NBC Training Report - Ball Bearing Division

Industrial Training Report
Mechanical Engg. Deptt. A.I.E.T., Jaipur
Page 1
Candidates Declaratio
I hereby declare that the work, which is being presented in the practical training seminar,
entitled BALL BEARING DIVISION in partial fulfillment for the award of Degree of
Bachelor of Technology in Mechanical Engineering, submitted to the Department of
Mechanical Engineering, Arya Institute of Engineering & Technology, Rajasthan Technical
University is a record of my own work carried under the Guidance of Mr.ADITYA
SHAHANI, (NATIONAL ENGINEERING INDUSTRIES LIMITED).
I have not submitted the matter presented in this Report anywhere for the award of any other
Degree.
(Signature of Candidate)
SANJAY KUMAR NIRANIA

Roll No.: 11EAIME053
Page 2
Acknowledgement
We wish to express our deep sense of gratitude to our Practical Training Guide Mr. ADITYA
SHAHANI, (NATIONAL ENGINEERING INDUSTRIES LIMITED) for guiding me
from the inception till the completion of the project. We sincerely acknowledge him/her for
giving his/her valuable guidance, support for literature survey, critical reviews and comments
for our Project.
We would like to first of all express our thanks to Dr. Arvind Agarwal, Chairman of Arya
Main Campus, for providing us such a great infrastructure and environment for our overall
development.
We express sincere thanks to Prof (Dr.) R C Bansal the Principal of AIET, for his kind
cooperation and extendible support towards the completion of our project.
Words are inadequate in offering our thanks to Er. Sandeep Jhamb, H.O.D of ME
Department, for consistent encouragement and support for shaping our project in the
presentable form.
We also express our deepest thanks to Er. Gurmeet Singh for his support in providing
technical requirement and fulfilling our various other requirements for making our project
success.
We also like to express our thanks to all supporting ME faculty members who have been a
constant source of encouragement for successful completion of the project.
Also our warm thanks to Arya Institute of Engineering & Technology, who provided us this
opportunity to carryout, this prestigious Project and enhance our learning in various technical
fields.
SANJAY KUMAR NIRANIA
Roll. No:-11EAIME053
Page 3
ABSTRACT
This papar present detail of a computer interface developed for vibration monitoring and
diagnostic of ball bearing based on experiments conducted for bearing fault diagnosis. An
experiment setup was designed and fabricated for testing various ball bering to obtain their
vibration chracteristics three defect free and nine defective tapered roller bearing with
outer race defects ,ball defects. The bearing vibration data were acquired using NI DAQ and
lab view virtual instrumention software, which were futher processed using computer
interface used various time and frequency domain parameters like peak to valley, RMS
value,kurtosis envelope analysisetc.
Page 4
CONTENT
Title
Page No.
Cover Page.....................................1
Certificates(Company & college).2
Candidate declaration...4
Acknowledgement..5
Chapter 1 INTRODUCTION.10-15
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
Company profile
Milestones
Technical collaboration
Main Customers
Manufacturing Facilities
BEARING INDUSTRY INDIAN SCENERIO
10
11
12
12
13
15
CHAPTER 2 ABOUT NEI.....16-17

2.1
Products
16
Chapter 3 BEARING...18-25
3.1 TYPES OF BEARING
18
3.2.1 Single Row Radial Ball Bearings
21
3.2.2 Single Row Radial Ball Bearing with Tapered Bore
22
3.2.3 Single Row Angular Contact Ball Bearing
22
3.2.4 Single Row Externally Aligning Ball Bearing
23
3.2.5 Double Row Self Aligning Ball Bearing
23
3.2.6 Double Row Self-Aligning Ball Bearing withTapered Clamping Sleeve and Nut23
3.2.7 Thrust Ball Bearing
23
3.2.8 Cylindrical Roller Bearing
23
3.2.9 Tapered Roller Bearing
24
3.2.10 Spherical Roller Bearing
25
Page 5
CHAPTER 4 COMPONENT OF BALL BEARING.26-28

4.1 Bearing races
27
4.2 Types of bearing races
27
4.3 Raw material
27
4.4 Outer & inner races
27
4.5 Cages
28
4.6 Balls
28
CHAPTER 5 MANUFATURING PROCESS OF BALL BEARING29-43

5.1 Heat treatment process
30
5.2 Hardning process
34
5.3 Different process &Machines
36
5.4 Face grinding
36
5.5 OD grinding
36
5.6 Laser marking system
38
5.7 Grinding
39
5.7.1 Centerless grinding
39
5.7.2 Types of centerless grinding
41
5.7.3 Throughfeed centerless grinding
41
5.7.4 Infeed centerless grinding
42
5.7.5 Endfeed centerless grinding
43
CHAPTER 6 BALL ASSEMBLING PROCESS...44-50

