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CHAPTER 1

ABOUT THE COMPANY

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 up to 2000 mm outer diameter. At NEI, the development of bearings

is a never-ending job. The name of the company was changed in 1958 to

"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

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
1.2. Milestones

Fig.1.1: Milestones of NEI

i. 1946 -Company established as National Bearing Company (NBC)

under technical collaboration with Hoffman, U.K.

ii. 1950 Ball Bearing Production started.

iii. 1958 Company is renamed National Engineering Industries Limited

(NEI); NBC Trademark retained.

iv. 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 Incorporated of U.S.A.

viii. 1985 Technical Collaboration with NTN Corporation of Japan for

Ball, Cylindrical & Spherical Roller Bearing.

ix. 1995 ISO - 9001 Quality Management System Certification.

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x. 1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd.,

Japan for Machine Retrofitting.

xi. 2007 Third Plant inaugurated in Manesar.

xii. 2008 NBC receives TPM Excellence Award.

xiii. 2010 NBC receives Deming Award.

xiv. 2012 NBC receives the ACMA awards for Manufacturing and

Technology Excellence

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)

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• RCF (Rail Coach Factor, Kapurthala)

• BEML (Bharat Earth Movers, Bangalore)

• TEXMACO

• Hindustan Motors Ltd.  Maruti Udyog Ltd.

• Mahindra & Mahindra

Automobiles-LCV: -

• Ashok Leyland

• Force Motors

• Eicher Motors

• Tata Motors

Two/Three-wheelers:-

• Hero Honda Motors Ltd.

• Honda Motorcycle & Scooters India Ltd.

• Suzuki Motorcycle India

• Majestic Auto  Piaggio India Ltd.

• Royal Enfield Ltd.

• Yamaha Motors India Pvt. Ltd.

• TVS

Tractors: -

• Eicher

• Escorts

• HMT

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• International tractors

• Mahindra & Mahindra

• TAFE

• VST Tillers

Electric Motors & Pumps:-

• Crompton Greaves

• G.E. Motors

• Kirloskar Electric

• NGEF

• MICO

Fans: -

• Bajaj Electricals

• Crompton Greaves

1.5. Manufacturing Facilities

NBC 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

• Newai (Gunsi) Plant

• Manesar Plant

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1.5.1. Newai (Gunsi) Plant

Established in the year 1980-81 as an expansion project of NEI Ltd. The

factory is equipped with fully automated grinding lines with electronic in-

process & post- process gauging and centrally air-conditioned assembly lines

with auto gauging and test equipment’s for quality and reliability of the

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

1.5.2 Manesar Plant

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 equipment.

Fig1.2: Manesar Plant

1.6. nbc Jaipur

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

across large area.

Fig 1.3: Jaipur Plant

(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 gauging in grinding and

centrally air-conditioned assembly lines with auto gauging and testing m/c. 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.

(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.

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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

Type of tapered Roller Bearing

Single Row Tapered Roller Bearing Double Row Tapered Roller Bearing

(a) (b)

Fig. 1.4: Tapered Roller Bearings

(IV). Railway Bearing:

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, 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 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.

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.

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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

manufacturer of these bearings in the world. Production of these bearings

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.

(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 diameter and weigh 4.39 tons.

The large diameter bearings are mainly manufactured out of case carburizing steel, heat

treated on special equipment and furnaces developed by NEI. 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. The Large

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

is available. The design of all types of bearings is done on Pro-Engineer 3D Modeling

& Analysis Software.

Fig.1.5: NBC Design and Development

With the signing of the technical collaboration agreement with NTN

Corporation, Japan & BRENCO Inc of USA, the capability to offer finest

engineering services in the bearing industry has enhanced. Services of team

of experienced engineers are available for selection of bearing as per

application.

Machine Building: NEI has the capability of machine building to design,

develop and manufacture special purpose CNC Grinding Lines, HT Lines,

Material Handling Equipments and other special purpose machines which

have been made for its captive use to keep pace with latest technology. A

well-equipped electronic design, development laboratory with all testing

facilities supports the Machine Building Division.

1.6.3. SAP-ERP In order to re-engineer and integrate the Business

processes for Sales, Production, Materials and Finance, NEI has success-

fully implemented SAP ERP

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CHAPTER 2

INTRODUCTION OF BEARING

A bearing is a machine element that constrains relative motion to only the

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,

such as by minimizing friction. Bearings are classified broadly according

to the type of operation, the motions allowed, or to the directions of the

loads (forces) applied to the parts.

