A REPORT ON

INDUSTRIAL TRAINING
AT

FEDERAL MOGUL BERINGS INDIA LIMITED

PARWANOO, HIMACHAL PRADESH

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS

OF THE

COURSE ME-714 – INDUSTRIAL TRAINING,

FOR THE DEGREE OF

Bachelor of Technology
(Mechanical Engineering)
BY

HIMANSHU RANA
ROLL NO-05BTD5020126(M.E)

1
 ACKNOWLEDGEMENT

Industrial training is an important part of learning experience in

order to have practical knowledge of what we read in books.
Industrial training helps in breaking the gap between the practical
and theoretical knowledge. During the training session, it is the
supervisor or the trainer who can help to make the most out of
this golden opportunity of getting the practical knowledge.

I would like to put forth my regardful thanks to Dr. Satish kumar

& G.H.E.C. all those who had helped me in guiding me to get the
most out of this golden opportunity to learn the most during such a
period of my training at Federal Mogul bearings India limited,
Parwanoo, Dist. Solan( H.P.)

I also pay my special thanks to Mr.Rakesh kaushik (Quality head)

and Mr. Tarun gera who allotted me the Quality Engg. Department
as it is the core of practical knowledge and allows me to separate
different machines. I would like to appreciate that they gave me
experience of every cell of the company so that I get maximum let
me experience doing my training.

Ahead I put my special regards to the management, workers and co-

trainees who have always been so supporting, loving and ready to help. I
would specially like to mention the names of Mr. Naresh Sharma and all
other supporter workers who were always there to help me and clarify all
my doubts. I have been in close touch with them from the beginning of
my training at Federal Mogul bearing india limited

2
 ABOUT FEDERAL MOGUL GROUP

FEDERAL MOGUL GROUP is a leading manufacturer of automotive

components and systems in India. With a sales turnover of US $ 326 millions,
it has the widest range of auto components, supplied to virtually every vehicle
and engine producer in country.

In 1961, MR.JOSHF MARIA ALLAPOT, chairman of Automotive Systems,

founded the group’s flagship company- FEDERAL MOGUL BEARING INDIA
in Mumbai for manufacture of shock absorbers. Today, FEDERAL MOGUL
comprises Eight companies spread in five states of the country. It has also
built up a sizable export market, currently about 13% of the total sales of
existing products, targets to reach 30% in the next few years.

Employing over 7204 people, FEDERAL MOGUL has 1700 professionally

qualified Engineers MBA’s and CA’s. It invests two percent of its sales every
year on the training and development programs conducted be its in – house
technical and management institute FEDERAL MOGUL UNIVERSITY.

VARIOUS COMPANIES UNDER FEDERAL MOGUL

GROUP
 FEDERAL MOGUL BEARING INDIA LIMITED PARWANOO
 FEDERAL MOGUL GROOVING PISTON INDIA LIMITED PATIALA
 FMG SINTERED INDIA LIMITED BHIWADI
 FM BEARING INDIA LIMITED KHANDSA
 FM AUTOMOTIVE LIMITED BHIWADI
 FMG PISTON INDIA LIMITED BANGALURU
 FMG RINGS INDIA LIMITED BANGALURU
 FM GOETZA TP INDIA LIMITED BANGALURU

3
LOCATIONS OF PLANTS IN INDIA

Companies:- 5
Location:- 8
Plant:- 7

India Locations

FMG
Head Office
Parwanoo

Patiala
New Delhi

Delhi
Bearings Khandsa
Bhiwadi

Calcutta

Nagpur
FMG Sintered
(Bhiwadi)
Mumbai
Hyderabad
Pune

Automotive Chennai
Products
(Bhiwadi)
Bengaluru

Madurai

India Federal-Mogul Corporation 8

4
 COMPANY PROFILE:-

In 1979, FEDERAL MOGUL BEARINGS INDIA LIMITED formerly GABRIEL

and ANAND ENGINE COMPONENTS diversified into the manufacture of thin wall
engine bearings. The engine bearing division was set up in collaboration with Federal
Mogul Corporation, USA, and world leaders in the thin-wall bimetal engine
Parwanoo in the state of Himachal Pradesh. From the inspection, this division has
become place setter in its fields as the only one in India to manufacture the complete
range of Bimetal Bearing, Bushes and thrust washers from the raw material stage.

It has an in-house fully equipped chemical and metallurgical laboratory to ensure that
only the best quality product will leave the plant. Its other testing facilities include a
gauge room with high precision metrological equipment’s such as Talleyrand and
Surfandyer and also an engine testing dynamometer for evaluation of bearing
performance under actual conditions of fitment and operation. A new semi automatic
manufacturing facility has been added for aluminum, tin and lead bearings. Gabriel
produces Bimetal engine bearings, thrust washers and bushes with an annual capacity
of over 12 million numbers.