6.1 Wire
45
6.2 Heading
45
6.3 Flashing
46
6.4 Grinding
47
6.5 Heat treatment
48
6.6 Tumbling
49
6.7 Lapping
49
6.8 Cleaning
49
LIST OF FIGURES
Page 6
1.1 MILSTONES OF NEI
11
1.2 NEWAI PLANT
14
1.2 MENASAR PLANT
15
3.1 SINGLE ROW RADIAL BALL BEARING
22
3.2 SINGLE ROW RADIAL BALL BEARING
22
3.3 TAPPER BORE
24
3.4 CYLINDRICAL ROLLER BEARING
25
3.5 TAPPERED ROLLER BEARING
25
4.1 COMPONENT OF BALL BEARING
26
5.1 CHUGAIRO FURNANCE
31
5.2 SALT BATH FURNANCE
36
5.3 CENTRELESS GRINDING
39
5.4 MECHANISM OF CENTRELESS GRINDING
40
5.5 THROUGH FEED GRINDING
41
5.6 DIMENSION OF THROUGH FEED GRINDING
42
5.7 INFEED GRINDING
43
5.8 ENDFEED GRINDING
43
6.1 WIRE
45
6.2 HEADER MACHINE
46
6.3 GRINDING MACHINE
47
6.4 HARD GRINDING MACHINE
48
6.5 CLEANING MACHINE
50
7.1 OUTER RACE GRINDING
51
7.2 DIAMOND TIP ALLIGNMENT
52
LIST OF FLOW CHART

1
2
3
MANUFATURING PROCESS OF BALL BEARING

HEAT TREATMENT PROCESS
ASSEMBLING PROCESS
29
33
44
CHAPTER 1
Page 7
INTRODUCTION
1.1. COMPANY PROFILE:The renowned industrialist, late Shree B. M. Birla founded National Engineering Industries
Ltd., Jaipur in the year 1946 as a pioneer industry in the field of bearing manufacture, under
the name of "National Bearing Company Ltd."
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, 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
Indigenization
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.
1.2. Milestones
Page 8
Fig.1.1 Milestones of NEI

i.
1946 -Company established as National Bearing Company (NBC) under technical
ii.
iii.
collaboration with Hoffman, U.K.

1950 Ball Bearing Production started.
1958 Company is renamed National Engineering Industries Limited (NEI); NBC
iv.
Trademark retained.
1967 Tapered Roller Bearing production started
v.
1975 Spherical Roller Bearings production begins
vi.
1981 Second Plant inaugurated in Newai.
vii.
1982 Cartridge Tapered Roller Bearing in Technical Collaboration with Brenco
viii.
Incorporated of U.S.A.
1985 Technical Collaboration with NTN Corporation of Japan for Ball, Cylindrical &
ix.
Spherical Roller Bearing.

1995 ISO - 9001 Quality Management System Certification
x.
1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine
Retrofitting
xi.
xii.
xiii.
xiv.
2007 Third Plant inaugurated in Manesar.

2008 NBC receives TPM Excellence Award
2010 NBC receives Deming Award
2012 NBC receives the ACMA awards for Manufacturing and Technology Excellence
Page 9
1.3. Technical collaboration

(i) BRENCO Incorporated of U.S.A. Since 1982 - For Cartridge Tapered Roller Bearings for
railroad applications.
(ii) NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical & Spherical
Roller Bearings, JPU Bearings, Double Row Angular Contact Bearings, Hub Bearings Since
1997 - for Tapered Roller bearings.
(iii) Izumi Kinzoku of JAPAN Since 1996 for remanufacturing, retrofitting and overhauling of
Grinding and Super-finishing machines for bearing races.
1.4. Main Customers

Rolling Stock:
DLW (Diesel Locomotive Work)

CLW (Chittaranjan Locomotive Works)
ICF (Integral Coach Factory, Chennai)
RCF (Rail Coach Factor, Kapurthala)
CIMMCO
BEML (Bharat Earth Movers, Bangalore)
TEXMACO
Hindustan Motors Ltd.
Maruti Udyog Ltd.
Mahindra & Mahindra
Automobiles-LCV:
Ashok Leyland
Force Motors
Eicher Motors
Tata Motors
Automobiles-Two/ Three Wheelers:
Bajaj Auto Ltd.
Hero Honda Motors Ltd.
Honda Motorcycle & Scooters India Ltd.
Suzuki Motorcycle India
Majestic Auto
Piaggio India Ltd.