Fig 2.1 Classification of Bearing

Ball Bearings:

Ball bearings are the most common and most used type of bearing found

in a number of objects. Also known as antifriction bearings, ball bearings

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

reduce friction in axle assemblies or in a series to absorb the weight placed

on a moving part.

Fig 2.2: Ball Bearing

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

as spherical roller bearings, needle roller bearings, , tapered roller bearing,

etc.

Fig 2.3: Roller Bearing

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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

where high rotational speed is involved but cannot accommodate axial

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

like pumps, compressors, rocker arm pivots, and transmissions.

Fig 2.4: Needle Bearing

Tapered Roller Bearing:

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

of tapered roller bearings provides a larger contact patch, which allows

greater loads to be carried as compared to spherical (ball) bearings. Taper

roller bearings are used in the wheel bearings of most trucks, buses, cars,

and so on. Due to manufacturing complexities, tapered roller bearings are

generally more expensive than ball bearings.

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Fig 2.5: Tapper Roller Bearing

Spherical Roller Bearings:

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

support misaligned loads.

The constructions of spherical rollers are complex and difficult to produce

so they are expensive. Apart from that these bearings have higher friction

compared to ball bearing because different parts of the spherical rollers run

at different speeds on the rounded race.. One of its important example is a

tie rod on a vehicle suspension. Other important uses of spherical bearings

have been in car suspensions, trackballs, computer mouse, heavy

machinery, sewing machines, drive shafts, etc.

Fig 2.6 Spherical Roller Bearing

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

housing and the rotating shafts.

Thrust bearings are of different varieties. Ball thrust bearings are

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

made of small tapered rollers arranged so that their axes Converge at a

point on the axis of the bearing.

Fig 2.7 Thrust Bearing

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CHAPTER 3

MANUFACTURING OF BEARING

3.1 Raw Materials:

Almost all parts of all ball bearings are made of steel. Since the bearing has

to stand up to a lot of stress, it needs to be made of very strong steel. The

standard industry classification for the steel in these bearings is 52100,

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

hard and tough by heat treating. Where rusting might be a problem,

bearings are made from 440C stainless steel. The cage is traditionally

made of thin steel, but some bearings now use molded plastic cages,

because they cost less to make and cause less friction.

3.2 The Manufacturing Process:

There are four major parts to a standard ball bearing: the outer race, the

rolling balls, the inner race, and the cage.

Races:

1. Both races are made in almost the same way. Since they are both rings

of steel, the process starts with steel tubing of an appropriate size.

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

before being finished, and the steel

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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

finished size after heat treating.

2.The rough cut races are put into a heat treating furnace at about 1,550

degrees Fahrenheit (843 degrees Celsius) for up to several hours

(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

which are both hard and tough.

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

finished, and ready to be put together with the balls.

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

ends in toward the middle.

Fig 3.2.2: bulge Mechanism

The bulge around the middle of the rolling balls is removed in a

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

Saturn, with a ring around the middle called "flash."

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

as thick as two sheets of paper.

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

race, cage, and ball.

Fig. 3.2.3 Finished Ball Bearing

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

taken out, ready for assembly.

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

that the bearing is assembled, it is coated with a rust preventative and

packaged for shipping.

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

out of round more than 25 millionths of an inch, even for an inexpensive

bearing. High-speed or precision bearings are allowed only five-millionths

of an inch.

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CHAPTER 4

MANUFACTURING OF TAPER ROLLER

BEARING

Fig 4.1 Process of manufacturing TRB

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

ring is called the cup. Internal clearance is established during mounting by

the axial position of the cone relative to the cup.

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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

by the Industry for Manufacturing of various Bearing components are as

under:

4.2 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 Asper 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 and steel bars

are purchased by the Industry 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

1.6Manganese 0.50 max Silicon0.15 to 0.35Sulphu r 0.025 (Max.)

Phosphorous 0.05.

4.3 Cages:

Cage is used to return balls at proper distance to prevent them from

containing each other and to prevent a temperature rise and resultant

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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%.

4.4 HEAT TREATMENT PROCESS:

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

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

8400C and further chamber contains the 8500C 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

1050C .then dried and cooled in air. The hardened material is obtained. The

systematic flowchart is shown in following fig:

Fig 4.2 Heat Treatment Process

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4.5 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: UCL +35 µm: LCL -35 µm

Width Variation: 5 µm

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

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2. Rough2

3. Fine finish

Size Limit: 15 to 35 µm

Target Size: +30 µm

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 - AUTO

Feed Mode - AUTO

Override-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 µm to -4 µm.