Over Rs.10 million have been invested in sophisticated R&D facilities for new
product development, process improvement and indigenous equipment design.
Federal Mogul’s most modern R&D center is available on an ongoing basis for testing
of new materials, products & processes.

Gabriel India’s coordinated development efforts ensure that the changing

requirements for the new generation applications for Automotive, Industrial,
Agriculture and Railway segments are met through continual product developmental
and up gradation.

The Anand Engine Components Parwanoo H.P. has been acquired by Federal Mogul
Corporation (USA). The name and all the policies of company have been changed.
The name is changed to Federal Mogul Bearings India Limited.

That only the quality product will leave the plant. A new semi automatic
manufacturing facility has been added for aluminum, tin and lead bearings. Federal
mogul bearing India ltd. Produces bimetals engines bearings, thrust washers and
bushes with an annual capacity of over 12 million numbers.

5
Over Rs 10 million have been invested in sophisticated R & D facilities for new
product development, process improvement and indigenous equipment

design. Federal mogul most modern R & D center is available on an ongoing basis for
testing of new materials, product and processes. Federal mogul bearing India ltd.
India’s coordinated development efforts ensured that the changing requirements for
the new generation’s applications for automotive, industrial, agriculture and railway
segments are met through continual product development and up gradation

1.1 VISION:
Be the leading supplier of filter solution in India and a global supplier of automotive
filters for both OE and Auto market applications.

1.2 MISSION:
CUSTOMER DELIGHTS – By providing superior products on time every time.
SHARE HOLDER DELIGHT – By providing better than market returns on investments.
EMPLOY DELIGHT – By providing opportunity to learn contribute and enjoy working in
FMIBL.

1.3 QUALITY POLICY:

Committed to service and achieve customer delight by meeting or exceeding their
expectation through effective quality management and continual improvements in: -
quality, cost, delivery, growth, and productivity.

1.4 ENVIRONMENT POLICY:

FEDERAL MOGUL BEARING INDIA LTD. is committed to prevent the generation
of waste. We believe al forms of wastes are detrimental to the environment. We all
combine with all regulation on environment & ensure that the usages of our products
have the least known impact on the environment.

1.5 HEALTH & SAFETY POLICY:

Federal mogul bearings India Ltd. is committed to achieve and maintains world-class
health & safety standards for all its employees. It shall be deployed through the first
key of FEDERAL MOGUL CORPORATION i.e. Health & Safety. We all develop
improve and sustain processes that will systematically eliminate health & safety
hazards.

6
 1.6 ABOUT THE OVERTAKER COMPANY:-
Federal – Mogul Corporation is an international leader in engine bearing technology.
It is the largest and most well known manufacture of engine bearings in the world. It
has highly sophisticated and modern R&D centers for the development and testing of
new bearing materials and manufacturing processes. Federal Mogul Bearings India
Ltd. has now entered into collaboration with Braunschweigner Huttenwerk-GmbII,
Germany. The new tie-up brings world-class expertise in the manufacture of large
sized and thin walled plain bearings, the first of its kind, to India. The new product
range for large size and thick wall bearings would cover a variety of applications
including:Plain bearings and bushes for diesel locomotives, stationery power
generation engines, marine diesel engines, compressors, turbines, gears, pumps and
blowers.Plain bearings for the cement industry, rolling mills and crushers.

2. ABOUT THE PROUCT

The main products of the FEDERAL MOGUL BEARING INDIA LTD. PARWANOO
are:
1. Plain sleeve Bearing.
2. Flange Bearing.
3. Washers.
4. Bushes.

Transmission
Connecting
Bush
Rod Bearing

Main Bearing Flange

Bearing
Fig.(2)Bushes places in
engine where

Fig.(1) Bearings places in engine where

7
 FEDERAL MOGUL BEARING INDIA PLANTS
OVERVIEW

With two manufacturing facilities in India which are TS certified,federal Mogul

Bearing also has an ultramodern BearingImpregnation plant, inParwonoo, the largest
of its kind in India.

ENGINE BEARING PLANT PARWANOO

8
FEDERAL MOGUL PLANT LAYOUT PARWANOO

9
 FEDERAL MOGUL CUSTOMERS

FEDERAL MOGUL ORIGINAL EQUIPMENT (OE)