Page 10
Royal Enfield Ltd.
Yamaha Motors India Pvt. Ltd.
TVS
Tractors:
Eicher
Escorts
HMT
International tractors
Mahindra & Mahindra
Punjab Tractors
TAFE
VST Tillers
Electric Motors & Pumps:
Crompton Greaves
G.E. Motors
Kirloskar Electric
NGEF
MICO
Bajaj Electricals
Crompton Greaves
Fans: -
1.5. Manufacturing FacilitiesNBC has manufacturing facilities at Jaipur (established in 1946), Newai (established in 1980)
and Manesar (established in 2006). A fourth plant, a green field project, at Savli in Gujarat
will ship out its first bearing in November 2013, ramping up production capacity to 150
million bearings per year once it is fully operational.
Jaipur Plant
Page 11
Newai (Gunsi) Plant

Manesar Plant
1.5.1. Newai (Gunsi) PlantEstablished 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
covered
area
of
7,200 Sq.
Meters.
Fig1.2: Newai (Gunsi) plant

1.5.2 Manesar Plant
Page 12
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.
Fig1.3: Manesar Plant
BEARING INDUSTRY INDIAN SCENERIO :

The Indian Bearing Industry is estimated at Rs. 30 BillionApproximately. The Industry has
established a highlydiversified 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
andspecial purpose.
The Indian bearing Industry can be divided in to theorganized sector and un-organized sector.
Page 13
The organized sector primarily caters to the original equipment Manufacturer (OEM)
Segment, which predominantly comprises Automotiverailway and other Industrial users. The
replacement market is dominatedby unorganized Sector.
CHAPTER 2
ABOUT NEI
National Engineering Industries(NEI) Ltd was established 150 year ago by multi-billion dollar
C.K. Birla group. It manufactures a wide range of maximum types of bearings bearings for
automotive and railway industry as well as for general industrial applications under the brand
name NBC . NEI was founded in the year 1946 as a pioneer industry in the field of bearing
manufacture. Now it manufactures nearly 80 Million Bearings per annum in over 500
different sizes ranging from 6 mm bore to 1300 mm outer diameter, also having capability to
manufacture the bearings upto 2000 mm as outer diameter.
NEI is one of the largest domestic bearing manufacturing company 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 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. 2300strong team, supported by a well-equipped R&D with bearing life testing facility.
Page 14
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 they were enjoying the consistently superior products and
assurance of highest quality for every NBC bearings theyuse .
2.1 Products: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. These products with
approx. 2300-strong team, supported by a well-equipped R&D with bearing life testing
facilities. The products are:
Ball Bearings
Tapered Roller Bearings
Cylindrical Roller Bearings
Axle Boxes Spherical
Roller Bearings
Cartridge Tapered Roller Bearings
Large Dia Special Bearings
Page 15
CHAPTER 3
BEARING
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
3.1 Types:There are many different types of bearings.
Type
Plainbearing
Description Friction
Stiffnes
Rubbing
Depends
Speed
Life
Notes
s
Good, Low to Low to very Widely used,
surfaces,
on
provide very
high -
relatively high
usually with materials d wear high
depends
friction, suffers
lubricant;
and
upon
from stiction in
some
constructi but
application
some applications.
and
Depending upon
is low,
bearings use on, PTFE some

Page 16
has
pumped
lubrication
and behave
similarly to
fluid
bearings.
coefficient
of friction
~0.050.35,
depending
upon
the application,
slack is
lifetime can be
normall
lubrication
higher or lower
than rolling
present
element bearings.
fillers
added
Rolling
coefficient
of friction
with steel
can be
~0.005
(adding
Ball or
resistance Good, te to
rollers are
due to
but
high
seals,
some
(often
prevent or
packed
slack is require
minimize
grease,
usually s
rubbing
preload
present cooling
Rollingelementbe used to
aring
Modera
and
Moderate to
high
(depends on
lubrication,
often
requires
Used for higher

moment loads than
plain bearings with
lower friction
maintenance)
misalignm
ent can
increase
friction to
as much
Jewel bearing
Off-center
bearing rolls
as 0.125)
Low
Low
Low
due to
Adequate
Mainly used in
(requires
low-load, high
Page 17
precision work
in seating
flexing
maintenance)
such as clocks.
Jewel bearings
may be very small.
Very
high
(usuall
y
Fluid is
forced
Fluid bearing
limited
Zero
between two friction at Very

faces and
zero
held in by
speed, low
high
to a
few
hundre
d feet
edge seal
per
second
at/by
Zero
infinite in
some
applications,
may wear at
startup/shutd
own in some
cases. Often
negligible
maintenance.
Indefinite.
Can fail quickly

