. Developed in collaboration with BRENCO Inc. USA, these bearings are being used in all broad gauge wagons of Indian Railways.
PRECISION STEEL BALLS

Manufactured using the most modern facilities available in India, Quality steel balls, upto 25 mm in diameter for NBC bearings are manufactured in precision lines imported from NTN Corporation, JAPAN. NBC ball bearings are now specially manufactured with high precision steel balls produced in ultra modern plant equipped with high speed headers, electronically controlled flashing, grinding, and lapping machines to ensure accuracies of sub-micron levels.
LARGE DIAMETER BEARINGS

We have the distinction of being one of the few bearing companies in the world to manufacture bearings upto 2000 mm outside diameter developed with indigenous technology. Bringing Shri B.M. Birla's vision of self-reliance to fruition, NBC large diameter bearings contribute to steel production and thermal power generation in India.
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CYLINDRICAL ROLLER BEARINGS NH318 (Bore 90 mm x OD 190 mm x Width 43 mm) Traction Motor Bearings NU1964 (Bore 320 mm x OD 440 mm x Width 56 mm) Suspension Bearing developed for Indian Railways for WAG-9 Locomotive NH1044 (Bore 220 mm x OD 340 mm x Width 56 mm) Suspension Bearing developed for Indian Railways for WAG-9 Locomotive
SUSPENSION TUBE KIT ASSEMBLY

Suspension tube kit assembly developed for Indian Railways for GM Locomotive WDG-4
LARGE DIAMETER BEARING
Large dia. bearings are designed in such a way that vertices of the cone for each roller and those for the inner and outer raceways coincides on the bearing axis or extensions of the raceways and rollers converge at a common point on the axis of rotation. This results in true rolling motion of the rollers on the raceways at every point along the rollers. The large dia. bearings support radial loads and axial loads from one direction only. The line contact between rollers and raceways provide the bearings with a high load carrying capacity. Large Dia. Bearing enables the shafts to take heavier axial load.
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The bearings are of separable type, enabling separate mounting of cups and cones. Since the Large Dia. bearings can absorb thrust loads in one direction only, these bearings should generally be installed as opposed mountings. The correct amount of radial and axial clearance is obtained by adjusting the two bearings against each other. Besides, double row and four row large dia. bearings are also widely used for heavy loads such as rolling mills. The inner and outer ring raceways are segments of cones and the rollers are also made with a taper so that the conical surfaces of the raceways and the roller axes if projected, would all meet at a common point on the main axis of the bearing.
This conical geometry is used as it gives a larger contact patch, which permits greater loads to be carried than with spherical (ball) bearings, while the geometry means that the tangential speeds of the surfaces of each of the rollers are the same as their raceways along the whole length of the contact patch and no differential scrubbing occurs. When a roller slides rather than rolls, it can generate wear at the roller-to-race interface, i.e. the differences in surface speeds creates a scrubbing action. Wear will degenerate the close tolerances normally held in the bearing and can lead to other problems. Much closer to pure rolling can be achieved in a tapered roller bearing and this avoids rapid wear. The rollers are guided by a flange on the inner ring. This stops the rollers from sliding out at high speed due to their momentum. The larger the half angles of these cones the larger the axial force that the bearing can sustain.
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Large Dia. Bearings have the following components: outer ring, inner ring, and roller assembly (containing the rollers and a cage). The non-separable inner ring and roller assembly is called the cone, and the outer ring is called the cup. Internal clearance is established during mounting by the axial position of the cone relative to the cup.
RAW MATERIAL
The Races & Rolling elements of Bearing are subjected to stress on a very small contact surface must be of such material also as to with stand wear and have high elastic Limit & fatigue Limit. The raw material being used by the Industry for Manufacturing of various Bearing components are as under:
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CUP AND CONE