CUSTOMERS

Ashok Leyland Bajaj Auto Caterpillar

Escorts Ford Force Motors

General Motors Honda Ingersoll Rand

Kirloskar Oil Mahindra &

Maruti Suzuki
Engines Limited Mahindra

Mitsubishi New Holland Punjab Tractors

Swaraj Mazda TAFE Tata Motors

10
FEDERA L MOGUL GLOGAL AFTE MARKET (GA) CUSTOMERS

11
2.1 ENGINE BEARINGS:
Bearings are devices used to transmit loads between relatively moving surfaces.
Bearings are used in all types of machinery, engines and mechanisms for supporting
and controlling the motion of the rotating, sliding or reciprocating parts. Shafts,
spindles or axles usually support the rotating parts. Bearings are designed to serve the
purpose with minimum friction, power loss, and generation of heat and are aided in
their requirement by suitable lubricants. Bearings are used in Automotive, Industrial,
Agricultural, Earth Moving, Marine and Stationary Engines among others. Bearings
that support the rotating shaft in a fixed position against loads acting perpendicular to
the axis of shaft only are called Radial Bearings. Those that support against loads
parallel to the axis of the shaft are called Thrust Bearings, while those, which resist
both radial and thrust loads, are called Angular or Radial-Thrust Bearings.

Bearings are of two types:

(A) Anti-Friction Bearings.

(B) Sleeve Bearings.

2.1 (A) ANTI-FRICTION BEARINGS:

These Bearings utilize Rolling Balls or Rollers to provide a Rolling Contact between
the surfaces. In an automobile, anti-friction Bearings are found in the Suspension,
Transmission and other parts of the Drive Train.

Figure 3: An anti-friction roller and ball bearing.

2.1 (B) SLEEVE BEARINGS:

The Sleeve Bearings are so called because they are shaped like a Sleeve and are
firmly held in place around a rotating Shaft, which results in a Sliding Contact. Sleeve
Bearings are found inside the Engine.

12
 Figure(4): Friction or sleeve bearing.

2.2 TYPES OF ENGINE BEARINGS:

Insert Bearings are manufactured in two basic configurations:

1. Full Round Insert Bearing

2. Split Insert Bearing

1. FULL ROUND INSERT BEARING:

The one-piece full Round Insert Bearing is used where it is possible to insert the
Bearings into place between the moving Engine part and the stationary Bearing
Housing. Camshaft Bearings are the Full Round types because the Camshaft can pass
through the inside of the Bearing.

2. SPLIT INSERT BEARING:

The Split insert Bearings must be assembled around the component because the
design of the component does not allow full round type of Bearing.

Crankshaft and Connecting Rod Bearings belong to this category. A Bearing Cap that
holds the whole assembly together holds these Bearings in place.

2.2 BEARINGS ARE USED IN THREE PALCES IN AN ENGINE: -

2.2 (A) CRANKSHAFT BEARINGS:

These are bearings used between the crankshaft and engine block. Most of these are in
split halves these are called main bearings. Upper and Lower are the two splits. Both
splits differ in design and manufacturing operations performed. These are as shown in
figure below.

13
 2.2 (B) CONNECTING ROD BEARINGS:

As the name suggests these are used between the crankshaft Pins and connecting rods.
All are in split halves. Generally there is no upper and lower category. Both splits
may have same design. These are shown in the engine assembly figure below.

Main bearing

Bush

Washer

Figure 5: Assembly of bearings in an engine. Flange bearing

2.2 (C) CAMSHAFT BEARINGS: -

These are used between camshaft and the engine block. Majorities of them are full
round. The crankshaft is held in place by main bearing caps, which are bolted to the
Engine block. The main bearing covers and supports the journals of the crankshaft. To
prevent the crankshaft from moving forward or backward, a thrust bearing is
provided. A thrust bearing has flanges on both sides to prevent the movement.

A connecting rod cap is used to hold the rod to the corresponding crankpin on the
crankshaft. Under normal operating conditions, the bearing and the moving parts it
supports does not touch. A film of oil is present between the shafts and bearing. Oil
holes in the bearing allow the lubricating oil to flow between bearing and the rotating
shaft.

14
Oil is pumped through the passages in the block to the camshaft and the main
bearings. Oil ways in the crankshaft from the main bearing journals allow reaching
the connecting rod bearings. As the journals rotate within their bearings, the
lubricating oil works its way to the outer edges of the bearings.

2.4 FUNCTIONS OF ENGINE BEARINGS:

Insert or Engine Bearings serve three important functions in an engine:

1. To Reduce Friction between moving surfaces.

2. To support the moving parts of an engine.
3. To serve as a replaceable wear surface.

TO REDUCE FRICTION BETWEEN MOVING PARTS:

Experiments have shown that dissimilar material against each other with less friction
and wear than similar materials. Thus, a Bearing made out of Copper, Aluminum, Tin
or Lead alloy does a better job of reducing friction between steel parts than a steel
bearing would. Also, the friction reducing

Capability of an insert Bearing depends on the addition of a Lubricant between the

moving part and the Bearing surface. In fact, a major objective of Bearing Design is
to establish and maintain a film of Lubricating Oil between the Surfaces.