due to grit or dust
or other
contaminants.
Maintenance free
in continuous use.
Can handle very
large loads with
low friction.
Magnetic
Faces of
bearings
bearing are friction at
practic Maintenance bearings (AMB)
kept
al limit free. (with
zero
Low
seal)
No
Virtually
Active magnetic
need considerable
separate by speed, but
electromagne power.
magnets
ts)
constant
Electrodynamicbea
(electromag power for
rings (EDB) do not
nets or
require external
levitation,
eddycurrent eddy
s)
power.
currents
are often
induced
when
movement
occurs,
Page 18
but may
be
negligible
if
magnetic
field is
quasistatic
Very high or
low
Material
depending on Limited range of
flexes to
Flexure bearing give and
Very low Low
constrain
Very
high.
movement
materials and movement, no

strain in
backlash,
application. extremely smooth

Usually
motion
maintenance
free.
Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct
from the friction of the bearing.
3.2 TYPES OF BEARING:

3.2.1 Single Row Radial 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.
Page 19
Fig. 3.1
Single row radial ball bearing
3.2.2 Single Row Radial Ball Bearing with Tapered Bore

The single row radial ball bearings with tapered bore are Identical to single row radial ball
bearings except that these have tapered bore which is used for easier mounting and for the
adjustment of radial clearance. Dimensions of tapered bore diameter refer to small bore.
Fig. 3.2
single row radial ball bearing with tapered bore
3.2.3 Single Row Angular Contact Ball Bearing

The single row angular contact ball bearings have higher axial load capacity than the single
row radial ball bearings. The radial load must always be less than axial load.The bearings can
carry axial load in one direction only andshould be adjusted against another bearing, if axial
load iscoming from both the directions.
Each bearing can be located endwise in one direction only.
Page 20
3.2.4 Single Row Externally Aligning Ball Bearing

The single row externally aligning ball bearings are usedwhere accurate alignment cannot be
guaranteed betweenbearing positions. It can take radial loads. Axial loads can also be
accommodated.The shell housing must not be made an interference fit on their outside
diameter. If an interference fit is used, the shell housing may contract and prevent
alignment.These bearings can be located endwise in both the directions.
3.2.5 Double Row Self Aligning Ball Bearing

The double row self-aligning ball bearings have the common outer spherical race for both the
rows. This feature gives the bearings self-aligning properties. The bearings have the same
external dimensions as there equivalent single row radial ball bearings. They can take radial
loads and very light axial loads.They can be located endwise in both the directions.
3.2.6 Double Row Self-Aligning Ball Bearing withTapered Clamping Sleeve

and Nut
The double row self-aligning ball bearings with tapered clamping sleeve and nut are identical
to double row self-aligning ball bearing except that these have a tapered bore, which is used
for easier mounting and also a clamping sleeve and nut to clamp the bearings on the shaft. The
tapered bore is also used for the adjustment of radial clearance.
3.2.7 Thrust Ball Bearing

The thrust ball bearings are used for high axial loads at low speeds. These cannot operate at
high speed as it will give rise to centrifugal or radial forces which cannot be taken by the
bearings.
They can be located endwise in one direction only.
3.2.8 Cylindrical Roller Bearing:

The cylindrical roller bearings have greater radial load capacity than ball bearings of same
external dimensions and are particularly suitable for arduous duties. The bearing features a
Page 21
modified line contact between rollers and raceways toeliminate edge stressing. These bearings
have a high radial load capacity and are suitable for high speeds. Due to detachabledesign
character they have advantage of mounting inner ring and outer ring separately.
Fig. 3.3
Cylindrical roller
bearing
3.2.9 Tapered Roller Bearing

Tapered roller 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 tapered roller 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. Steep angle tapered roller bearing with exceptionally steep cone angle enables the
bearings to take heavier axial load.
The bearings are of separable type, enabling separate mounting of cups and cones.
Since the tapered roller 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 tapered roller bearings are also widely used for heavy loads
such as rolling mills.
Page 22
Fig. 3.4
tappered roller bearing
3.2.10 Spherical Roller Bearing

Spherical roller bearings are particularly suitable for carrying heavy loads. They are usually of
the double row design, both of the rows of the rollers having common spherical raceways in
the outer ring. This feature of this bearing has great practical importance in those cases where
it is difficult to obtain exact parallelism between the shaft and housing both axes. So these
bearings are suitable where misalignment can arise from mounting errors or from deflection of
the shaft.
Page 23
Fig 3.5 Spherical roller bearing
CHAPTER 4
COMPONENT OF BEARING
There are four major parts to a standard ball bearing: the outer race, the rolling balls, the inner
race,
and
the
cage
or
Page 24
retainer.
Fig. no. 4.1 component of ball bearing
4.1 BEARING RACE'S

The SSI Races Manufacturing Units of Jaipur areManufacturing outer & Inner Bearing Races
in Different sizes.According to the Demand in the market. The turned Races aresupplied in
Soft
condition
and
remaining
operation
of
Hardening,
Tempering
Grinding
Honing/polishing are beingdone by the Bearing Manufacturer.

