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AN INDUSTRIAL INTERNSHIP REPORT

NATIONAL ENGINNERING INDUSRIES LIMITED


Submitted by

Ajaypal Singh Panwar

in partial fulfillment for the award of the degree


of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

SIR PADAMPAT SINGHANIA UNIVERSITY, UDAIPUR

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.

Signature of the Student

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SIR PADAMPAT SINGHANIA UNIVERSITY


UDAIPUR 313601

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.

AJAYPAL SINGH PANWAR


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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

1.1 Bearing Industry Global Scenerio

1.2 Bearing Industry Indian Scenerio

Overview of company

2.1 Company profile

2.2 Milestones

2.3 Technical Collaboration

2.4 Main Customers

2.5 Manufacturing Plants

2.6 Products

10

Introduction to bearing

11

3.1 Defination of Bearing

11

3.2 Classification of Bearing

13

3.3 Types of Bearing

15

3.4 Operating Condition

19

Ball bearing

23

4.1 Components of Ball Bearing

23

4.2 Bearing Race's

24

4.3 Raw Material

24

4.4 Requirements for Bearing Prouduction

26
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Chapter 5

Chapter 6

Manufacturing of Ball Bearing

27

5.1 Manufacturing of inner race and outer race

27

5.2 Heat Treatment Process

28

5.3 Hardening Procedure

32

5.4 Different process and Machines

35

5.5 Grinding

37

Manufacturing of Ball

42

6.1 Ball manufacturing process

42

6.2 Heading Process

43

6.3 Flashing

44

6.4 Grinding

45

6.5 Heat Treatment

46

6.6 Hard Grinding

47

6.7 Tumbling

48

6.8 Lapping

48

6.9 Cleaning

49

6.10 Testing

49

6.11 Fine Inspection

50

6.12 Packing & Launching

50

Conclusion..

51

Future scope...

51

References...

52

FIGURE LIST
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Figure

Page

No.
Figure 2.1

Milestone

Figure 2.2

Newai (Gunsi) Plant

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

Single Row Radial Ball Bearing

16

Figure 3.5

Single Row Radial Ball Bearing with Tapered Bore

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Figure 3.6

Cylindrical Roller Bearing

19

Figure 4.1

Components of Ball Bearing

23

Figure 5.1

Centre less Grinding

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

Different types of bearing

12

Table 4.1

Bearing Races with inner diameter range

25

Table 5.1

Hardening Procedure of HC Steel

33

Table 5.2

Hardening Procedure of LC Steel

34

ABBREVIATION LIST
SSC

Small Scale Indusrtries

DRAC

Double row angular contact

SAE

Society of Automotive

Engineers
CRCA

Cold Rolled Close Annealed

DLW

Diesel Locomotive Work

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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

Industry varies over time and between different countries


Industrial linkage is:When one Industry depends on the output of another

This can cause problems if one industry has production problems or closes down
The CAR INDUSTRY is a good example each component (engine parts, lights, body
etc.) may be produced by a different company

Before it goes to the ASSEMBLY PLANT.

1.1 Bearing Industry Global Scenerio:


The world Market of quality Bearing is very vast. The Big players of bearing sector are
present in U.S.A, Russia, Japan, China and Eastern Europe. Some of leading bearing
Manufacturers are: -

NSK Japan
NTN Japan
KOYA Seiko Japan
FAG Germany

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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

Manufacturer.International Collaboration gives Access to best technology in the world.


1.2 Bearing Industry Indian Scenerio:
The Indian Bearing Industry is estimated at Rs. 30 Billion Approximately. The Industry
has established a highly diversified product range of around 1000 type of Bearing having
High Volume Demand. As much as 70% of the total demand for common varieties and
size of bearing is met by the domestic Industry, and the remaining demand to the tune of

30% is imported essentially for Industrial Application and special purpose.


The Indian bearing Industry can be divided in to the organized sector and un-organized
sector. The organized sector primarily caters to the original equipment Manufacturer
(OEM) Segment, which predominantly comprises Automotive railway and other
Industrial users. The replacement market is dominated by unorganized Sector.

CHAPTER 2:
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Overview of Company

2.1 Company profile:

The renowned industrialist, late Shree B. M. Birla founded National Engineering


Industries Ltd., Jaipur in the year 1946 as a pioneer industry in the field of bearing
manufacture, under the name of "National Bearing Company Ltd."

The first bearing was manufactured in 1950 with a modest start of 30,000 bearings in 19
sizes. The company is now manufacturing nearly 3.8 million bearings per month in over
500 different sizes ranging from 6 mm bore to 1300 mm outer diameter and has the
capacity to manufacture bearings upto 2000 mm outer diameter. At NEI, the development
of bearings is a never ending job. With ever increasing activities and grant of industrial
licenses for other vital industries and manufacturing of Roller Bearing Axle Boxes for
Railway Rolling Stock, Steel Balls, Tapered Roller Bearings, Spindle Inserts etc., the
name of the company was changed in 1958 to "National Engineering Industries Ltd."
retaining its original trade mark NBC.

The industry is spread over 118 acres of land in Jaipur and 56 acres in Gunsi (Newai).
This is the only unit in the country manufacturing wide variety and range of bearings
such as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical Roller Bearings
& Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings, Cartridge
Tapered Roller Bearings and Large Diameter special Bearings in separate fully equipped
factories. The development of National Engineering Industries Ltd., was pioneered with a
theme Indigenization and Self-reliance".

NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors, Electric
Motors, Railway wagon, Coach and Locomotive manufacturers as Original Equipment
and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and Thermal
Power Plants all across the country.

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2.2 Milestones:

Figure 2.1 Milestone

1946 -Company established as National Bearing Company (NBC) under technical

collaboration with Hoffman, U.K.


1950 Ball Bearing Production started
1958 Company is renamed National Engineering Industries Limited (NEI), NBC

Trademark retained
1967 Tapered Roller Bearing production stated
1975 Spherical Roller Bearings production begins

1981 Second Plant inaugurated in Newai.

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1982 Cartridge Tapered Roller Bearing in Technical Collaboration with Brenco

Incorporated of U.S.A.
1985 Technical Collaboration with NTN Corporation of Japan for Ball, Cylindrical &

Spherical Roller Bearing.


1995 ISO - 9001 Quality Management System Certification

1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine
Retrofitting

2007 Third Plant inaugurated in Manesar


2008 NBC receives TPM Excellence Award
2010 NBC receives Deming Award
2012 NBC receives the ACMA awards for Manufacturing and Technology Excellence
2014 Production commences at fourth plant at Savli (near Baroda), Gujarat

2.3 Technical Collaboration:

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

Since 1997 - for Tapered Roller bearings.


Izumi Kinzoku of JAPAN Since 1996 for remanufacturing, retrofitting and overhauling
of Grinding and Super-finishing machines for bearing races.

2.4 Main Customers:

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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Mahindra & Mahindra

Automobiles-LCV:-

Ashok Leyland
Force Motors
Eicher Motors
Tata Motors

Automobiles-Two/ Three Wheelers:-

Bajaj Auto Ltd.


Hero Honda Motors Ltd.
Honda Motorcycle & Scooters India
Suzuki Motorcycle India
Majestic Auto
Piaggio India Ltd.
Royal Enfield Ltd.
Yamaha Motors India Pvt. Ltd.
TVS

Tractors:-

Eicher
Escorts
HMT
International tractors
Mahindra & Mahindra
Punjab Tractors
TAFE
VST Tillers

Electric Motors & Pumps:-

Crompton Greaves
G.E. Motors
Kirloskar Electric
NGEF
MICO

Ltd.

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Fans: -

Bajaj Electricals
Crompton Greaves

2.5 Manufacturing Plants:

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 ship out its first bearing in November 2013, ramping up production capacity to

150 million bearings per year once it is fully operational.


2.5.1 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
equipments for quality and reliability of the products. The plant is spread over a covered
area of 7,200 Sq. Meter.

Figure 2.2 Newai (Gunsi) Plant


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2.5.2 Manesar Plant:

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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Figure 2.3 Manesar Plant

2.5.3 Jaipur Plant

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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Figure 2.4 Jaipur Plant

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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Cylindrical Roller Bearings


Axle Boxes Spherical
Spherical Roller Bearings
Cartridge Tapered Roller Bearings
Large Dia Special Bearings
DRAC Bearings

CHAPTER 3:

Introduction to bearing

3.1 Defination of Bearing:

Figure 3.1 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

In addition to Radial Loads, Axial Loads can be imposed in

either direction.
Highly Suitable for applications where High Speed & Low

Power loss are required.


They are capable of taking Radial Load & also the Axial Load

in one direction.
4 contact angles 15, 25, 30 & 40 are available. Higher the

contact angle, higher is the Axial Load carrying capacity.


For Higher Speed lower contact angles are preferred.

They are 2 single Row Angular Contact Ball Bearing mounted

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

Spherical Raceway with its centre of curvature coincident with

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

primarily for high Precision Instruments.


They are capable of taking high Radial Loads & also Axial

Load in one Direction.


Depending upon the contact angle they are divided into 3
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Bearing

types, Normal, Medium & Steep Angle.


1

Due to coincide of the centre of curvature of the outer ring


raceway surface with the bearing axis, they are also called as

Spherical
Roller

Self Aligning Bearing.


They can take Heavy Radial Load & some Axial Load in either

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.

Table 3.1 Different types of Bearing

3.2 Classification of Bearing


According to nature of relative motion between two contacting surface

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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.

3.2.1 Sliding Contact Bearing:

Hydrodynamic Bearing:

Load supporting high pressure fluid film is created due to the shape and relative motion
between the two surfaces.

Figure 3.2 Hydrodynamic Bearing

Hydrostatic Bearing

The load supporting fluid film is created by an external source, like pump.

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Figure 3.3 Hydrostatic Bearing

3.2.2 Rolling Contact Bearing

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.

Tapered Roller Bearings

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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.

3.3 Types of Bearing:

3.3.1 Single Row Radial Ball Bearings:

Figure 3.4 Single Row Radial Ball Bearing

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.

3.3.2 Single Row Radial Ball Bearing with Tapered Bore:

The single row radial ball bearings with tapered bore are Identical to single row radial
ball bearings except that these have tapered bore which is used for easier mounting and
for the adjustment of radial clearance. Dimensions of tapered bore diameter refer to small
bore.

Figure 3.5

Single Row Radial

Ball Bearing

with Tapered Bore

3.3.3 Single Row Angular Contact Ball Bearing:

The single row angular contact ball bearings have higher axial load capacity than the
single row radial ball bearings. The radial load must always be less than axial load. The
bearings can carry axial load in one direction only and should be adjusted against another
bearing, if axial load is coming from both the directions. Each bearing can be located

endwise in one direction only.


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

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3.3.5 Double Row Self Aligning Ball Bearing

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

3.3.6 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 Operating Condition:

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

50% of bearings have a lifespan at least 5 times as long.


The industry standard life calculation is based upon the work of Lundberg and Palmgren
performed in 1947. The formula assumes the life to be limited by metal fatigue and
that the life distribution can be described by a Weibull distribution. Many variations of
the formula exist that include factors for material properties, lubrication, and loading.
Factoring for loading may be viewed as a tacit admission that modern materials
demonstrate a different relationship between load and life than Lundberg and Palmgren
determined.

3.4.2 Failure Modes:

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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

very slowly rotating bearings is called "static" maximum load.


If a bearing is rotating, but experiences heavy load that lasts shorter than one revolution,
static max load must be used in computations, since the bearing does not rotate during the
maximum load.

3.4.3 Maximum Load:


In general, maximum load on a ball bearing is proportional to outer diameter of the
bearing times width of bearing (where width is measured in direction of axle).
3.4.4 Lubrication:
For a bearing to operate properly, it needs to be lubricated. In most cases the lubricant is
based on elastohydrodynamic effect (by oil or grease) but working at extreme

temperatures dry lubricated bearings are also available.


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. The
recommended dynamic viscosity is inversely proportional to diameter of bearing. The
recommended dynamic viscosity decreases with rotating frequency. As a rough
indication: for less than 3000 RPM, recommended viscosity increases with factor 6 for a
factor 10 decrease in speed, and for more than 3000 RPM, recommended viscosity

decreases with factor 3 for a factor 10 increase in speed.


For a bearing where average of outer diameter of bearing and diameter of axle hole is 50
mm, and that is rotating at 3000 RPM, recommended dynamic viscosity is 12

mm/s.

Note that dynamic viscosity of oil varies strongly with temperature: a temperature

increase of 5070 C causes the viscosity to decrease by factor 10.


If the viscosity of lubricant is higher than recommended, lifespan of bearing increases,
roughly proportional to square root of viscosity. If the viscosity of the lubricant is lower
than recommended, the lifespan of the bearing decreases, and by how much depends on
which type of oil being used. For oils with EP ('extreme pressure') additives, the lifespan
is proportional to the square root of dynamic viscosity, just as it was for too high
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viscosity, while for ordinary oil's lifespan is proportional to the square of the viscosity if a

lower-than-recommended viscosity is used.


Lubrication can be done with a grease, which has advantages that grease is normally held
within the bearing releasing the lubricant oil as it is compressed by the balls. It provides a
protective barrier for the bearing metal from the environment, but has disadvantages that
this grease must be replaced periodically, and maximum load of bearing decreases
(because if bearing gets too warm, grease melts and runs out of bearing). Time between
grease replacements decreases very strongly with diameter of bearing: for a 40 mm
bearing, grease should be replaced every 5000 working hours, while for a 100
mm bearing it should be replaced every 500 working hours. Lubrication can also be done
with an oil, which has advantage of higher maximum load, but needs some way to keep
oil in bearing, as it normally tends to run out of it. oil quality; therefore, the oil is usually

changed less frequently than the oil in bearings.

3.4.5 Direction of load:


Most bearings are meant for supporting loads perpendicular to axle ("radial
loads"). Whether they can also bear axial loads, and if so, how much, depends on the type

of bearing. Thrust bearings are specifically designed for axial loads.


For single-row deep-groove ball bearings, Maximum axial load is circa 50% of maximum
radial load, but it also says that "light" and/or "small" bearings can take axial loads that

are 25% of maximum radial load.


For single-row edge-contact ball bearings, axial load can be circa 2 times max radial load,
and for cone-bearings maximum axial load is between 1 and 2 times maximum radial

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

ISO/TS 16281 should be used with the help of a calculation software.


3.4.6 Avoiding undesirable axial load:

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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

a bearing is loaded axially, both sides must be fixed.


If an axle has two bearings, and temperature varies, axle shrinks or expands, therefore it
is not admissible for both bearings to be fixed on both their sides, since expansion of axle
would exert axial forces that would destroy these bearings. Therefore, at least one of

bearings must be able to slide.


A 'freely sliding fit' is one where there is at least a 4 m clearance, presumably because
surface-roughness of a surface made on a lathe is normally between 1.6 and 3.2 m.
3.4.7 Fit:
Bearings can withstand their maximum load only if the mating parts are properly sized.
Bearing manufacturers supply tolerances for the fit of the shaft and the
housing so that this can be achieved. The material and hardness may

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

4.1 Components of 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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Figure 4.1 Components of Ball Bearing

4.2 Bearing Race's:


The SSI Races Manufacturing Units of Jaipur are manufacturing outer & Inner Bearing
Races in Different sizes. According to the Demand in the market. The turned Races are
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supplied in Soft condition and remaining operation of Hardening, Tempering Grinding &

Honing/polishing are being done by the Bearing Manufacturer.


The Detail of type and size of Bearing Races are as under:S.No.
1.
2.
3.
4.
5.

Type of Bearing Races

Inner Dia. Ranger

Ball Bearing Races:


10mm to 80mm
Roller Bearing Races:
17mm to 100 mm
Cylindrical Roller Bearing Races:
20mm to 75 mm
Special type of Bearing Races for:
20mm to 75 mm
Transport Vehicles (Thrust Bearing)
Axle Box Bearing Races for Railway:
100mm to 200 mm
Passenger coaches and wag

Table 4.1 Bearing Races with inner Diameter Range

4.3 Raw Material:


The Races & Rolling elements of Bearing are subjected to stress on a very small contact
surface must be of such material so 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:

4.3.1 Outer and Inner Races:


The raw material used in the Manufacturing of bearing Races is SAE 52100 high Carbon
Chrome bearing steel. The raw material for Bearing Races is in the form of Rods &
Seamless Hollow Tubes. This is a Spheroids Annealed Steel. Approx. 80% of the
Seamless Hollow tubes are purchased by the Industry from M/s. Indian Seamless Metal
tube PUNE, while the rest of the tube used in the cluster is imported material. The Steel
bar are purchased from M/s. Indian Seamless Steel & Alloy Pune & M/s. Mahindra Ugine
Steel Company KHAPOLI (Maharashtra). Some of the units are buying the steel scrap
rod for manufacturing bearing races.
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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

bearing races are Constitute % Composition


Carbon 0.95 to 1.1
Chromium 1.4 to 1.6
Manganese 0.50 max.
Silicon 0.15 to 0.35
Sulphur 0.025 (Max.)
Phosphorous 0.05
4.3.2 CAGE'S:
Cage is used to return balls at proper distance to prevent them from containing each other
and to prevent a temp. rise and resultant damage due to friction.
The Material for manufacturing cages is CRCA Strips of C2015 Bearing grade steel
having carbon percentage at 0.08% max. and Magnesium ranging from 0.25% to 0.45%

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.

4.4 Requirements for Bearing Prouduction:


Raw material, Centre less lath machine, grinding machine, grinding wheels, roughing
stone, finishing stone, diamond to set curvature of grinding wheel, pp. gauge to measure
the bore.

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CHAPTER 5:
Manufacturing of Ball Bearing
5.1 Manufacturing of inner race and outer race:

Forged rings (De-scaled) as raw material


(SAE 52100 steel)

Turning Operation

Centre Less Grinding

Heat Treatment

Hardness Testing

Rough Grinding

Finish Grinding

Honing & Super Finishing

Washing
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Application for Rust Preventive

Ready For Dispatch to Assembly

5.2 Heat Treatment Process:

Heat treatment process is the process of hardening the soft material. The row material is
soft material and it has to be hardened before grinding, and hardening increase the life of

bearing.
Hardening is done in a special furnace named CHUGAIRO furnace. The soft machined
material is feed in the furnace and washed at 60 0 C, then send to a chamber where the
material heated in four chambers the first chamber has the temperature 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

(Carbon Shield Layer increases Hardness)

(10 12 hrs.) (940 0C) (GC Furnace)

Hardness I
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(Revolving Furnace)

(920 0C) (Time Dependent on Job)

Annealing

(6 hrs.) (650 0C)

Shot Blasting

Hardening II

(Revolving Furnace)

(820 0C) (Time Dependent on Job)

Sub-Zero Treatment

(-60 0C) (Increases Toughness)

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Tempering

(160 0C) (4 hrs.)

Shot Blasting
(Wheel Abrator)

Hardness Inspection

(60 HRC)

After heat treatment following process are done to get a new ready to use ball bearing.

Steel Material Carbon (0.9% - 1.10%)

5.3 Hardening Procedure:

HC Steel (High Carbon Steel)

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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

Table 5.1 Hardening Procedure for HC Steel

LC Steel (Low Carbon Steel)

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.

Table 5.2 Hardening Procedure for LC Steel

5.4 Different process and Machines:


5.4.1 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.

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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At G-12 line the different machines

G-114 Outer race track grinding machine

G-115 Outer race track honing machine

G-103 Inner race bore grinding

G-343 Inner race track grinding

G-363 Inner race face grinding machine

G-344 Inner race track honing machine

Assembly Line:

A-439 Auto inner outer race washing m/c

A-440 Auto inner outer race measuring m/c

A-441 Auto inner outer race combining m/c

A-442 Auto cage assembly m/c

A-443 Auto demagnetizing m/c


A-444 Auto washing m/c for semi-finished product

A-445 Shower cleans

A-446 Auto inner outer diameter inspection and sensitivity checking m/c
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A-447 Auto radial internal clearance inspection m/c


A-448 Auto washing and drying m/c.
A-449 Auto double side vibration testing m/c
A-450 Auto Greasing and weighing m/c.
A-451 Auto shielding m/c
A-452 Auto conservation oil spraying and visual inspection m/c

5.5 Grinding:

5.5.1 Centre less Grinding:

Figure 5.1 Centre less Grinding

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Centerless grinding is a method of material removal through grinding, similar to centered


grinding except for the absence of the spindle. It has high throughput, i.e. a large number
of parts can be manufactured in a short time.