2. TO SUPPORT MOVING PARTS OF ENGINE:

The second function of an engine Bearing is to support the moving engine parts of an
engine. This means that the Bearing must be able to stand up to the heavy loads
placed on it during engine operation and still allow the moving parts to operate freely.

3. TO SERVE AS REPLACABLE WEAR SURFACE:

The third function of an engine Bearing is to serve as a replaceable wear surface
between the moving engine parts. Although, the use of dissimilar metals and a film of
lubricating oil serve to reduce the friction between the moving engine parts, some
wear may still occur during engine operation.

15
3. PLANT STRUCTURE DETAIL

THE MANUFACTURING PLANT HAS FOLLOWING MAIN DEPARTMENTS

FOLLOWED BY PROCESS SEQUENCE OF BEARING MANUFACTURING.

PLANT
STRUCTURE

POWDER PLANT

SINTER LINE

SANDING
&ANNEALING
SECTION

PLANT 1
(MANNUAL PLANT
SECTION)

PLANT 2 (TOOL
ROOM SECTION)

PLANT 3
(CUMMINS LINE
SECTION)

PLANT 4
(AUTOLINE 1)

PLANT 5
(AUTOLINE2)

PLANT 6 (ALL
VENDORS)

LSB SECTION

PLATING SECTION

QUALITY AUDIT
DEPARTMENT

METALLURGICAL

GAUGE ROOM

PACKING
DEPARTMENT

DISPATCH
SECTION

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DIVISION OF MANUFACTURING CELLS
 POWDER PLANT
 SINTER LINE1&2&3
 FLANGE BEARING1&2
 BUSH LINE
 CON ROD CELL LINE
 MAIN BEARING LINE1&2
 AUTO LINE 1&2
 BLANKING CELL
 CUMMINS LINE
4. POWDER PLANT
There are three type of Powders are manufactured in the powder plant that is
1) HF – 2
2) HF – 16
3) HF – 24

Lining Composition Properties Application

Material

High physical strength, Piston pin, steering,

excellent resistance to track rollers,
CU – 80% pounding and shock, high- cylinders, wear plate
HF- 2 Sn – 10% load capacity, good wear high impact thrust
Pb – 10% resistance washers (hard shaft
desirable)
Very high fatigue and very Heavy- duty camshaft,
HF- 16 CU – 72% good Combines good electric motor,
Sn – 3.5% friction, embed ability, automatic
Pb – 23% compatibility with medium transmission,
load capacity, will accept hydraulic pump, gear
higher surface speed and changers
Heavy- duty engines,
HF- 24 Cu – 74.5% Very high fatigue and very pumps, compressors
Sn – 1% good corrosion resistance for soft and hard
Pb – 24.5% shafts.

17
The various equipments and their working are briefly describe as follows:

POWDER PLANT PROCESS

RAW MATERIAL TESTING

MELTING

MELTING

POURING

ATOMISING

DRYING

CLASSIFYING

BLENDING

POWDER TESTING

SINTERLINE

INDUCTION FURNACE:
Heat is generating by means of eddy currents. The furnace operates at 100 Hz and
800 Volts. It is hydraulically tilt, pneumatically covered and water-cooled. The
crucible has a capacity of 150 K.G. It is made of silicon carbide and can withstand as
much as eighty heats.

POURING CHAMBER:
18
It consists of a crucible made of silicon carbide, which is surrounded by refractory
bricks. There is gap between the refractory bricks called the annular gap. Burners
using mixture of compressed air and atomized diesel heat this crucible, commonly
known as ‘pouring crucibles’.

Two such burners are arranged around the circumference so that pouring crucibles
totally covered with flames of intense heat. Pouring crucible has three holes at its
bottom, which always lie in a straight line. The diameter of each hole is 9/64” and
pitch 1.24”. The time taken by crucible to empty itself of molten alloy is called
pouring time. The pouring time is an important parameter. Variation in time taken by
crucible to empty itself indicates the widening or clogging of the holes.

ATOMIZING TANK:

It is a large cylindrical vessel with cones at top and bottom. The top of the tank is
connected to the bottom of the pouring chamber. Atomization takes place in this tank
as high-pressure water jets strike the streams of the molten alloy. A manifold at the
top of this tank accommodates five nozzles on each side of these nozzles are fed with
high-pressure water and mounted at an angle of 10-15deg.

Water coming from the nozzle strikes the streams of molten alloy and converts it into
powder. Powder and water accumulates at the bottom of the pump, which is
connected to slurry pump. Centrifugal pump pumps out the excess water from the
atomizing tank to the other tank. The atomizing tank constantly fed with nitrogen to
check out oxidation of the powder. Pumping time, water pressure and temperature,
diameter of holes and their pitch are critical parameters.