The Detail of type and size of Bearing Races are as under:-
4.2 Type of Bearing Races Inner Dia Ranger
1. Ball Bearing Races:
10mm to 80mm
2. Roller Bearing Races:
17mm to 100 mm
3. Cylindrical Roller Bearing Races:
20mm to 75 mm
4. Special type of Bearing Races for:
20mm to 75 mm
Page 25
&
Transport Vehicles (Thrust Bearing)

5. Axle Box Bearing Races for Railway:
100mm to 200 mm
4.3 RAW MATERIAL:

The Races & Rolling elements of Bearing are subjected tostress on a very small contact
surface must be of such materialso as to with stand wear and have high elastic Limit & fatigue
Limit. The raw material being used by the Industry forManufacturing of various Bearing
components are as under:
4.4 Outer and Inner Races

The raw material used in the Manufacturing of bearingRaces is SAE 52100 high Carbon
Chrome bearing steel, whichhas composition similar to EN-31 (100 CR 6 As per
BISspecification). The raw material for Bearing Races is in the formof Rods & Seamless
Hollow Tubes. This is a SpheroidsAnnealed Steel. Approx. 80% of the Seamless Hollow tubes
arepurchased by the Industry from M/s. Indian Seamless Metal tubePUNE, while the rest of
the tube used in the cluster is importedmaterialThe Steel bar are purchased from M/s. Indian
SeamlessSteel & Alloy Pune & M/s. Mahindra Ugine Steel CompanyKHAPOLI
(Maharashtra). Some of the units are buying the steelscrap rod for manufacturing bearing
races.
Bearing Races material and their heat treatment arerequired to be selected carefully, taking
account the mechanicalstrength and required life of the Bearing, so that each materialmay
perform at maximum capability.Approximate required composition for bearing races
areConstitute % 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.)
Page 26
Phosphorous 0.05
4.5 CAGE'S
Cage is used to return balls at proper distance to preventthem from containing each other and
to prevent a temp.rise and resultant damage due to friction.
The Material for manufacturing cages is CRCA Strips ofC2015 Bearing grade steel having
carbon percentage at0.08% max. and Magnesium ranging from 0.25% to 0.45%
4.6 BALL'S
Steel Balls of grade 20, 16 &10 with close tolerance,smooth surface made by using SAE
52100 High CarbonChrome Bearing Steel.
CHAPTER 5
MANUFACTURING OF BALL BEARING
MANUFACTURING PROCESS OF BALL BEARING:
Forged rings (De-scaled) as raw material

(SAE 52100 steel)
Turning Operation
Centre Less Grinding
Heat Treatment
Hardness Testing
Page 27
Rough Grinding
Finish Grinding
Honing & Super Finishing
Washing
Application for Rust Preventive
Ready For Dispatch to Assembly

Flow chart 1
Manufacturing process of ball bearing
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 600 C, then send to a chamber where the material
heated in four chambers the first chamber has the temperature 840 0 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.
Page 28
Fig 5.1 Chugairo Furnance
Reference: http//www.nbcprojectreport.com
Page 29
Reference: http//www.heattreatmentprocess.com
Heat Treatment
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)
Page 30
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)
Flow chart 2
heat treatment
Page 31
After heat treatment following process are done to get a new ready to use ball bearing.
Hardening Procedure
Steel Material Carbon (0.9% - 1.10%)
HC Steel (High Carbon Steel)
Air
Process
Hardening
Heat the
Furnace
Procedure
850-870O C
Quenching
Fast cooling
600 C Oil
Quenching
Tempering
Cooling
Furnace
Cool at Room
Heating
Temperature
1650-1800C
1800C Salt Bath
Hardness
Time
------
35-60 min.
62 66 HRC
5-15 min.
60 64 HRC
------
150 min.
------
According to
the job
Page 32
Hardening Procedure
Steel Material
LC Steel (Low Carbon Steel)
Process
Carburizing
Hardness
Time
Quenching
Tempering
Carbon Furnace
Furnace
Fast cooling 600
Heat the
heating at
temperature at
C for oil
Furnace at
8500 C 8700 C
quenching only
1650 C-1800 C
60 64 HRC
52 62 HRC
5-15 min.
120-180 min.
Procedure
Hardening
940 C - 950 C
.200 - .250
8 10 hours
------
35-60 min.
According to
the job.
Salt Bath Furnace
Page 33
Reference : http//www.superheatfurnance.com
FIG NO. 5.2 SALT BATH FURNANCE
Different process and Machines:-
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.
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 two times to get highly finished. First rough and second highly finished.
At G-12 line the different machines.
Job No. 6211
G-114 Outer race track grinding machine.
G-115 Outer race track honing machine.
Page 34
G-103 Inner race bore grinding.