The raw material used in the Manufacturing of bearing Races is SAE 52100 high Carbon Chrome bearing steel, which has composition similar to EN-31 (100 CR 6 As per BIS specification). The raw material for Bearing Races is in the form of Rods & Seamless Hollow Tubes. This is a Spheroids Annealed Steel. Approx. 80% of the Seamless Hollow tubes are purchased by the Industry from M/s. Indian Seamless Metal tube PUNE, while the rest of the tube used in the cluster is imported material. The Steel bar are purchased from M/s. Indian Seamless Steel & Alloy Pune & M/s. Mahindra Ugine Steel Company KHAPOLI (Maharashtra). Some of the units are buying the steel scrap rod for manufacturing bearing races. Bearing Races material and their heat treatment are required to be selected carefully, taking account the mechanical strength and required life of the Bearing, Approximate required composition for bearing races are Constitute % Composition Carbon 0.95 to 1.1 Chromium 1.4 to 1.6 Manganese 0.50 max. Silicon 0.15 to 0.35 Sulphur 0.025 (Max.) Phosphorous 0.05
CAGE'S
Cage is used to return balls at proper distance to prevent them from containing each other and to prevent a temperature rise and resultant damage due to friction. The Material for manufacturing cages is CRCA Strips of C2015 Bearing grade steel having carbon percentage at0.08% max. and Magnesium ranging from 0.25% to 0.45%
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MANUFACTURING PROCESS OF LARGE DIA. BEARING Forged rings (De-scaled) as raw material (SAE 52100 steel) Turning Operation Centre Less Grinding Heat Treatment Hardness Testing Rough Grinding Finish Grinding Honing & Super Finishing Washing Application for Rust Preventive Ready For Dispatch to Assembly
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Bore finishing
COMPUTERIZED NUMERIC CONTROL(CNC) M/C
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Heat Treatment Process

Heat treatment process is the process of hardening the soft material. The row material is soft material and it has to be hardened before grinding, and hardening increase the life of bearing. Hardening is done in a special furnace named CHUGAIRO furnace. The soft machined material is feed in the furnace and washed at 60 0 C, then send to a chamber where the material heated in four chambers the first chamber has the temperature 8400 C and further chamber contains the 8500 C temperature. Then it dipped into an oil tank at temperature 250C where the material get quenched then it washed and then it tempered in water about 90 min. at temperature 1050 C . then dried and cooled in air. The hardened material is obtained.
The systematic flowchart is shown in following fig:
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Heat Treatment Process
Chugai Ro Heat Treatment Furnance
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Hardening Procedure
Steel Material LC Steel (Low Carbon Steel)
Table 1 Hardening
Process
Carburizing
Hardening
Quenching
Tempering
Carbon Furnace heating at

Procedure
9400 C - 9500 C
Furnace temperature at 8500 C 8700 C
Fast cooling 600 C for oil quenching only
Heat the Furnace at 1650 C-1800 C
Hardness
.200 - .250
------
60 64 HRC
52 62 HRC
Time
8 10 hours
35-60 min. According to job. the
5-15 min.
120-180 min.
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Salt Bath Furnace
Heat Treatment
Raw Material
(Carbon Steel)
Carburizing
(Carbon Shield Layer increases Hardness) (10 12 hrs.) (940 C) (GC Furnace)
0
Hardness I
(Revolving Furnace) (920 C) (Time Dependent on Job)
0
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Annealing
(6 hrs.) (650 C)
0
Shot Blasting
Hardening II
(Revolving Furnace) (820 C) (Time Dependent on Job)
0
Sub-Zero Treatment
(-60 C) (Increases Toughness)
0
Tempering
(160 C) (4 hrs.)
0
Shot Blasting
(Wheel Abrator)
Hardness Inspection
(60 HRC)
Page 38
After heat treatment following process are done:
DIFFERENT PROCESS FOR CONE