DRYER:When the dryer is half full of slurry, it is rotated on its horizontal axis at 6
r.p.m. Steam at 150C and 5 Kgf/sq.cm enters the annular space provided between the
outer and inner walls of dryer. This process continues for 8-9 hrs vacuum is creating
to extract any stream or moisture left. The vacuum pump then runs for two hours, the
dryer is then allow to cool for 2-3 hrs after which the powder is transferred to
classifier at control rate.

CLASSIFIER:

It consists of two sieves of sizes 40 and 80 ASTM. The sieves are shaken and the
powder obtained is transferred to the blender. Coarse powder remaining on the sieves
is recycled for powder manufacture.

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BLENDER:The blender blends the powder for the formation of homogeneous
mixture. It is a closed vessel that rotates on its horizontal axis at 22 r.p.m. Blending is
the final stage of powder manufacturing.

HIGH PRESSURE PUMP:

It is a three-cylinder pump that receives water from buffer tank and delivers it at high
pressure to the manifold accommodating nozzles in the atomizing tank.

LOW PRESSURE PUMP:

It takes water from the buffer tank and pumps it to the bottom of the atomizing tank
for the formation of a good powder water mixture (slurry). Good slurry reduces the
chances of blockage and increases the effectiveness of a good slurry pump.

5. SINTER LINE

INTRODUCTION:

Sintering is a process of bonding solid particles by atomic forces. Sintering forces

tend to decrease with increase in temperature but obstruction to sintering viz.
incomplete surface contact; presence of surface films and lack of plasticity decreases
much more with increase in temperature. Thus increase in sintering time or
temperature results in stronger bond and greater tensile strength. But sintering must be
carried out at a temperature below the melting point of the constituent element with
least melting point.

Bond development involves diffusion of atoms where there is close contact between
adjacent particles. This leads to development of grain boundaries. Much increase in
strength and hardness results after relatively short exposure to high temperature. The
newly form grain areas are called ‘NECKS’ grow in size by next stage followed by
poor bonding.

STEEL:-
The steel back material, which is used to make the strip to manufacture the product,
must have the sufficient mechanical strength for retention and durability as well as
that required for holding shape and size. Also, it must be chemical and physically
suitable for bonding the lining. The steel back material specification and their use as
follows:
DEGREASING: - It is done with the help of alkaline solution of caustic soda
(alkaline 44 caustic Soda) two containers are filled with if and the third one is having
fresh water. The first two remove the grease and oil and the last one removes the soda.

20
SANDING: -
In the third step the degreased sheet is passed through the region containing a Sanding
belt of roughness 80 and from the other side the sheet is rolled again.
SINTERING PROCESS:

In this unit, the actual sintering operation is performed. The Sanded strip is mounted
over a decoiler. This Strip is further passed through a Straightner, which consists of a
number of rollers. These rollers are so placed that when the Steel Strip is passed
through them, the strip gets rid of all types of bends over it. Thus the Straightner unit
straightens the Strip.

The next operation is spreading of Powder over the Strip. This is performed with the
help of a spreader. This spreader consists of enough tools to control the spreading of
the Powder over the Strip in terms of:
1) Width
2) Loose Powder Thickness
3) Uniformity
The Strip with powder on it is passed through a furnace for the sintering take place.
This is performed in two stages:
1) First Sintering
2) Second Sintering

Both the sintering procedures are same but they are performed to
Strengthen the bond between the powder and the strip.
Sintering is a process of bonding solid particles by atomic forces. Sintering Forces
tend to decrease with increase in temperature but obstruction to sintering viz.
incomplete surface contact, presence of surface films and lack of plasticity

MACHINE CELL:-
This cell consists of various machines (mostly presses of different capacities and
SPM’S means special purpose machines) required for manufacturing of the bearing.
The input to the machine cell is sintered bimetallic strip. The sintered bimetallic strip
is firstly chopped into small blanks in the blanking presses.
These blanks are then formed & coined into the proper shape of the bearing & then
these shaped blanks undergo various manufacturing processes so as to be converted
into the required form & shape of the bearing half as per application. Whereas the
sequence of these processes is decided according to the type of the bearing to be

21
manufactured & the requirement of the customer. In this plant only straight bearings
& flange bearings are manufactured.
Below is given the Process Flow Charts for the manufacturing of Straight Bearings &
Flange Bearings. However the number of processes to be performed on the bearing
varies depending upon the application of the bearing for example: con rod bearing has
no groove & no hole, so we bypass these processes. Similarly, the processes that need
not to be performed on the bearing are bypassed. The Process Flow Charts for the
manufacturing of Straight Bearings & Flange Bearings are as follows: -
PROCESS FLOW CHART FOR STRAIGHT BEARING:-