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

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use weight sensors and position sensors to identify the position and

weight of cone. All dimensions should be checked in this machine. M1

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

It automatically discards the work piece if its dimensions are not

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 :

Honings 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.

4.6 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


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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: 15 to 35 µm

Target Size: +30 µm

Honing Machine :

Honing 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.

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

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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 their 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 down stroke

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 work piece 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.

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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, run out and comets 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, comet 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 work piece are sent again

for correction.

Packing:

Finally, finished product is packed for market use and export.

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CHAPTER 5

PROJECT

5.1 OBJECTIVE: Study of manufacturing of Cartridge Tapered Roller

Bearing (CTRB) 6X11.

5.2 CARTRIDGE TAPERED ROLLER BEARING (CTRB):

For fitment to the new BOX-IN Updated Wagons designed by the RDSO.

NEI is the only manufacturer in the country to indigenize these bearings to

a high percentage in 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.

The BRENCO-NBC CTRB is a self-contined, pre-assembled, preadjusted,

pre-lubricated, completely sealed unit and is applied to or removal from

the axle without exposing the bearing elements seals or lubricants to

contamination or damage.

5.3 NOMENCLATURE AND DESCRIPTION OF BEARING PARTS:

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

positive locking for the grease seals.

3. Spacer :

The spacer width is precision ground and selected at the factory to achieve

proper axial clearance in an assembled bearing. Subsequent adjustment or

interchange at the time of installation should not be done.

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

diameter of the wear ring has an interference fit with axle.

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5. Grease seal: :

The seal is made of special synthetic rubber of superior oil resistance

quality bonded with metal casing by a special process. The primary

function of the roller bearing seal is to keep vital lubricating grease inside

the bearing.

The BRENCO-NBC Cartridge Roller Bearing are fitted with the

DDL(double Dust Lip) grease seals which are best seals, proven for

excellent performance& also helps in reducing fuel consumption and

cooler running of bearing.

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

prevent ingress of water.

7. Axle Cap Screws :

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

be lubricated with oil before installation.

8. Locking Plate :

The locking plate provides tabs which are bent against the flats of the cap

screws after tightening, thus preventing their undesired turning and

subsequent loss of bearing lateral clamp.

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9. Backing ring :

The backing ring positions the bearing, provides a firm base and helps

prevent intrusion of dirt, water and other foreign substances.

5.4 MAINTENANCE AND REPAIR OF CARTRIDGE TAPERED

ROLLER BEARING:

Bearing Disassembly

For disassembly of the CTRB steps to be followed are listed below:

1. Remove backing ring, wear rings and excess grease and excess grease

from the bearing for disassembly bench work.

2. Remove the grease seals from the cup using suitable tools (pry bar or

with the help of seal dismounting jig).

Care must be taken to prevent unnecessary damage to the bearing while

removing seals. Used grease seals must be scrapped

3. Remove both cone-assemblies and spacer from the cup.

4. All parts disassembled from the bearing must be precleaned by

removing residual grease as much as possible before wash cleaning.

5. Wash the bearing with the help of suitable media to remove all lubricants

and dirt. Bearing washing may be accomplished through automatic

cleaners, washers, agitators or spray systems. The cleaning media must not

be harmful to roller bearing parts. Washing media must be filtered before

reuse.

a Backing rings and end cap must be cleaned separately.


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b Take bearing parts for visual and dimensional inspection.

c Do not intermix roller bearing parts of different make.

5.5 INSPECTION OF BEARING COMPONENTS

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

parts during inspection.

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

cap on wear ring face must be corrected if possible otherwise defective

end cap is to be rejected.

Backing Ring :

1. Check the backing ring visually for crack, distortion, excessive

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

screws must be lubricated before reapplication.

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 .

Cone assembly should always be checked for indentations, electric burns,

crack etc. Use suitable well lit stand for the inspection of the cone assembly

and turn cage and rollers while examination of 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

also as it reveals excessive wear of the adapter. In case of fully worn-out

adapter the cup starts contacting the adapter at the ends also. Worn out

adapters must be scrapped. Displaced adapters also form two distinguished

marks on the cup outside diameters.

Visually examine cup raceways for staining, acid etching, corrosion,

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

treatment, grinding and further operations.

5.6 D EFECTS OF BEARING UNITS

5.7 GRINDING OPERATION:

Following are the process flow for grinding carried out in NBC for CTRB

parts:

Process flow for cup:

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 :

It is a double disc grinder having reciprocating shuffle for better accuracy.

It also has Digital Read out (DRO) for size adjustment.

