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BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
July 2015
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DECLARATION
I hereby declare that work entitled summer training project report, Submitted towards
completion of vocational training after Third year of B.Tech (MECHANICAL) at SIR
PADAMPAT SINGHANIA UNIVERSITY comprises of my original work pursued under the
supervision of guides at National Engineering Industries Limited, Jaipur. The Project embodied
in this report have not been submitted to any other Institute or University for the fulfillment of
any other curriculum.
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GUIDES CERTIFICATE
This is to certify that Mr. Ajaypal Singh Panwar has completed the industrial internship at
National Engineering Industries Limited, Jaipur for 45 days and reported the work as per
university guidelines.
Signature
Mr. Wasim Akram
Supervisor
Dept. of Mechanical Engineering
SPSU, Udaipur
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ACKNOWLEDGEMENT
Words fail me to express my sincerest gratitude to this esteemed organization, which has
conferred on us the privilege to pragmatically convert our theoretical knowledge into practical
viable experience. During the course of my training at NATIONAL ENGINEERING
INDUSTRIES LIMITED, JAIPUR so many people have guided me and I will remain indebted
to them throughout my life for making my training at NBC, a wonderful learning experience.
I would like to thank MR. PAWAN NAMA my project head, MR. RAKESH MOURYA for
providing me the opportunity for the practical training. His words were a true inspiration for me.
The exposure to the working of the industry that I have got here would not have been possible
without his kind support.
He took keen interest in my project and ensured that my tenure at NBC, JAIPUR is a learning
experience for a lifetime for me.
Thanks to all those operators, Diploma Engineer Trainees and my trainee colleagues with whom
I had developed a special bond.
EXECUTIVE SUMMARY
NBC Bearings Limited, a member company of C.K. BIRLA group of Companies - is a leading
player in the Indian Bearing industry.
The company manufactures a very wide range of bearings conforming to the stringent
international quality standards.
NBC manufacturing plants, located at Gunsi (Newai) Rajasthan, Manesar Haryana & Jaipur was incorporated in the year 1946. Its feature the most advanced manufacturing technology. The
company is certified to ISO/TS 16949, ISO 9001, and ISO 14001 standards.
NBC India is a leading OEM supplier to the automotive industry, mechanical and electrical
engineering industry, besides the Railways.
Bearings produced at the EOU plant have gained ready acceptance and recognition of customers
located in India & Indian Sub Continent, Europe & Africa.
NBCs main competitors in bearing are SKF, TIMKEN, NRB, FAG and other local brands.
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CONTENTS
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Title
Page No.
Introduction to industry
Overview of company
2.2 Milestones
2.6 Products
10
Introduction to bearing
11
11
13
15
19
Ball bearing
23
23
24
24
26
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Chapter 5
Chapter 6
27
27
28
32
35
5.5 Grinding
37
Manufacturing of Ball
42
42
43
6.3 Flashing
44
6.4 Grinding
45
46
47
6.7 Tumbling
48
6.8 Lapping
48
6.9 Cleaning
49
6.10 Testing
49
50
50
Conclusion..
51
Future scope...
51
References...
52
FIGURE LIST
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Figure
Page
No.
Figure 2.1
Milestone
Figure 2.2
Figure 2.3
Manesar Plant
Figure 2.4
Jaipur plant
10
Figure 3.1
Bearing
11
Figure 3.2
Hydrodynamic Bearing
14
Figure 3.3
Hydrostatic Bearing
14
Figure 3.4
16
Figure 3.5
17
Figure 3.6
19
Figure 4.1
23
Figure 5.1
37
Figure 5.2
Mechanism
38
Figure 5.3
Through-Feed Grinding
39
Figure 5.4
In-Feed Grinding
41
Figure 5.5
End-feed Grinding
41
Figure 6.1
Wire
43
Figure 6.2
Heading Process
44
Figure 6.3
Flashing
45
Figure 6.4
Grinding
46
Figure 6.5
Heat Treatment
47
Figure 6.6
Hard Grinding
48
Figure 6.7
Cleaning
49
Figure 6.8
Fine Inspection
50
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TABLE LIST
Table
Page No.
