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Company Ltd." The first bearing was manufactured in 1950 with a modest
nearly 3.8 million bearings per month in over 500 different sizes ranging from
"National Engineering Industries Ltd." retaining its original trade mark NBC.
This is the only unit in the country manufacturing wide variety and range of
bearings such as Ball Bearings, Steel Balls, TRB, Cylindrical Roller Bearings
& Axle Boxes for Railway Rolling Stock including Spherical Roller
Self-reliance".
NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors,
Shovels, Tillers and Thermal Power Plants all across the country.
1
1.2. Milestones
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x. 1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd.,
xiv. 2012 NBC receives the ACMA awards for Manufacturing and
Technology Excellence
(ii) NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical
bearings.
races.
Rolling Stock: -
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• RCF (Rail Coach Factor, Kapurthala)
• TEXMACO
Automobiles-LCV: -
• Ashok Leyland
• Force Motors
• Eicher Motors
• Tata Motors
Two/Three-wheelers:-
• TVS
Tractors: -
• Eicher
• Escorts
• HMT
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• International tractors
• TAFE
• VST Tillers
• Crompton Greaves
• G.E. Motors
• Kirloskar Electric
• NGEF
• MICO
Fans: -
• Bajaj Electricals
• Crompton Greaves
plant, a green field project, at Savli in Gujarat will ship out its first bearing in
• Jaipur Plant
• Manesar Plant
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1.5.1. Newai (Gunsi) Plant
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 equipment’s for quality and reliability of the
products. The plant is spread over a covered area of 7,200 Sq. Meters.
NEI has set up its third Ball Bearing manufacturing plant in the fastest
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
This plant is located in the heart of Pink City of India, which is also famous
for its Tourists spots. Spread over a total area of 4,78,900 m2 and a covered
area of 75,310 m2, Jaipur plant has state of the art manufacturing facilities
and capable to manufacture all types of Ball and Roller Bearings of NEI
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product range. It has a separate division to manufacture all these spread
centrally air-conditioned assembly lines with auto gauging and testing m/c. The latest
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.
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.
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.
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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.m
Single Row Tapered Roller Bearing Double Row Tapered Roller Bearing
(a) (b)
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
ICF broad and meter gauge coaches. Over a million NBC bearings and boxes are in
service with the Indian Railways. The development of completely indigenized 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.
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.
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Cartridge Tapered Roller Bearing: For fitment to the new BOX-IN Up rated
Wagons designed by the RDSO, NEI is the only manufacturer in the country to
indigenize these bearings to a high percentage under collaboration with the largest
commenced in the year1984. 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. M.
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 diameter and weigh 4.39 tons.
The large diameter bearings are mainly manufactured out of case carburizing steel, heat
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,
Diameter Bearings Division is spread over a covered area of 2,508 Sq. Meters.
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RESEARCH & DEVELOPMENT AT JAIPUR:
Complete in-house facility for design development of all types of bearings and tooling
Corporation, Japan & BRENCO Inc of USA, the capability to offer finest
application.
have been made for its captive use to keep pace with latest technology. A
processes for Sales, Production, Materials and Finance, NEI has success-
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CHAPTER 2
INTRODUCTION OF BEARING
desired motion, and reduces friction between moving parts. The design of
the bearing may, for example, provide for free linear movement of the
moving part or for free rotation around a fixed axis; or, it may prevent a
motion by controlling the vectors of normal forces that bear on the moving
parts. Many bearings also facilitate the desired motion as much as possible,
Ball Bearings:
Ball bearings are the most common and most used type of bearing found
are small metallic or ceramic spheres used to reduce friction between axles
and shafts in numerous applications. These bearings are able to handle both
thrust and radial loads, and are used for applications where the load is
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relatively small. Since the ball is spherical in shape, it contacts the inner
and outer race at a very small point, which helps it spin evenly and
smoothly. But the contact area holding that load is very small, so if the
bearing is overloaded then the balls can deform, ruining the bearing, to
on a moving part.
Roller Bearings:
Roller bearings use cylinders instead of spheres that means the contact
between the inner and outer race is a line not a point. Thus the load is
spread over a larger area enabling the bearing to handle greater loads than
ball bearings. Roller bearings are used in conveyer belt rollers where they
hold heavy radial loads, however these bearings are not designed to handle
much thrust loading. Roller bearings are found in different varieties, such
etc.