Dimensions Checking Before starting the grinding process, various dimensions of cone should be checked in a machine or manually. Various dimensions to be checked are: Flange diameter Cone width Cone track diameter Bore diameter Face Grinding Face is the surface at side of the inner and outer race , face should be finished indeed to get the desire width of the bearing and since the bearing is a mating part and it has to be assembled somewhere in the machine where it should be fit precisely. The face grinding is done in a machine where the faces are grinded in between the grinding wheel. Size Limit : : Width Variation : UCL LCL 5 m +35 m -35 m
There are various semi-automatic face grinding machine installed in taper section for cone 1. DAISHO MACHINE 2. NISSEI MACHINE
OD (Outer Dia.) Grinding OD is the circumferential surface of the outer race of the bearing. The OD should be surface finished since the bearing has to be assembled in machine. It is obtain in an OD grinding machine. In this machine the outer race is rotated between two grinding wheel. The outer race is passed in machine three times to get highly finished as follows: 1. Rough1 2. Rough2 3. Fine finish
Page 39
Size Limit Target Size
: :
15 to 35 m +30 m
Flange Grinding The flange should be surface finished since the bearing has to be assembled in machine. It is obtain in the flange grinding machine. In this machine one grinding stone is used to cut and grind the flange portion of cone. NC Mode Feed Mode Override AUTO AUTO 120% (used to change machine speed.)
Tool movement during grinding is in all three dimensional axes i.e. X, Y, Z axis.
Bore Grinding Bore is the inner circumferential surface of the bearing. The bore should be surface finished since the bearing has to be assembled in machine. It is obtain in the bore grinding machine. In this machine the grinding stone is moved in X and Y axis. Size Limit : +4 m to -4 m.
TOOL movement during grinding is in only two dimensional axes i.e. X, Z axis.
Auto Dimension Check Various dimensions of cone are checked in this machine. This machine includes various sensors for sensing the dimension of cone. This machine use weight sensors and position sensors to identify the position and weight of cone. All dimensions should be checked in this machine. M1 M2 M3 M4 M5 0.7 2.1 -2 -0.2 1.6 ID1 - X ID 2 - X TAPER ID1 - Y ID 2 Y
Page 40
M6
0.9
OVALITY
It automatically discards the work piece if its dimensions are not compatible with pre-feed data. The limitations of size are: Size limit TAPER OOR CHATTER SQUARENESS : : : +4 m to -4 m.
5 m maximum : : 5 m maximum 3 m maximum
5 m maximum
Honing Machine Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture.
DIFFERENT PROCESS FOR CUP

OD Grinding OD is the circumferential surface of the outer race of the bearing. The OD should be surface finished since the bearing has to be assembled in machine. It is obtain in an OD grinding machine. In this machine the outer race is rotated between two grinding wheel. The outer race is passed in machine three times to get highly finished as follows: Rough1, Rough2, Fine finish.
Size Limit Target Size
: :
15 to 35 m +30 m
Honing Machine Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture.
Page 41
ASSEMBLY LINE Once respective CUP and CONE of corresponding bearing is finished, they are sent in the Assembly line where these cup and cone get assembled with retainers having rollers in them and after some important test, they are finally packed and are ready for use. Laser Printing Machine It is a machine which is used for marking purpose of the company brand and specification on respective cup or cone. This technology utilizes laser beam for marking. The movement of laser beam is controlled by automatic 3d table movement. The point on metal surfaces where these laser beams hits leave marks as required. Names of few Laser Machine which are installed in Taper Bearing Section are: 1. AKSHAR FIBER-PRO 2. SAJIAJANAND Laser Technology ltd Roll Filling Machine It is an automatic machine which is actuated by pneumatic technology. In this machine, first Retainer is placed on first station where rollers are inserted at there respective position. Then they are sensed by position sensor, actuated by pneumatic and then cone is fixed within cage. Pressing Machine It is an automatic machine which is actuated by pneumatic and hydraulic technology both. The Cone is pressed against Retainer with downstroke powered by hydraulics and upstroke powered by pneumatics.
Weight check At this station, Weight of bearing is checked and if the weight is not compatible with the given standard of weight limits, machine will reject the workpiece sample. Demagnetizer It is a machine which is used to remove magnetism induced during the above process. It is done by impact hitting. Washing: Then the bearing is washed by fast stream of kerosene jet. Noise checking: The bearing is supposed to be produce low noise hence this machine rotates the bearing at certain rpm and noise is checked. The noise limit is nearby 0.1 Mpa.
Page 42
Press checking: At this station, the bearing is checked whether its assembly is pressed properly or not. Final checking This machine has 2 or 4 stations where various dimensions of final bearing are checked. If any bearing is found incompatible with the given dimensions and tolerances, they are rejected by the machine. In ideal position 1, width of bearing, runout and commet or clearance of bearing is checked. And at ideal position 2, bore size, taper and roundness are checked. All those bearings which does not have compatible size and tolerance with the given data, they are rejected by the machine itself. Ideal position 1 : width, run out, commet Ideal position 2 : bore size, bore taper, bore roundness Oiling and Drawer Machine: In this machine, bearing is subjected to a fast flowing stream of coolant which is used to lubricate the bearing parts. And then the excess oil is again sucked by the machine. Visual Inspection: Now, the bearing is checked manually by the operators. All the dimensions and surface properties are checked and rejected workpiece are sent again for correction. Packing: Finally, finished product is packed for market use and export.
Laser Marking System
A Laser marking system marks a highly visible mark on the job without touching it.
Job Number NBC INDIA Date Code
Page 43
Important parts a) b) c) d) e) f) g) Marker Controller Water-cooled Unit Filter Kit Console Control Panel Mechanical Handing System
The Laser is produced with the help of a diode which is focused on the job by using a lens. The Laser beam produces a external high thermal energy; this thermal energy marks a dark mark on the job extra thermal energy is then absorbed through the cooling system.
Thus, in this form the laser beam produced from a diode marks a dark mark on the job. With the help of the machine customer requirements like; customer code, part number etc. can be marked accordingly.
Ball Bearing Division
Wire
(High Chromium Steel)
Heading Machine
Flashing (Rough Grinding)