2. Bore Grinding :

In this there is simultaneous track & Counter bore grinding.

Process flow for cone:

1. Face Grinding:

It is done though a double disc grinder featured with auto dressing and auto

load unload by gantry.

2. Track, Flange, Rib OD Grinding :

In this process there is simultaneously track, flange & rib OD grinding.

Dressing is done by interpolation of roll dressers. In this there is only a

single pass through which black to finish grinding is done.

3. Bore Grinding :

In it dressing is done by roll dressers. In this process cup surface is grinded

from black surface to finish surface in single pass.

Process flow for rollers:

1. Outer Diameter Rough Grinding, End face Grinding

2. Outer Diameter finish Grinding, Outer diameter crowning

3. Outer diameter super-finishing after this inspection of rollers is done,

then they are fitted into cage.

Page 37 of 43
5.8 C(Phosphate Coating) – SHOP

Objectives - Phosphate coating are used on steel part for

1. Corrosion resistance,

2. Lubricity,

3. Foundation for subsequent coating or painting Cup and cone are

forwarded for phosphating.

PROCESS - The application of phosphate coating makes use of

phosphoric acid and takes advantage of the low solubility of phosphates in

medium or high pH solutions. Iron, zinc or Mg-phosphate salts are

dissolved in a solution of phosphoric acid. When steel or iron parts are

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

deposit. In the case of depositing zinc phosphate or Mg-phosphate the

additional iron phosphate is frequently an undesirable addition to the

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

this sodium nitrite is frequently added to act as an oxidizing agent that

reacts with the hydrogen to form water. This chemistry is known as a

nitrate solution. Hydrogen is prevented from forming a precipitating layer

on the surface by the oxidant additive.

Powder Coating : Steps in powder coating

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Fig 5.8.1 :Steps of powder coating

After Phosphating, cone is forwarded for assembly. Phosphated cone are

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.

5.9 Process Flow In Assembly Line:

1. Firstly a cone assembly is put into a cone with an axle alignment

2. Spacer is put between the two cone assembly in a cup and then the

assembly is proceeded for laser marking.

3. Grease seals are put on the cup.

4. Then end cap and back rings are put on the assembled bearing and then

preceded for packing.

Packing:

Special attention has been given to protective packing. Bearing assembly

is wrapped in polythene sheet and greaseproof brown Paper. A cardboard

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

 While Engineered Surfaces have been successfully applied to a


variety of components, our first and most extensive experience is
using these processes with anti-friction bearings. Timken research
revealed that modifying the topography of a bearing’s contact
surfaces resulted in significant improvement in overall performance.
 Inadequate lubrication, poor maintenance, extreme operating
environments and vibration can be detrimental to bearing
performance. Engineered Surfaces enable bearings to better resist
these potentially damaging environmental factors.
 Real-world benefits have been demonstrated in rugged applications
that include bearings used in aircraft landing gear, heavy equipment
drive trains and industrial rolling mills.
 In many applications CTRB bearings are used in back-to-back pairs
so that axial forces can be supported equally in either direction.
 Pairs of tapered roller bearings are used in car and vehicle wheel
bearings where they must cope simultaneously with large vertical
(radial) and horizontal (axial) forces. Applications for CTRB
bearings are commonly used for moderate speed, heavy duty
applications where durability is required. Common real world
applications are in agriculture, construction and mining equipment,
axle systems, gear box, engine motors and reducers

Page 40 of 43
CHAPTER 6

CONCLUSION AND DISCUSION


6.1. Training experience

My training period of 41 days turned out to be a wonderful experience both

industrially and learning wise; experiencing the functionalities of Heavy Fabrication

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

experience. I have improved my efficiency to work in practical environment for a

given period of time with full dedication, enthusiasm and energy.

6.2. About report

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

every aspect of the NBC Bearings.

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

National Engineering Industries Limited, Jaipur. (nbc)

How an Industry works.


Learning of practical aspects of various dept. (Heat treatment,
Grinding) in railway bearings.
Got a brief idea about various heat treatment processes along-with
their industrial use.
Working of conventional machining process (grinding).
Industrial applications of all types of grinding and finishing
processes.
Use of various gauges along-with applications of dial indicators in
gauges.
How all the maintenance and inspections is done on in line
processing or after processing.
Various techniques of inspection methods.

Page 42 of 43
REFERENCES

• “Internet Guidelines”, http://www.google.com

• 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. .

• AutoTech Review, "Auto Tech Reviews," National Engineering


Industries- Setting Benchmark for Bearing of Tomorrow,

Page 43 of 43

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