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Needle Roller Bearing:
Needle roller bearings are special roller bearings having slender cylindrical
rollers that enable them to bear highest load capacity for a given radial
space of all rolling element bearings. Such bearings also suit applications
loads. Thrust needle bearings are flat and use a radial pattern of needles
while radial needle bearings are cylindrical and use rollers parallel to the
axis of the shaft. Needle bearings are primarily used in engine components
Tapered roller bearings use conical rollers that run on conical races. Both
the inner and outer raceways are segments of cones and the rollers are also
made with a taper. Unlike other roller bearings, they support both radial
and axial loads, and are able to carry higher loads. The conical geometry
roller bearings are used in the wheel bearings of most trucks, buses, cars,
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Fig 2.5: Tapper Roller Bearing
Rollers used in spherical roller bearings are thicker in the middle and
narrow at the ends, and its race is shaped to match. They can adjust to
so they are expensive. Apart from that these bearings have higher friction
compared to ball bearing because different parts of the spherical rollers run
Thrust Bearings:
Thrust bearings are particular types of rotary bearing that allow rotation
between parts used but they are designed to support axial loads like vertical
shafts for which spherical, conical or cylindrical rollers are used. They are
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used in gear sets like in car transmissions between gears and between the
composed of ball bearings supported in a ring. They are used in low thrust
applications where the radial load is very small. Thrust roller bearings are
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CHAPTER 3
MANUFACTURING OF BEARING
Almost all parts of all ball bearings are made of steel. Since the bearing has
which means that it has one percent chromium and one percent carbon
(called alloys when added to the basic steel). This steel can be made very
bearings are made from 440C stainless steel. The cage is traditionally
made of thin steel, but some bearings now use molded plastic cages,
There are four major parts to a standard ball bearing: the outer race, the
Races:
1. Both races are made in almost the same way. Since they are both rings
Automatic machines similar to lathes use cutting tools to cut the basic
shape of the race, leaving all of the dimensions slightly too large. The
reason for leaving them too large is that the races must be heat treated
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Fig 3.2.1: Cold Heading Process
Surprisingly, the rolling balls start out as thick steel wire. Then, in a cold
heading process, the wire is cut into small pieces smashed between two
steel dies. The result is a ball that looks like the planet Saturn, with a ring
around its middle called "flash." They can be machined back to their
2.The rough cut races are put into a heat treating furnace at about 1,550
(depending on the size of the parts), then dipped into an oil bath to cool
them and make them very hard. This hardening also makes them brittle, so
the next step is to temper them. This is done by heating them in a second
oven to about 300 degrees Fahrenheit (148.8 degrees Celsius), and then
letting them cool in air. This whole heat treatment process makes parts
3.After the heat treatment process, the races are ready for finishing.
However, the races are now too hard to cut with cutting tools, so the rest
of the work must be done with grinding wheels. The surfaces where the
bearing fits into the machine must be very round, and the sides must be
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flat. This means that very fine abrasive slurry is used to polish the races for
several hours to get almost a mirror finish. At this point, the races are
Balls:
4.The balls are a little more difficult to make, even though their shape is
very simple. Surprisingly, the balls start out as thick wire. This wire is fed
from a roll into a machine that cuts off a short piece, and then smashes both
machining process. The balls are placed in rough grooves between two
cast iron discs. One disc rotates while the other one is stationary; the
friction removes the flash. At any rate, the balls now look like the planet
5.The first machining process removes this flash. The ball bearings are put
between the faces of two cast iron disks, where they ride in grooves. The
inside of the grooves is rough, which tears the flash off of the balls. One
wheel rotates, while the other one stays still. The amount of steel left for
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finishing is not much; only about 8/1000 of an inch (.02 cm), which is about
6.The heat treatment process for the balls is similar to that used for the
races, since the kind of steel is the same, and it is best to have all the parts
wear at about the same rate. After this, the balls are moved to a lapping
machine, which has cast iron wheels and uses the same abrasive lapping
compound as is used on the races. Here, they will be lapped for 8-10 hours,
depending on the four parts of a finished ball bearing: inner race, outer
Cage:
7.Steel cages are stamped out of fairly thin sheet metal, much like a cookie
cutter, and then bent to their final shape in a die. A die is made up of two
pieces of steel that fit together, with a hole the shape of the finished part
carved inside.The die is then opened, and the finished part is taken out,
ready to be assembled.
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8.Plastic cages are usually made by a process called injection moulding. In
this process, a hollow metal mould is filled by squirting melted plastic into
it, and letting it harden. The mould is opened up, and the finished cage is
Assembly:
9.Now that all of the parts are made, the bearing needs to be put together.
First, the inner race is put inside the outer race, only off to one side as far
as possible. This makes a space between them on the opposite side large
enough to insert balls between them. At this point, the cage is installed to
hold the balls apart from each other. Plastic cages are usually just snapped
in, while steel cages usually have to be put in and riveted together. Now
Quality Control:
Bearing making is a very precise business. Tests are run on samples of the
steel coming to the factory to make sure that it has the right amounts of the
alloy metals in it. Hardness and toughness tests are also done at several
stages of the heat treating process. There are also many inspections along
the way to make sure that sizes and shapes are correct. The balls can't be
of an inch.