BLANKING

FORMING & COINING

FACING & CHAMFERING

GROOVING

FIRST HOLE

LIPPING

SECOND HOLE

I.D. / O.D. C.SINKING

NOTCHING

LIP MILLING

CORNER CHAMFERING

I.D. BROACHING

PLATING

BAKING

HEIGHT BOACHING

22
PROCESS FLOW CHART FOR FLANGE BEARING:-
BLANKING

FLARING

COINING

COUNTER BORING

PRE HEIGHT

BAR TURN

I.D BORE

GROOVING

FIRST HOLE

LIP PUNCHING

SECOND HOLE

I.D. / O.D. C.SINKING

LIP MILLING

I.D. BROACHING

PLATING

BAKING

DEBURRING

SHEAR BROACH

POCKET MILLING

HEIGHT BROACHING

23
BLANKING AND STAMPING:
Blanking is defined as the process of cutting the strip into pieces of desired length and
these pieces are called blanks. Stamping is defined as the process of punching the
desired data (part no., Coil no.) on the blanks.
Both processes are carried out on the same machine know as blanking machine. It
consists of three parts – decoiler, straightner and blanker. The coil is brought to the
blanking machine after slitting. It is then mounted on the decoiler. It uncoils the coil
and pushes it into the straightner.
The straightner has the function of straightening the strip and pushing it into the
blanker. On the straightner there is a limit switch which controls the amount of strip
passing through the straightner.
Then the strip comes into the blanker where both blanking and stamping operations
are carried out. It has push roller which pushes the strip into the blanker for cutting
operation and the amount of the strip pushed into the blanker is equal to the width of
the blank required. The push rollers are controlled with the amount of offset with the
crank shaft.
The lower die acts as the holding device and the core attached to the ram acts as the
cutting tool. The stamp is also attached to the same ram as that of the core. The ram is
connected to the camshaft. The cam performs the function of converting the rotary
motion provided by the electric motor into the reciprocating motion of the ram. The
speed of the ram is adjusted in accordance with the material and thickness of the strip.

FORMING AND COINING:

It is the process in which the blanks after blanking operation are converted into the
semi circular shaped. After coining, it is not a perfect semi-circular but the edges are
at some angle. With forming it is completely turned into semi circular shape.
The machine used for this operation is called coiner. It consists of lower die which
acts as the holding device, core attached to the ram which acts as the cutting tool. The
ram is attached to the camshaft which converts the rotary motion provided by the
electric motor into the reciprocating motion of the ram. Both die and core are made of
high speed steel. The work piece is carried out of the machine with the help of the
conveyor belt.
The blanks are placed in the rack with the alloy upwards. The ram pushes the blanks
one by one into the die. The core attached to the ram performs the coining operation.
Then ram pushes it little further where forming operation takes place. Then the ram

24
pushes it out of the die and with the help of the conveyor it comes out of the machine
and stacking is done.
The engagement and disengagement of the clutch which is there between the camshaft
and the motor is pneumatically controlled.

FACING AND CHAMFERING:

Facing is the process of removal of the roughness from the sides of the work piece
and the chamfering is the process of cutting the sides at some acute angle so as to
remove its sharpness.
The machine used for this operation is called facing and chamfering machine. It is
pneumatically driven machine. It consists of four cutting tools on each side- 2 facing,
1 ID corner chamfer, 1 OD corner chamfer. In this machine the work piece is fed to
the moving tool. There are chucks on both the sides to hold the tools and shuttle
between both the chucks to hold the work piece. The chucks are rotated with the help
of electric motor and forward and reverse movement of the chucks and the upward
and downward movement of the shuttle is performed with the help of pneumatic
system.
The tools are made of High Speed Steel.
In this machine after setup the operator inserts the work piece in to the shuttle and
presses the buttons. The shuttle moves towards the tool and stops between the two
chucks. The chuck starts moving towards the work piece and starts the facing and
chamfering operation. With the help of bolts the amount of cutting is controlled.
There are limit switches to automatically pull the chucks back after the desired
amount of cutting is done. The lubrication system is also there for the lubrication of
machine components.

LIP PUNCHING:
It is the process in which a lip is punched on the work piece with the help of lip
punching machine. The lip is provided so as to hold the bearing in its position. It acts
as a lock and prevents any movement of the bearing. The machine used is called lip
punching machine. A lip punching machine gets the motion with the help of electric
motor. The work piece is held in the die and punch is there in the place where
punching is to be done.

The ram reciprocates with the help of cam mechanism on the rotating shaft. The shaft
is connected to a fly wheel through a clutch. The flywheel is further connected to

25
electric motor which imparts the rotary motion to the flywheel. The engagement and
disengagement of the clutch is done with the help of pneumatic system.
The operator sets the work piece in the lower and then presses the buttons. The clutch
gets engaged and thus leads to rotary motion of the shaft. The cam on the shaft makes
the ram to reciprocate. The ram press the bar present over the die which moves the
punch and thus punch performs the punching operation.