Table 3.1
12
Table 4.1
25
Table 5.1
33
Table 5.2
34
ABBREVIATION LIST
SSC
DRAC
SAE
Society of Automotive
Engineers
CRCA
DLW
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CHAPTER 1:
Introduction to industry
Any type of Economic Activity producing GOODs or SERVICES
It is part of a chain from raw materials to finished product, finished product to service
sector, and service sector to research and development.
It includes AGRICULTURE, MANUFACTURING and SERVICES
This can cause problems if one industry has production problems or closes down
The CAR INDUSTRY is a good example each component (engine parts, lights, body
etc.) may be produced by a different company
NSK Japan
NTN Japan
KOYA Seiko Japan
FAG Germany
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SKF Sweden
NRB France
Timken USA
There are few of leading bearing manufacturer present in India. Most of the big player is
having
either
technical
or
financial
Collaboration
with
leading
Auto
CHAPTER 2:
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Overview of Company
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.
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2.2 Milestones:
Trademark retained
1967 Tapered Roller Bearing production stated
1975 Spherical Roller Bearings production begins
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Incorporated of U.S.A.
1985 Technical Collaboration with NTN Corporation of Japan for Ball, Cylindrical &
1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine
Retrofitting
BRENCO Incorporated of U.S.A. Since 1982 - For Cartridge Tapered Roller Bearings for
Railroad applications.
NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical & Spherical
Roller Bearings, JPU Bearings, Double Row Angular Contact Bearings, Hub Bearings
DLW
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.
Rolling Stock:-
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Automobiles-LCV:-
Ashok Leyland
Force Motors
Eicher Motors
Tata Motors
Tractors:-
Eicher
Escorts
HMT
International tractors
Mahindra & Mahindra
Punjab Tractors
TAFE
VST Tillers
Crompton Greaves
G.E. Motors
Kirloskar Electric
NGEF
MICO
Ltd.
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Fans: -
Bajaj Electricals
Crompton Greaves
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NEI has set up its third Ball Bearing manufacturing plant in Manesar, the fastest growing
industrial town of Haryana 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. The
plant is spread over a covered area of 5200 Sq. Meters.
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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 sq. meters and a covered area of
75,310 sq.meters, Jaipur plant has state of the art manufacturing facilities and capable to
manufacture all types of Ball and Roller Bearings of NEI product range.It has a separate
division to manufacture all these spread across large area.
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2.6 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
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CHAPTER 3:
Introduction to 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.
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Name
Single Row
Radial Ball
Bearing
Single Row
Angular
Contact
Ball
Application
either direction.
Highly Suitable for applications where High Speed & Low
in one direction.
4 contact angles 15, 25, 30 & 40 are available. Higher the
2
3
back to back.
They have only one inner and one outer ring.
They can take axial load in either direction.
The Inner Ring has 2 Raceways & Outer Ring has a single
Bearing
Double
Row
Angular
Contact
Ball
Bearing
Self
Aligning
Ball
Bearing
Cylindrical
Roller
Bearing
Tapered
Roller
bearing axis.
This has an advantage of correcting minor angular
misalignment of Shaft and Housing caused by Machining or
Mounting Error.
They have High Radial Load capacity and are suitable for High
Speed.
Double Row bearing have high Radial Rigidity and are used
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Bearing
Spherical
Roller
direction.
They are suitable for the use where there are Heavy or Impact
Load.
They are capable of taking High Axial Load and some amount
of Radial Load.
Outer & Inner Rings are called as Washer because they seems
Bearing
Thrust
Bearing
to be as Washer in Structure.
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There are numerous different kinds of bearings that are designed to handle radial load,
thrust load, or some combination of the two. Because different applications require
bearings that are designed to handle a specific kind of load and different amounts of
weight, the differences between types of bearings concern load type and ability to handle
weight.
Hydrodynamic Bearing:
Load supporting high pressure fluid film is created due to the shape and relative motion
between the two surfaces.
Hydrostatic Bearing
The load supporting fluid film is created by an external source, like pump.