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CHAPTER 4
BEARING
Tapered roller bearings and 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
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4.1 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
under:
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 Asper BIS specification). The raw material for Bearing Races
Annealed Steel. Approx. 80% of the Seamless. Hollow tubes and steel bars
are purchased by the Industry from M/s. Indian Seamless Steel & Alloy
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
Phosphorous 0.05.
4.3 Cages:
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damage due to friction. The Material for manufacturing cages is CRCA
Heat treatment process is the process of hardening the soft material. The
raw material is soft material and it has to be hardened before grinding, and
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
8400C and further chamber contains the 8500C temperature. Then it dipped
into an oil tank at temperature 250C where the material get quenched then
1050C .then dried and cooled in air. The hardened material is obtained. The
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4.5 DIFFERENT PROCESS FOR CONE:
Dimensions Checking
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
Width Variation: 5 µm
1. DAISHO MACHINE
2. NISSEI MACHINE
race is rotated between two grinding wheel. The outer race is passed in
1. Rough1
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2. Rough2
3. Fine finish
Size Limit: 15 to 35 µm
Flange Grinding :
The flange should be surface finished since the bearing has to be assembled
grinding stone is used to cut and grind the flange portion of cone.
NC Mode - AUTO
Z axis.
Bore Grinding :
Bore is the inner circumferential surface of the bearing. The bore should
obtain in the bore grinding machine. In this machine the grinding stone is
X, Z axis.
includes various sensors for sensing the dimension of cone. This machine
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use weight sensors and position sensors to identify the position and
Φ0.7 ID1 - X
M2 Φ2.1 ID2 - X
M3 Φ-2 TAPER
M4 Φ-0.2 ID1 - Y
M5 Φ1.6 ID 2–Y
M6 Φ0.9 OVALITY
compatible with pre-feed data. The limitations of size are: Size limit: +4
µm to 4 µm.
TAPER: 5 µm maximum
OOR: 5 µm maximum
CHATTER: 3 µm maximum
SQUARENESS: 5 µm maximum
Honing Machine :
OD Grinding:
race is rotated between two grinding wheel. The outer race is passed in
Fine finish.
Size Limit: 15 to 35 µm
Honing Machine :
Assembly Line:
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
3d table movement. The point on metal surfaces where these laser beams
hits leave marks as required. Names of few Laser Machine which are
1. AKSHAR FIBER-PRO
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Roll Filling Machine:
this machine, first Retainer is placed on first station where rollers are
Pressing Machine:
technology both. The Cone is pressed against Retainer with down stroke
Weight check:
compatible with the given standard of weight limits, machine will reject
Demagnetizer:
Washing:
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.
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Press checking:
properly or not.
Final checking:
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.
which is used to lubricate the bearing parts. And then the excess oil is again
Visual Inspection:
Now, the bearing is checked manually by the operators. All the dimensions
and surface properties are checked and rejected work piece are sent again
for correction.
Packing:
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CHAPTER 5
PROJECT
For fitment to the new BOX-IN Updated Wagons designed by the RDSO.
1984. These bearings are grease packed and require no field lubrication for
a period of 7 years.
contamination or damage.
1. Cone Assembly :
The cone, rollers and cage assembly is perfectly matched to ensure long service life.
Assembly configurations are similar to standard single row tapered roller bearing. Both
cone and rollers are manufactured from bearing quality case hardened steel.
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Fig 5.1: CTRB Bearing Parts
2. Cup :
The double cup is forged, rolled and machined from bearing quality case
hardened steel. The cup has two tapered raceways. It also has seal grooves
located at each end, precision machined to affect a leak -proof fit to provide
3. Spacer :
The spacer width is precision ground and selected at the factory to achieve
4. Wear ring :
The wear ring is a steel ring, heat treated& precision ground on the OD to
provide a smooth, concentric mating surface for the grease seal. The bore
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5. Grease seal: :
function of the roller bearing seal is to keep vital lubricating grease inside
the bearing.
DDL(double Dust Lip) grease seals which are best seals, proven for
6. End cap :
The end cap is affixed to the axle by three cap screws and is designed for
sufficient rigidity to maintain proper cap screw tension, even after years of
service. The wear ring should seat properly inside the recess of end cap to
The axle cap screws affix the axle end cap with axle to provide sufficient
clamping of the bearing on the journal. Both used & new cap screws should
8. Locking Plate :
The locking plate provides tabs which are bent against the flats of the cap
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9. Backing ring :
The backing ring positions the bearing, provides a firm base and helps
ROLLER BEARING:
Bearing Disassembly
1. Remove backing ring, wear rings and excess grease and excess grease
2. Remove the grease seals from the cup using suitable tools (pry bar or
5. Wash the bearing with the help of suitable media to remove all lubricants
cleaners, washers, agitators or spray systems. The cleaning media must not
reuse.