HOLE PUNCHING:
Hole punching is the operation in which a hole is punched in the work piece with the
help of hole punching machine. The hole is used as the entrance for the oil to lubricate
the bearing.
In hole punching machine the operation of the clutch and the ram is same as that of lip
punching machine. But the die and the tool are different from that of lip punching.
The die acts as the holding device and it is such that the work piece when placed in
the die, the place where hole is to be punched comes under the ram. The tool is
attached to the ram and covered with the rubber material.

The operator sets the work piece in the die and engages the clutch. The ram with the
tool punches on the work piece thus creating a hole on the work piece. The scrap
comes out through a slot inside the die and is collected at the back of the machine.
There is rubber provided around the tool which performs the function of stopping the
work piece from getting stuck in the tool.

LIP MILLING:
Lip milling is the operation of removal of burr from the lip of the work piece. The
machine used for this operation is called lip milling machine. It is an automatic
machine i.e. the operator just inserts the pieces and collects them after lip milling
operation is done.
In this machine the work piece is fed to the rotating tool. In this machine there is a
rack to hold the work piece. The rotation to the tool is provided with the help of
electric motor. The work piece is clamped but the help of clamp which is
pneumatically driven and is sensor controlled. The movement of the tool in upward
and downward direction is controlled with the help of sensor and is pneumatic driven.

The operator performs the setting of the machine as per the requirement. Then
operator places the work piece in the rack. The pusher ram pushes the work piece one
by one toward the tool. The clamp there holds the work piece and thus does not allow
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any movement. The sensors senses and starts moving the tool in the upward direction,
the tool performs the milling operation and cuts as per the setting and then it moves in
the downward direction. Then same process carries on. The conveyor automatically
stacks the work pieces and the operator collects them from the end of the conveyor.

GROOVING:
It is the operation in which a way is created for the entrance of the lubricating oil in
the bearing. From the hole a path is required for the oil to completely lubricate the
bearing.
There are three type of grooving. These are:
a) Partial Grooving
b) Full Grooving
c) Milling
d) DB Groove

a) Partial Grooving: This kind of grooving is done on the lower bearing which
allows the flow of oil in the lower bearing.
b) Full Grooving: This kind of grooving is done on the upper part which allows
flow of the oil from hole to all parts of the bearing.
c) Milling: It is the type which is done on the lower half which creates path for
the oil flow in lower part.
d) As per customer requirements.

The type of grooving is done based on the requirement given by the customer.
The machine used for this operation is known as grooving machine. In grooving
machine tools rotate and the work piece is stationary. The grooving bits are the
cutting tool and the die is the holding device. The vertical movement of the cutting
tool is controlled with the help of hydraulic system. The rotary motion to the cutting
tools is provided with the help of the electric motor. The amount of the cutting is
controlled with the help of bolts and hydraulic system for vertical motion is controlled
with the help of limit switches.

The operation performs the required setting and places the work piece in the die. Then
operator presses the button which hydraulically moves the cutting tool towards the
work piece. The limit switch automatically makes the hydraulics push the cutting
tools upward after the required cutting is done.

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CORNER CHAMFERING AND WIRE BRUSH:
The process of creating a chamfer at the edge of the work pieces is called corner
chamfering and the process in which the work piece is passed through wire brush is
called wire brushing. The corner chamfering is done in order to avoid the formation of
burr at the work pieces after height broaching operation and wire brush is done in
order to remove the rust from the bearings.
The machine used for this operation is called corner chamfer & wire brush machine. It
consists of both corner chamfer part and wire brush part. In corner chamfer there is a
cutter which rotates with the help of electric motor and there is a supporting belt
which moves above the cutter. The work piece is made to pass between the belt and
cutter. The belt resists the work piece from upward movement and also pushes it out
of the corner chamfering machine. In wire brush machine there is one wire brush
made of copper and supporting roller. After the work piece get wire brushed the
conveyor belt takes the work piece to stacking table.

COUNTER SINKING:
After the hole punching operation there is burr produced near the hole on the both
sides of the work piece. The operation for the removal of burr is called counter
sinking.
The machine used for this operation is drilling machine. The holding device is the die
and cutting tool is drill. The rotary motion to the drill is provided with the help of
electric motor and the vertical movement of the drill is controlled with the help of
handle.
The operator set the die for outer diameter c/sinking and inner diameter c/sinking
separately and the drills are also separate. The operator places the work piece on the
die and moves the drill in the downward direction. Only small amount of cutting is
done just to remove the burr. The inner diameter and outer diameter counter sinking
are done separately.