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Ball Bearings
Ball bearings are extremely common because they can handle both radial and thrust
loads, but can only handle a small amount of weight. They are found in a wide array of
applications, such as roller blades and even hard drives, but are prone to deforming if
they are overloaded.
Roller Bearings
Roller bearings are designed to carry heavy loads, The primary roller is a cylinder, which
means the load is distributed over a larger area, enabling the bearing to handle larger
amounts of weight. This structure, however, means the bearing can handle primarily
radial loads, but is not suited to thrust loads. For applications where space is an issue, a
needle bearing can be used. Needle bearings work with small diameter cylinders, so they
are easier to fit in smaller applications.
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This style of bearing is designed to handle large radial and thrust loads as a result of their
load versatility, they are found in car hubs due to the extreme amount of both radial and
thrust loads that car wheels are expected to carry.
The initial technology was from Hoffman Manufacturing Company Ltd., U.K. a
collaboration, which continued for 20 years.
It 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
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technology i.e. thermo mechanical bearings (TMB) and tensioner bearings available
today and our wide range of ball bearings is increasing under this collaboration.
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.
Figure 3.5
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 and should be adjusted against another
bearing, if axial load is coming from both the directions. Each bearing can be located
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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.
3.3.6 Double Row Self-Aligning Ball Bearing with Tapered 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.
3.3.7 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.
3.3.8 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 modified line contact between rollers and raceways to eliminate edge stressing.
These bearings have a high radial load capacity and are suitable for high speeds. Due to
detachable design character they have advantage of mounting inner ring and outer ring
separately.
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Figure 3.6
Cylindrical Roller
Bearing
3.4.1 Lifespan:
The calculated life for a bearing is based on the load it carries and its operating speed.
The industry standard usable bearing lifespan is inversely proportional to the bearing load
cubed. Nominal maximum load of a bearing (as specified for example in SKF
datasheets), is for a lifespan of 1 million rotations, which at 50 Hz (i.e., 3000 RPM) is a
lifespan of 5.5 working hours. 90% of bearings of that type have at least that lifespan, and
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If a bearing is not rotating, maximum load is determined by force that causes plastic
deformation of elements or raceways. The identations caused by the elements can
concentrate stresses and generate cracks at the components. Maximum load for not or
mm/s.
Note that dynamic viscosity of oil varies strongly with temperature: a temperature
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viscosity, while for ordinary oil's lifespan is proportional to the square of the viscosity if a
load.
If both axial and radial loads are present, they can be added vectorially, to result in total
load on bearing, which in combination with nominal maximum load can be used to
predict lifespan. However, in order to correctly predict the rating life of ball bearings the
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The part of a bearing that rotates (either axle hole or outer circumference) must be fixed,
while for a part that does not rotate this is not necessary (so it can be allowed to slide). If
also be specified.
Fittings that are not allowed to slip are made to diameters that prevent slipping and
consequently the mating surfaces cannot be brought into position without force. For a
bearing to have its nominal lifespan at its nominal maximum load, it must be lubricated
with a lubricant (oil or grease) that has at least the minimum dynamic viscosity (usually
denoted with the Greek letter ) recommended for that bearing.
CHAPTER 4:
Ball bearing
There are four major parts to a standard ball bearing: the outer race, the rolling balls, the
inner race, and the cage or retainer.
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supplied in Soft condition and remaining operation of Hardening, Tempering Grinding &
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Bearing Races material and their heat treatment are required to be selected carefully,
taking account the mechanical strength and required life of the Bearing, so that each
material may perform at maximum capability. Approximate required composition for
4.3.3 BALL'S:
Steel Balls of grade 20, 16 &10 with close tolerance, smooth surface made by using SAE
52100 High Carbon Chrome Bearing Steel.
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CHAPTER 5:
Manufacturing of Ball Bearing
5.1 Manufacturing of inner race and outer race:
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Application for Rust Preventive
Ready For Dispatch to Assembly
Heat treatment process is the process of hardening the soft material. The row material is
soft material and it has to be hardened before grinding, and hardening increase the life of
bearing.