After this cleaning take palace bearing parts to the inspection area. The
inspection area must be well lighted and clean. Use bearing manufacturer's
specifications for sizes and wear limits for all bearing assembly component
End cap :
Inspect the end cap for surface damage, cracks, breakage, wear or
distortion. Any other condition that would affect proper seating of the end
Backing Ring :
corrosion, wear and heavy pitting and scrap backing rings having such
defects.
2. Ensure that counter bore of the backing ring must provide a press fit on
wear ring.
3. Breakout diameter of the backing ring shall not exceed the specified
limits.
Cap screws :
Cap screw thread for damage and wear, cap screw body for elongation are
checked. Cap screws having burrs extending beyond washer face on the
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under side Of cap screw head as this will damage the locking plate. Cap
Grease seals :
Used grease seals must be scrapped and must be replaced with new grease
seals only.
Spacer :
Spacers are visually examined for cracks, nicks. Cracked spacer must be
scrapped.
Cone Assembly :
Inspect the raceways visually for staining, acid etching, corrosion, spailing .
crack etc. Use suitable well lit stand for the inspection of the cone assembly
Cup :
All cups should be checked for wear patterns seen on the cup outside
diameter not only because of its importance on the life of the bearing but
adapter the cup starts contacting the adapter at the ends also. Worn out
pitting, heat discoloration false brinelling and spalling, electric burns, crack
etc. After the visual inspection, the defective piece which cannot be used
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again are thrown away while the other piece are again send for heat
Following are the process flow for grinding carried out in NBC for CTRB
parts:
1. O.D Grinding:
O.D Grinding means grinding of outer diameter surface of cup. In this there
is a grinding wheel and a regulating wheel. In this there are 3passes for a
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new job in which it is turned from black to finish while 2 passes for used
one.
2. Face Grinding :
2. Bore Grinding :
1. Face Grinding:
It is done though a double disc grinder featured with auto dressing and auto
3. Bore Grinding :
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5.8 C(Phosphate Coating) – SHOP
1. Corrosion resistance,
2. Lubricity,
placed in phosphoric acid, a classic acid and metal reaction takes place
which locally depletes the hydronium ions, raising the pH, and causing the
dissolved salt to fall out of solution and participated on surface. The acid
and metal reaction also creates iron phosphate locally which may also
coating. The acid and metal reaction also generates hydrogen gas in the
form of tiny bubbles that adhere of the metal. These prevent the acid from
the reaching the metal surface and slows down the reaction. To overcome
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Fig 5.8.1 :Steps of powder coating
assembled with cage having rollers and are pressed so that the rollers don't
come out and then they are lubricated and sent to assembly line.
2. Spacer is put between the two cone assembly in a cup and then the
4. Then end cap and back rings are put on the assembled bearing and then
Packing:
packing tube (triangular) is also inserted inside the bearing to keep the
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spacer aligned with the cone assembly. Each bearing assembly is packed
in a corrugated box and each wooden box contains two cartons of bearing
assemblies.
The Axle end cap & Locking plate, axle cap screws, side frame key, bolt
& nut with spring washer & adapter are packed in separate corrugated
boxes, each wooden box contains parts for four bearing assembly.
5.10Applications
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CHAPTER 6
Block, flow of knowledge as well as decision making processes within the block.
Working with the employees and learning from them was such a life changing
This report describes the NBC bearing industry and its technology. My Through this
report, I have tried to present a comprehensive study of the various functionalities and
responsibilities of NBC Bearings. Starting from the overview of the company till the
explanation of various type of process i.e. heat treatment, grinding, facing and the
different type of machines used in that processes like for grinder, machines for honing
& super finishing machines are available. This report tries to throw light on each and
6.3. Conclusion
Maximum of their work was done manually. While in railway bearing division, the
whole processing is automatic. But now days they are trying to set up new NOVA
CNC machines. It will reduce the human effort or will increase productivity up to a
large extent.. The project guide are always tends to fill us with information with
regards to our career and how to set goals and achieve. He helps me to complete my
report work and I am very thankful to him for his painstaking efforts. The report I am
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submitting in the institute carries all the major and minor segments I learned in
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REFERENCES
• www.nbcbearing.com
• www.rdso.indianrailways.gov.in\
• https://en.wikipedia.org/wiki/Bearing\
• https://en.wikipedia.org/wiki/Bearing(mechanical)\
• http://www.nbcbearings.com/who-weare.html. .
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