HEIGHT BROACHING:
It is the process of removal of material from the tip of the work piece thereby making
the final height of the work piece as per the requirement. In this process the tips of the
work piece as made smooth and also the height of the bearing is maintained.
The machine used for this operation is called height broaching machine. In this
machine work piece is fed to the moving tools. The tools are attached to the ram the
subjects of the motion by electric motor and is connected to the motor through

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flywheel. The ram is connected to the flywheel through clutch which is pneumatically
controlled. The ram is partially constrained to move in only one direction so it only
performs the reciprocatory motion. There is a clamp which holds the work piece in
the die and does not allow any movement of the work piece.
The operator performs the desired setting and then places the work piece into the die
and when operator press the button the clutch gets engaged and the ram reciprocate
once with the help of limit switch. The tool under the ram performs the cutting
operation thereby the height broaching operation is done.

INNER DIAMETER (ID) BROACHING:

It is the process of removal of the material from the inner diameter of the surface to
make the thickness of the bearing as per the requirement. In this process the internal
diameter is increased by removing the excess material thus decreasing the thickness of
the bearing. The machine used for this operation is called inner diameter broaching
machine. It consists of ram which is connected to flywheel through the clutch which
is pneumatically controlled. The flywheel is connected to the electric motor which
imparts rotary motion to the flywheel and the motion of the ram is partially
constrained thus the ram reciprocates. Below the ram is attached the cutting tool
which performs the broaching operation. The die acts as the holding device.
The operator makes the setting as per the requirement. Then operator places the work
piece in the die. When the operator press the button to engage the clutch then the ram
reciprocates just once. The one reciprocation is controlled with the help of the limit
switch. The tool broaches the inner diameter and thus inner diameter broaching is
done.

PLATING DEPARTMENT

INTRODUCTION:

Plating is a process of covering the bearings with the coating of Lead, Tin and
Copper. The thickness of coating applied on the bearing is about .01 inches. The
bearing to be plated is first of all degreased in the degreaser, which is described
ahead. In the degreaser the oil from the bearing is removed, so that the plating can be
done efficiently. There after to remove rough surfaces the bearing are put in tumbler.
After degreasing and tumbling the plating is done by the help of the plating machine,
which composed of various parts containing solution according to the need for
plating, and is described in the section to be followed In plating process the first thing
which take place is cleaning of bearing ion the alkaline bath and thereafter washed in
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water tank and passes through HCl bath and then again there is water bath. Then
comes nickel bath where nickel is applied to the bearing surface as it has large
cohesive force that help it to firmly stuck to bearing and also ensures the plating of
Lead, Tin and Copper (LTC) on the surface. Now the main bath that is LTC bath
comes, in which coating is of Lead, Copper and Tin, which is applied on the bearing,
surface. At last bearing is dipped in Tin bath, which provides shinning to the bearing.
Plating section layout is shown below.

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MAINTENANCE DEPTT:-

Maintence is defined as the act of maintaining or the state of being maintained or we can also say
that the work of keeping something in proper condition; upkeep is called maintenance.

In the industry all the functions are interrelated & it is very necessary to control / maintain these
functions for their effective & efficient working. The following diagram shows the basic
structure of the machine, so to keep the machine in proper condition these functions should be
upkeep, for which the maintenance department is responsible in an industry.

TYPES OF MAINTENANCE:

There are a number of types of maintenance which are performed at the Industry: Maintenance
operations have been categorized based on their frequency and their motivating factors. Four of
the most common designations are described below - predictive, preventative, corrective and
Breakdown

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Predictive maintenance involves a series of steps prior to actually performing maintenance. It
begins with sampling physical data over time, such as vibration or particulate matter in oil.
Analysis is then performed on the collected data to create an appropriate maintenance schedule,
and maintenance is performed according to the schedule. This type of maintenance analysis
works well for mechanical systems because the failure modes are well understood. Additionally
there is historical data useful for creating and validating performance and maintenance models
for mechanical systems.

Preventative maintenance refers to maintenance performed when a system is functioning

properly to prevent a later failure. Generally, it is performed on a regular basis and the
maintenance will be performed regardless of whether functionality or performance is degraded.
The frequency of the maintenance is generally constant, and is usually based on the expected life
of the components being maintained, but there is not necessarily any monitoring occurring at the
same time (as there would be in predictive maintenance). One common example is lubrication of
mechanical systems after a certain number of operating hours. Another is replacement of
lightning arresters in jet engines after a certain number of lightning strikes.

Corrective maintenance refers to maintenance done to correct a problem when something has
failed, or is failing. The need for corrective maintenance can be beneficial or detrimental
depending on the product and the profit model used during the design phase of the product. On
the most obvious level, corrective maintenance is detrimental to operation because it means that
something failed, and the system is (probably) not available during the time needed to perform
the maintenance. On the other hand, it may be that the economics and planned functionality of a
system are such that using a cheaper, replaceable device for which failure is anticipated, makes
sense.

Breakdown Maintenance

Activities associated with the repair of site features, building and plant or equipment, which
have become inoperable or unusable due to failure of component parts.

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