Hardening is done in a special furnace named CHUGAIRO furnace. The soft machined
material is feed in the furnace and washed at 60 0 C, then send to a chamber where the
material heated in four chambers the first chamber has the temperature 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.
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Raw Material
(Carbon Steel)
Carburizing
Hardness I
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(Revolving Furnace)
Annealing
Shot Blasting
Hardening II
(Revolving Furnace)
Sub-Zero Treatment
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Tempering
Shot Blasting
(Wheel Abrator)
Hardness Inspection
(60 HRC)
After heat treatment following process are done to get a new ready to use ball bearing.
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Proces
Hardeni
Heat the
870O C
Fast cooling
600 C Oil
Quenching
------
Furnace
Cool
at
Room
1650-
Tempe
1800C
62 66
35-60
min.
Coolin
g
Heating
HRC
Time
1800C Salt
ess
Air
rature
Bath
Hardn
Temperi
850-
ure
ng
Furnace
Proced
Quenching
ng
60 64
------
HRC
5-15 min.
150
------
min.
Accordi
ng to the
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job
Hardening Procedure
Steel Material
Proces
Proced
ure
Carburizin
Hardening
Quenchi
ng
Carbon
Furnace
Tempe
ring
Fast
Heat
Furnace
temperatu
cooling
the
heating at
re at 8500
600 C
Furnac
C 8700
for oil
e at
quenchi
1650
940 C -
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9500 C
C-1800
ng only
Hardn
.200 - .
ess
------
250
60 64
HRC
52
62
HRC
Time
8 10
hours
35-60
min.
5-15
min.
According
to
120180
min.
the
job.
5.4.2 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.
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Assembly Line:
A-446 Auto inner outer diameter inspection and sensitivity checking m/c
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5.5 Grinding:
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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.
Through feed 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.
Mechanism:
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centerless grinding:
Through-feed grinding
In-feed grinding.
End-feed grinding
Through-Feed Grinding:
In through-feed grinding, the part rotates between the grinding wheel and a regulating
wheel as shown below.
For through-feed grinding, one or both wheels of the centerless grinding machine are
canted out of the horizontal plane. 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.
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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.
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.
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.
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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.
CHAPTER 6:
Manufacturing of Ball
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Heading Operation
Grinding
Flashing
Heat treatment
Hard Grinding
Lapping
Tumbling
Washing
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6.2 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
mechanism.
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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.
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6.3 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 is 18hrs approx.
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6.4 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 be gain to take shape but not
fully finished.
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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. The gas used in heat treatment is Indo Gas which is mixture of LPG & Air In
the heat treatment there are 3 steps.
Heating
Quenching
Tempering
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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
6.7 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.
6.8 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
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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.
6.9 Cleaning:
In this process the finished balls are washed in Kerosene Oil for approx. 1hr.
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6.10 Testing:
In the testing we test each ball individually. Three test are performed at each ball
The test in case of failure the ball is rejected and the cause of failure is discontinuity in
internal structure.
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In this segment the each ball is inspected by human eyes the surface defect are inspected
by
that means.
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The finished OK tested balls are then packed in approx.5 Kg. weight per pack for
assembly section.
Conclusion:
Future scope:
Most Ball Bearings rely on things called retainers to hold their balls in place. A retainer is
essentially a small cage made of metal or plastic, which fits around the balls and keeps
them form bumping into each other. This spacing is crucial to the bearings smooth
operation but it also introduces a little bit of additional friction into the system which is
typically remedied with grease.
A Japanese engineering firm by the name of Coo Space has developed a new type of
bearing that spins with up to 10 times less friction than the bearing we currently use and
it manages to do so without the aid of grease or any other sort of lubrication.
Ajaypal/ME/SPSU/NBC/2015-16
Right now they only exist as prototype, but Coo Space is working with manufacturers to
bring out of the lab and into the market. In future, This Could lead to super-efficient car
wheels, industrial machines that require far less maintenance, and bikes that can coast
down a flat street for miles and miles.
References:
RAO P.N, volume 2, Abrasive Processes, Tata McGraw Hill Education Private Limited,
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