G-343 Inner race track grinding.
G-363 Inner race face grinding machine.
G-344Inner race track honing machine.
Assembly Line:A-439Auto inner outer race washing m/c.

A-440Auto inner outer race measuring m/c.
A-441Auto inner outer race combining m/c.
A-442Auto cage assembly m/c.
A-443 Auto demagnetizing m/c.
A-444Auto washingm/c for semi-finished product.
A-445Shower cleans.
A-446 Autoinner outer diameter inspection and sensitivity checking m/c.
A-447 Auto radial internal clearance inspection m/c.
A-448Autowashing and drying m/c.
A-449 Auto double side vibration testing m/c.
A-450 Auto Greasing and weighing m/c.
A-451 Auto shielding m/c.
A-452 Auto conservation oil spraying and visual inspection m/c.
Page 35
Laser Marking System:
A Laser marking system marks a highly visible mark on the job without touching it.
Job Number
NBC INDIA
Date Code
Important parts
a) Marker
b) Controller
c) Water-cooled Unit
d) Filter Kit
e) Console
f) Control Panel
g) 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 customerrequirements like; customer code, part number etc. can be
marked according.
GRINDING
Centre less Grinding
Page 36
Fig 5.3
Centerless Grinding
Centerless grinding is a method of material removal through grinding, similar to centered

grinding except for the absence of the spindle. It has high throughput, i.e. a large number of
parts can be manufactured in a short time.
The workpiece is set up between the regulating wheel (or back up wheel) and the grinding
wheel, and is supported by the work blade (or work rest). The work rest is located between the
wheels. The work is placed upon the work rest, and the latter together with the regulating
wheel is fed forward forcing the work against the grinding wheel. Axial movement of the
work past the grinding wheel is accomplished by tilting the regulating wheel at a slight angle
from horizontal. An angular adjustment of 0 to 8 or 10 degrees is provided in the machine for
this purpose.
Centerless grinding is classified into two types:
Throughfeed grinding - the workpiece is fed into the machine along the work blade
Plunge grinding - the workpiece is placed between the wheels on a work blade and the
grinding wheel is plunged into the workpiece.
Some of the benefits of centerless grinding include the ability to grind parts with geometries
that do not allow them to be OD ground, the ability to remove three, five and other odd
numbered lobing on the shaft of a part, and to maintain size beyond what is typically capable
of an OD grinder due to the low overall pressures spaced out along the workpiece.
An example of a centerless ground application is the outer diameter of the bearing races.
Page 37
Mechanism:
Fig no 5.4 Mecanism of centerless grinding
Types of Centerless grindings
There are three main types of centerless grinding:

1.
Through-feed grinding.
2.
In-feed grinding.
Page 38
3.
End-feed grinding.
Through-Feed Grinding
In through-feed grinding, the part rotates between the grinding wheel and a regulating wheel
as shown below.
Fig. no. 5.5 Through feed grinding
For through-feed grinding, one or both wheels of the centerless grinding machine are canted
out of the horizontal plane, as shown below. This imparts a horizontal velocity component to
the work piece, so that outside feed mechanisms are not necessary.
The grinding wheel is canted with respect to the other two axes so that a component of its
surface velocity pushes the part in the direction shown below. This auto feeding characteristic
is useful for rapidly processing many parts in quick sequence.
Because of the axial movement, through-feed parts can only have right circular cylindrical
ground surfaces. The wheel cannot be dressed to grind more complex shapes.
Page 39
Below are parts produced with the through-feed centerless grinding process. As can be seen
from the quantities produced, through-feed grinding is primarily a mass-production process
because of its high throughput.
Fig. no 5.6 Dimensios Of through feed grinding
In-Feed Grinding
In-feed grinding differs from through-feed grinding in that the part is not fed axially so that
the ground surface does not need to be a right circular cylinder. The grinding wheel can be
dressed to accomodate the part. Once the work piece part is in place, the grinding wheel is fed
in radially.
Because of the set up time involved for each part, in-feed griding does not have the high
throughput of through-feed grinding. In-feed grinding is illustrated below.
Page 40
Fig, no. 5.7 infeed grinding
End-Feed Grinding
In end-feed grinding, the part moves in axially between the grinding wheels, stops for
grinding, and then moves out again. The wheel can be dressed to form more complex shapes,
but the part can only get progressively smaller in diameter. End-feed grinding is illustrated
below.
Fig. no. 5.8 End feed grinding
CHAPTER 6
Page 41
ASSEMBLING PROCESS
BALL ASSEMBLING PROCESS:-
Forged wire(De-scaled) as raw material