(Scale : 0.01-10mm) (High Grind Oil + H2O)
Soft Grinding
Page 44
(Scale : 0.001-1mm) (High Grind Oil + H2O)
Heat Treatment
Work Hardening Tumbler

(60 HRC)
Hard Grinding (G2)
Finish Grinding (G3)

(Kerosene)
Rough Lapping (L1)
Finish Lapping (L2)
Ultra Sonic Washing Machine

(Kerosene)
Page 45
Visual Inspection
Anti-Rust Oil Packaging

Maxi Grind Oil + H2O and High Grind Oil +H2O (Coolant)
Ring Rolling Mill

In this section ring blanks are produced with solid steels bars by forging process.
A systematic process of ring rolling shop may be as follows:-
Page 46
VIEW OF CALIBRATION PRESS:-
Figure 1 Calibration Press
Another flow chart for ring rolling operation may be drawn as follows:Raw material (Bar/slug) (Bar / Slug) If Induction heating Bar
Page 47
If Bar
Up setting
Slug cutting or shear cutting
Pre - punching
Finish Punching Rolling
Forming and finish rolling
Dimensional Inspection
Sizing and calibration
Page 48
GRINDING MACHINE
Page 49
GRINDING
Centre less Grinding
Figure 2 Centreless Grinding
Cone Track Grinding
Page 50
Causes of Step in Cone
a) b) c) d)
Baking plate is not properly aligned in accordance Width of Grinding Wheel is Less Width of Cone Track is more Undercut Width is less.
Cartridge Roller Bearings Components
a) b) c) d) e) f) g) h) i)
Cone Assembly Cup Spacer Wear Ring Grease Seal Axel and Cup Axel Cup Screw Locking Plate Backing Ring
Page 51
Bearing Designation

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Page 1

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

A very important element in curriculum of an Engineering student is the Practical Training.

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

The group companies include

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

The Calcutta Medical Research Institute B. M. Birla Heart Research Centre

Arts and Science Centers

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

(I) PLANT AT JAIPUR

(ii). Steel Ball

(iii). Tapered Roller Bearing

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

(iv). Railway Bearing

(v). Large Diameter Bearing

(II) PLANT AT GUNSI (NEWAI)

(III) PLANT AT MANESAR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

BEARING INDUSTRY GLOBAL SCENERIO

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

BEARING INDUSTRY INDIAN SCENERIO

NATIONAL ENGINEERING INDUSTRY LIMITED(NEI)

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

RESEARCH & DEVELOPMENT

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

YAMAHA MOTORS LIMITED

KINETIC ENGINEERING KINETIC MOTORS

TVS MOTOR INDIA(P)LTD

MAJESTIC AUTO LIMITED

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

MAHINDRA & MAHINDRA LTD.

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

MAHINDRA & MAHINDRA LTD.

TATA MOTORS LTD

MAHINDRA & MAHINDRA LTD.

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

SONALIKA International Tractors Ltd

BRENCO INC., USA

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

6. LARGE DIAMETER BEARING

MADHYA PRADESH POWER GENERATION COMPANY LTD.

TAMILNADU STATE ELECTRICITY BOARD

PUNJAB STATE ELECTRICITY BOARD

UTTAR PRADESH VIDYUT UTPADAN NIGAM LTD.

TATA POWER, MUMBAI

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

Good, but some slack is usually present

Moderate to high (often requires cooling)

Moderate to high (depends on lubrication, often requires maintenance)

Off-center Jewel bearing rolls in Low bearing seating

Low due Low to flexing

Adequate (requires maintenance)

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

Indefinite. No Maintenance practical free. (with limit electromagnets)

Limited range of movement, no backlash, extremely smooth motion

GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR