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RKB multi-level quality control system

for rolling bearings

Post-process
quality control

In-process
quality control

Pre-process
quality control

Supplier
quality control
Supplier Quality
Material Quality Control QCB departments
Assurance
Guidelines Bureau
Agreement
JX80X Series (QCB) PACD laboratories
(SQAA)

Released documents

Product Approval
Raw Material Bearing Lot Quality Technical
Control
Approval Quality Approval Service
Department
(RMA) (BLQA) (QTS)
(PACD)

Advanced Metallographic
Metrological Mechanical Quality Control of Inspection
Measurements Quality Control Certificate of
Laboratory Testing Laboratory Conformity Data Certificate Data
Laboratory Laboratory Inspection
(ML) (MTL) Sheet Sheet
(AML) (MQCL) (CI)
(QCCDS) (ICDS)

In-Process Quality
Control
Department
Measuring Raw Material (IPQCD)
Masterpiece
Instruments Approval Quality
Quality Certificate
Certificate Final Report
(MQC)
(MIAC) (RMQFR)

Bearing
Forging Heat Treatments Turning Grinding
Assembling
Operational Plans Operational Plans Operational Plans Operational Plans
Operational Plans
(FOP) (HTOP) (TOP) (GOP)
(BAOP)

RKB Quality Control Bureau structure


RKB supplier quality control
Raw material supplier
identification

RKB Material
NO
Supplier Quality Assurance Agreement (SQAA) Guidelines JX80X
Series adoption

YES

ISO 9001 NO
certificated

YES

Valid accomplishment
OHSAS 18001 NO NO NO Rejected
plan and requirements
certificated supplier
fulfillment NO

YES
YES
ISO 14001 NO
certificated

YES

Favorable periodic NO
audit results

YES

Raw material
metallographic
multi-test inspections

Acceptable raw NO
material

YES
PACD/MQCL approval and
issue of
Approved supplier
Raw Material Quality Control
Final Report
Chemical Trace element analysis (ISO 683-17:1999)
composition
analysis

Blue fracture test (assessment of non-metallic macro-


inclusion content, ISO 3763:1976)
Macro-structure Macro-etching method (evaluation of porosity, segregation
inspection and other material defects ASTM E 340-00:2006)

Micro-etching method (assessment of non-metallic inclusion


Micro-structure
content, carbide size, carbide networks, carbide streaks and
inspection
carbide segregation rate, ISO 4967:1998 (E) and ISO
5949:1983)

Mechanical Brinell hardness test (ISO 6506-1:2005)


properties
determination
Rolling contact fatigue test (RKB internal protocols)

PACD/MQCL
Issuing of Raw Material Quality Control Final Report lot
approval of raw traceability
material

RKB raw material metallographic multi-test inspection protocol


Rough, fine grinding and polishing machine Metallographic microscopes

RKB Metallographic
Quality Control Laboratory

Chemical reagents Spectrometer analyzer


Statistical values of contact fatigue life test
Rating life Average life
Steel Weibull Life ratio
L10 L50
supplier coefficient
Million of revolutions L10/L10 supp2 L50/L50 supp2
Supplier 1 1.6729 0.7570 2.3341 1.86 1.39
Supplier 2 1.3305 0.4078 1.6802 1 1
Supplier 3 1.2495 0.4992 2.2547 1.22 1.34
Supplier 4 1.4811 0.5738 2.0474 1.41 1.22
Supplier 5 1.3548 0.5557 2.2323 1.36 1.33

2
1,86
1,8

1,6

L10 /L10 supp2 and L50 /L50 supp2


1,39 1,41
1,4 1,34 1,36 1,33
1,22 1,22
1,2
1 1
1

0,8

0,6
Ball-on-washer life prediction testing rig
0,4

0,2

0
Steel supplier Steel supplier Steel supplier Steel supplier Steel supplier
1 2 3 4 5
L10/L10 supp2 L50/L50 supp2
RKB pre-process quality control

RKB rolling bearing rings masterpieces production RKB rolling bearing rollers masterpieces production
CNC lathe machine for rings masterpieces
turning operation CNC grinding machine for rings masterpieces
fine grinding operation

CNC grinding machine for rollers masterpieces


fine grinding operation CNC machine for rollers masterpieces
superfinishing operation
24032CAC4STHB1W33S1VL inner ring, outer ring and roller
masterpieces for turning, rough grinding
and fine grinding operations

High precision measurements of 24032CAC4STHB1W33S1VL


inner ring masterpiece for fine grinding operation
using COORD 3 coordinate measuring machine
RKB in-process quality control

RKB rolling bearing rings production RKB rolling bearing rollers production
Forging quality parameters

Operation
parameters
Steel properties Dimensional
Dimensions (e.g. bar parameters
diameter and length) Heating (diameters, width,
Weight temperature length)

Pre-operation Product
parameters parameters

Heating temperature control Forged ring width measuring


using a pyrometer using an analog vernier caliper

Forged ring bore diameter measuring Forged bulk material measuring


with an analog vernier caliper using an analog external caliper
Heat treatment quality parameters

Operation
parameters
Form accuracy
Steel properties Furnace atmosphere parameters
Diameter parameters Rockwell C
Thickness Heating time hardness
Heating temperature Microstructure
Quenching time characteristics

Pre-operation Product
parameters parameters

Hardening temperature control Microstructure inspection


using a pyrometer using a metallographic microscope

Rockwell C hardness measuring Form accuracy parameter measuring


with an electronic hardness meter using an analog comparator gauge
Machining quality parameters

Operation
parameters

Cutting speed
Feeding rate Dimensional parameters
Dimensions Depth of cut Geometrical parameters
Stone granulation
Coolant quantity and
quality
Pre-operation Product
parameters parameters

Parallelism control using an Raceway curvature control Flange width measuring with an
analog comparator gauge using a geometrical pattern analog vernier caliper

Flange inner face angle measuring Bore taper angle control Bearing total height measuring
with an analog angle gauge with two analog vernier calipers using an analog vernier caliper
Magnetic Particle Inspection
(MPI) of rollers

Magnetic Particle Inspection


(MPI) of bearing rings

Ultrasonic Micro-Crack Detection (UMCD)


test of bearing rings
RKB post-process quality control

Visual Dimensional and Surface Chemical Mechanical


Macro-structure Micro-structure
inspection geometrical control quality control composition properties
inspection inspection
analysis determination

Waviness and Chemical Blue fracture test for Non-metallic


inclusions (thin and Rockwell C hardness
Packaging Radial and/or axial internal roughness of inner composition of inner macro-inclusions of of inner rings, outer
ring bore and rings, outer rings, inner rings, outer rings heavy series) of inner
conditions clearance (DIN 620-4:2004) rings and rollers
raceway surface rollers and cages and rollers rings, outer rings
and rollers (ISO 6506-1:2005)
(ISO 683-17:1999) (ISO 3763:1976)
(ISO 4967:1998 (E))
Bearing boundary Waviness and
roughness of outer Carbide size,
Bearing dimension deviations networks, streaks and
and geometrical ring outer surface Porosity of inner rings,
identification code and raceway outer rings and rollers segregation rate of
parameters (ISO 492:2002, inner rings, outer rings
ISO 355:2007, ISO 104:2002) surface (ASTM E 340-00:2006)
and rollers
(ISO 5949:1983)
Dimension deviations Waviness and
Bearing and geometrical roughness of roller
parts identification parameters of inner rings, raceway and Forged rollers Decarburization layer
outer rings, rollers and lateral end surfaces material flow-lines of inner rings, outer
cages (ISO 492:2002, ISO pattern rings and rollers
355:2007, ISO 104:2002) (ISO 3887:2003)
Profile of inner rings,
Bearing
outer rings and
surface quality
rollers raceway Superficial
(scratches, Carburizing layer of
surface macro-cracks
indentations etc) inner rings, outer rings
detection of inner
rings, outer rings and rollers
and rollers (ISO 2639:2002)

RKB rolling bearing post-process multi-test inspections


COORD 3 coordinate measuring machine Talyrond 131

Talyrond 73 Form Talysurf Intra


ARL 4460 spectrometer

Neophot 2 metallographic microscope

Handy Esatest digital hardness tester


The best improved bearing steel
Latest knowledge of micro-geometry
and surface topography
Improved manufacturing technology
(high precision machining and special
heat treatments)

Advanced software engineering


Advanced material engineering
Special heat treatments (bainite
treatment - HB and anti-wear
treatment - AWT)
High precision machining RKB
SPECIFIC
QUALITY
PROTOCOLS
Bainite treatment and dimensional
stabilization for rings (HB+S1)
Outer ring guided cage MA design
with special open-end design
Controlled radial clearance in
restricted range
Precision class higher than standard
for 223 series

Co-engineering and
customized/optimized solutions
Advanced software engineering
Advanced material engineering
Improved manufacturing technology
RKB total quality policy
Conclusions

RKB MULTI-LEVEL QUALITY CONTROL SYSTEM FOR ROLLING BEARINGS:


IS THE OPERATIONALIZATION OF THE TOTAL QUALITY POLICY
CONCEPT PURSUED BY OUR COMPANY
IS ORGANIZED AND SUPERVISED BY THE RKB QUALITY
CONTROL BUREAU, WHICH IS AN EXECUTIVE STRUCTURE OF
THE RKB TECHNICAL DIVISION DEDICATED TO MANAGING
QUALITY UNDER ALL RESPECTS
HAS THE OBJECTIVE OF ENSURING THAT THE APPROPRIATE
QUALITY PROCEDURES ARE IN PLACE AND CONSTANTLY
FOLLOWED AT ALL LEVELS OF ORGANIZATION

SUPERIOR QUALITY ASSURANCE OF PRODUCTS AND SERVICES

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