(SAE 52100 steel)
Heading Operation
Flashing
Grinding
Heat treatment
Hard Grinding
Tumbling
Lapping
Washing
Testing and Fine Inspection
Packing and launching
Flow chart 4
Assembling Process
Page 42
1. WIRE
Fig. no. 6.1 Wire
2. HEADING PROCESS:Heading is the process in which the wire of suitable dia is pressed b/w two dies one is
fixed and another is reciprocating
moveable
die.
That
die works at slider crank
mechanism.
The process is known as heading due to formation of head and flash as the extra metal. The
extra metal remains due to passes between two dies. Use of head and flash is to assure that
the formed ball is completely filled and fully solid with metal.
Page 43
Fig. no. 6.2 Header machine
3.FLASHING:The flashing is the operation in which we remove the flash on the ball having head and flash.
It is also a grinding operation.The wheels are used are coarse grain type. The time taken in
flashing is18hrs approx.
Page 44
Fig. no. 6.3 Flashing
3. GRINDING:After flashing balls are send to grinding machines.Soft grinding process are used to finish the
ball to remove the major defect the balls are now begain to take shape but not fully finished.
Fig. no .6. 4 grinding machine
Page 45
4.HEAT TREATMENT:The grinded ball are soft due to many operation like heading, flashing, grinding performed
earlier so by using Chugai RO furnace . The heat treatment is been done by which the balls
are hardened and the hardened balls capable to have loading at it for along time. Thegas used
in heat treatment is Indo Gas which is mixture of LPG & Air.In the heat treatment there are 3
steps.
Heating
Quenching
Tempering
The process time is approx 3 hrs.
5.HARD GRINDING:The heat treated balls are then send to hard grinding where is the extra metal are remove. It is
also a similar operation like a soft grinding but the wheel used is harder than the soft grinding
machine. The process time is approx 3hrs.
Fig. no. 6.5 hard grinding machine
Page 46
6. Tumbling :Tumbling is the process is which the hard grinded balls are washed in a slower process in
emulsion and at here the defective ball are removed from the lot.
7. Lapping :It is also a metal removal process in which the balls are finished very well. The metal removal
is very less in order to microns. The wheels which are used are finer grain sized and the
friction agent between the balls is abrasive paste of hollino oil. The lapping operations
are of two types.
Lapping-1:The lapping-1 is the process in which the diameter of balls
is reduces in order to micron.
The finishing of balls are very high. The dB values, tally round, surface finish, parameters are
acheive. The process time is 36hrs
Lapping-2-3:The lapping 2-3 is the operation in which the dia is not reduced so much but the surface finish
is increased very much. The polish is used instead of abrasive paste so the friction is
less. The process time 24hrs.
8.CLEANING:In this process the finished balls are washed in Kerosene Oil for approx 1hr.
Page 47
Fig. no. 6.6 Cleaning machine
9.TESTING:In the testing we test each ball individually. Three test are performed at each ball
ECT eddy current test
EOT optical test
EVT vibration test
The test in case of failure the ball is rejected and the cause of failure is discontinuity in
internal structure.
10.FINE INSPECTION:In this segment the each ball is inspected by human eyes the surface defect are inspected by
that means.
Page 48
CHAPTER 7
PROBLEM STUDIED DURING TRAINING:Ball Bearing Grinding
Problem No. 1:G-1 Line Job No. 6213 (outer race of bearing)
Machine No. G-241
The abnormal lines were seen at the face of job. Initial prediction was that the backing plate is
damaged. The backing plate is part of machine which holds the job during grinding process at
rotates the job against the grinding wheel. The backing plate has worn out because it has
friction and relative motion between job, when it hold the job.
The backing plate has certain limit to wear about 3 mm. Scratches occur on the face of
backing plate which further produce the lines on the job face. The backing plate holds the job
as shown in fig.
Fig. no. 7.1 outer race grinding

Page 49
The backing plate supports the job at the back side.