The workpiece is set up between the regulating wheel (or back up wheel) and the
grinding wheel, and is supported by the work blade (or work rest). The work rest is
located between the wheels. The work is placed upon the work rest, and the latter
together with the regulating wheel is fed forward forcing the work against the grinding
wheel. Axial movement of the work past the grinding wheel is accomplished by tilting
the regulating wheel at a slight angle from horizontal. An angular adjustment of 0 to 8 or
10 degrees is provided in the machine for this purpose.

Centerless grinding is classified into two types:

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.

An example of a centerless ground application is the outer diameter of the bearing


races.

Mechanism:

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Figure 5.2 Mechanism

Types of Centerless grindings:

Centerless grinding is similar to centered grinding except that there is


no spindle. This allows high through-put since parts can be quickly
inserted and removed from the process. There are three main types of
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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.

Figure 5.3 Through-Feed Grinding

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.

Figure 5.4 In-Feed Grinding

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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.

Figure 5.5 End-Feed Grinding

CHAPTER 6:

Manufacturing of Ball
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6.1 Ball manufacturing process:

Forged wire (De-scaled) as raw material

(SAE 52100 steel)

Heading Operation

Grinding

Flashing

Heat treatment

Hard Grinding

Lapping

Tumbling

Washing

Testing and Fine Inspection

Packing and launching

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Figure 6.1 Wire


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

moveable die. That die works at slider crank

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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Figure 6.2 Heading Process

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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Figure 6.3 Flashing

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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Figure 6.4 Grinding

6.5 Heat Treatment:


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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

The process time is approx. 3 hrs.

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Figure 6.5 Heat Treatment


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6.6 Hard Grinding:

The heat treated balls are then send to hard grinding where is the extra metal are remove.
It is also a similar operation like a soft grinding but the wheel used is harder than the soft
grinding

machine. The process time is approx 3hrs.

Figure 6.6 Hard 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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Figure 6.7 Cleaning

6.10 Testing:

In the testing we test each ball individually. Three test are performed at each ball

ECT eddy current test

EOT optical test

EVT vibration test

The test in case of failure the ball is rejected and the cause of failure is discontinuity in
internal structure.
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6.11 Fine Inspection:

In this segment the each ball is inspected by human eyes the surface defect are inspected
by

that means.

Figure 6.8 Fine Inspection

6.12 Packing & Launching:

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The finished OK tested balls are then packed in approx.5 Kg. weight per pack for
assembly section.

Conclusion:

My training at NATIONAL ENGINEERING INDUSTRIES, JAIPUR was very fruitful


and I gained a lot of practical knowledge about various manufacturing processes and
techniques. I also got the opportunity to realize the challenges faced and expertise
required in manufacturing processes for mass production.

It was indeed a great experience undergoing training at the plant.

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.

The name of Bearing is Autonomous Decentralized Bearing. Instead of using a retainer to


maintain the space between bearings spheres, The ADB uses a simply design feature:
divots. A series of small indentations to the surface of outside rail cause the balls to
consistently slow down and speed up ever so slightly, effective preventing them from
clashing into each other as they roll around even without a cage to hold them in place. No
cage means less friction, and less friction means the bearing require less energy to rotate.
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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,

Tenth Reprint 2011


RAO P.N, volume 1, Engineering Materials, Tata McGraw Hill Education Private

Limited, Second Reprint 2009


RAJVANSHI A.K., Manufacturing Processes, Genius Publications
https://en.wikipedia.org/wiki/Ball_bearing
http://www.nbcbearings.com/

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