The backing plate and the shoe and shoe fixture was replaced.
But the wowel was found in the job rotation, the shoe is the device which supports the job at
bottom and one side during the grinding process. And shoe fixture fixes the shoes.
The woweling was produced due to the carbide tip was damaged when the disassembling the
backing plate.
Problem No. 2:G-1 Line Job No. 6213 (Inner race track grinding)
Machine No. G-245
Inner race track grinding wheel changed because the wheel was has completed its life and not
able further use. Then it dressed for curvature setting as normally it dressed. But the black and
hot job obtained at outlet of machine. The prediction is that the dressing of wheel was not
done properly and curvature is not settled for job. Then prediction was that diamond has
finished then it was changed. New diamond setted and then dressed the grinding wheel but the
curvature was not right then and job was heated. Then again wheel dressed and job obtained
satisfactory
But the diamond has to be changed very frequently, and curvature was not satisfactory. The
problem was that the diamond position was not right the right position is shown in the
following fig.
Page 50
Fig 7.2 diamond tip alignment
Problem No. 3:G-1 Line Job No. 6213 (Inner race track grinding)
Machine No. G-245
The machine was taking more cycle time to grind the job. The machine was checked no
problem was found. Then the ovality checked of input job then it was found about 100 to 300
micron. Then 100 random pieces were checked then it was found the ovality was more than
the standard limit. When the ovality is more the wheel has to remove more material From
job.Hence increased cycle time.
Ovality occurs when the job heat treated. And it can be controlled.
Problem No. 4:G-1 Line Job No. 6213 (outer race track grinding)
Machine No. G-252
The track center of the outer race was found varied from the standard dimension. Initially the
lock nut to be adjusted, it was found that there was ply in the lock nut and the lock nut was
damaged due to hammering. The new lock nut was prepared in the tool room and fitted in the
machine. Now the track center adjusted.
Problem No. 5:G-12Line Job No. 6

211 (Inner race track Honing)
Machine No. G-343
Job rotation problem was found. It was due to the band in the window.
Window is the holding device for the honing stone and O ring. The band was due to
hammering action of the arbor.
Page 51

NBC Training Report - Ball Bearing Division

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Industrial Training Report

Mechanical Engg. Deptt. A.I.E.T., Jaipur

Industrial Training Report

SANJAY KUMAR NIRANIA

Mechanical Engg. Deptt. A.I.E.T., Jaipur

Industrial Training Report

Mechanical Engg. Deptt. A.I.E.T., Jaipur

Industrial Training Report

Mechanical Engg. Deptt. A.I.E.T., Jaipur

Industrial Training Report

CHAPTER 2 ABOUT NEI.....16-17

3.2.1 Single Row Radial Ball Bearings

3.2.2 Single Row Radial Ball Bearing with Tapered Bore

3.2.3 Single Row Angular Contact Ball Bearing

3.2.4 Single Row Externally Aligning Ball Bearing

3.2.5 Double Row Self Aligning Ball Bearing

3.2.8 Cylindrical Roller Bearing

3.2.9 Tapered Roller Bearing

3.2.10 Spherical Roller Bearing

Mechanical Engg. Deptt. A.I.E.T., Jaipur

Industrial Training Report

CHAPTER 4 COMPONENT OF BALL BEARING.26-28

4.2 Types of bearing races

4.3 Raw material

4.4 Outer & inner races

CHAPTER 5 MANUFATURING PROCESS OF BALL BEARING29-43

5.2 Hardning process

5.3 Different process &Machines

5.4 Face grinding

5.6 Laser marking system

5.7.1 Centerless grinding

5.7.2 Types of centerless grinding

5.7.3 Throughfeed centerless grinding

5.7.4 Infeed centerless grinding

5.7.5 Endfeed centerless grinding

CHAPTER 6 BALL ASSEMBLING PROCESS...44-50

6.5 Heat treatment

Industrial Training Report

1.1 MILSTONES OF NEI

1.2 NEWAI PLANT

1.2 MENASAR PLANT

3.1 SINGLE ROW RADIAL BALL BEARING

3.2 SINGLE ROW RADIAL BALL BEARING

3.3 TAPPER BORE

3.4 CYLINDRICAL ROLLER BEARING

3.5 TAPPERED ROLLER BEARING

4.1 COMPONENT OF BALL BEARING

5.1 CHUGAIRO FURNANCE

5.2 SALT BATH FURNANCE

5.3 CENTRELESS GRINDING

5.4 MECHANISM OF CENTRELESS GRINDING

5.5 THROUGH FEED GRINDING

5.6 DIMENSION OF THROUGH FEED GRINDING

5.7 INFEED GRINDING

5.8 ENDFEED GRINDING

6.2 HEADER MACHINE

6.3 GRINDING MACHINE

6.4 HARD GRINDING MACHINE

6.5 CLEANING MACHINE

7.1 OUTER RACE GRINDING

7.2 DIAMOND TIP ALLIGNMENT

LIST OF FLOW CHART

MANUFATURING PROCESS OF BALL BEARING