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INDUSTRIAL TRAINING PRESENTATION

NATIONAL BEARING CORPORATION


PRESENTED BY :
SURAJ SINGH MEHTA
VEDANT SHARMA
CONTENTS

OBJECTIVES
COMPANY PROFILE
TECHNOLOGY AND R&D
BEARINGS : TYPES
TAPERED ROLLER BEARING
MANUFACTURING PROCESS OF TAPER ROLLER
BEARING:
HEAT TREATMENT PROCESS
DIFFERENT PROCESS FOR CONE
DIFFERENT PROCESS FOR CUP

OBJECTIVE
The main objective of this training is to learn different
engineering processes and to develop skills and with that
attitude I had done my engineering training with NBC
Bearings Ltd.
In this one month training period I had seen different work
and key responsibility of various bearings department.
Training was started with brief introduction program of NBC
Bearing Ltd. and plant visit of different department.
It was such a great experience to learn various engineering
production methods used now a days & to better correlate
the theoretical knowledge with practical observations and
understandings
COMPANY PROFILE
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 14001standards. 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

Facilities
The company has three manufacturing facilities located at Jaipur, Newai and
Manesar. The company will be investing Rs 500 crore for expansion in existing facilities
and the setting up of a fourth plant.The fourth plant at Savli, near Vadodara, is about
to commence production. A machine building plant at Jaipur reconditions as well as
assembles specific work units.The employee strength is 2500 across three plants.
Market
It is the second-largest Original Equipment Manufacturer (OEM) bearings to
all the leading companies of India and abroad . In addition, the company
exports bearings to more than 21 countries including OEMs in Europe and
USA.Being one of the largest exporters of bearings from India, around 50
percent of its exports are for railways.

Capacity
NBCs current capacity is to make 100 million bearings annually across its
three plants. NEI aims to double the production capacity in next seven
years.The NBC brand commands a market share of 24% in the domestic
market. Approximately 70% of NEI's sales are to original equipment
manufacturers and 30% into the replacement market.
The turnover approximates 60% from the auto sector (OEM and aftermarket),
30% for railway products and 10% from the low volume industrial
applications. The ability to meet customers needs from product concept
resulted in development of 60 new products in the year.


Clients
The client portfolio includes Indian Railways, Hero MotoCorp, Maruti Suzuki,
Tata Motors, Mahindra & Mahindra, Daimler AG, Bajaj Auto and Honda
Motorcycle & Scooter India.

Products
NEI manufactures bearings in about 1000 different sizes.The size of bearings
manufactured by NBC ranges from 25 mm to 1.3 metre Outer Diameter.
Ball bearings
Steel ball bearings
Tapered roller bearings
Railway bearings
Large diameter bearings
Technology

NEI uses a heat treatment machine (furnace) from Chugairo,
Japan.
The grinding technology is sourced from Izumi of Japan, Nova of
Italy, LMT of Sweden and FMT of Italy.
NEI operates 22 grinding lines out of which 17 are used for Deep
Groove Ball Bearing (DGBB) and five are used for Double Row
Angular Contact (DRAC) Bearings.
NEI is also provided technical assistance by NTN (Japan) and
Amsted Rail (Brenco, USA).
Research and Development


NEI invests in R&D activities. Currently, the company has developed a low
torque bearing that can reduce friction up to 20%, which results in fuel
efficiency. The product was developed as a result of understanding the
various torque contributors to the bearing such as grease, seal and
internal bearing geometry.
The low torque grease has been developed by various fundamentals on
tribo-meter along with design of low torque seal and optimization of
internal geometry to improve fuel efficiency. The company spends 1% of
its turnover on R & D activities with an eye on increasing it to 2% in
coming years. The department is staffed by 115 experts and the new
facility built in 2006 is in active growth mode. Thanks to the effort, 12
patents applications have successfully been made last year.
The research work has been split into tribology (the lubrication science),
advanced materials, advanced processes, product design, virtual
simulation and testing. For simulation of actual work conditions there are
35 test rigs, which include four for railways.
BEARINGS
A bearing is a machine element that constrains relative motion between
moving parts to only the desired motion. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free
rotation around a fixed axis; or, it may prevent a motion by controlling the
vectors of normal forces that bear on the moving parts. Many bearings also
facilitate the desired motion as much as possible, such as by minimizing
friction. Bearings are classified broadly according to the type of operation,
the motions allowed, or to the directions of the loads (forces) applied to the
parts
TYPES OF BEARINGS
Rolling Contact Bearings load is transferred
through rolling elements such as balls, straight
and tapered cylinders and spherical rollers.

Journal (sleeve) Bearings load is transferred
through a thin film of lubricant (oil).

Rolling Contact Bearings

Load is transferred through elements in rolling
contact rather than sliding contact.

Journal (Sleeve) Bearings

Load is transferred through a lubricant in sliding
contact

Tapered Roller Bearing

Tapered roller bearings are designed in such a way that vertices of the
cone for each roller and those for the inner and outer raceways coincides
on the bearing axis or extensions of the raceways and rollers converge at a
common point on the axis of rotation. This results in true rolling motion of
the rollers on the raceways at every point along the rollers.
The tapered roller bearings support radial loads and axial loads from one
direction only. The line contact between rollers and raceways provide the
bearings with a high load carrying capacity. Steep angle tapered roller
bearing with exceptionally steep cone angle enables the bearings to take
heavier axial load.
The bearings are of separable type, enabling separate mounting of cups
and cones. Since the tapered roller bearings can absorb thrust loads in
one direction only, these bearings should generally be installed as
opposed mountings. The correct amount of radial and axial clearance is
obtained by adjusting the two bearings against each other.



Designed to withstand high radial loads, high thrust loads, and
combined loads at moderate to high speeds. They can also
withstand repeated shock loads.

RAW MATERIAL:
The Races & Rolling elements of Bearing are subjected to
stress on a very small contact surface must be of such material
also as to with stand wear and have high elastic Limit &
fatigue Limit. The raw material being used by the Industry for
Manufacturing of various Bearing components are as under:

CUP AND CONE:
The raw material used in the Manufacturing of bearing Races
is SAE 52100 high Carbon Chrome bearing steel, which has
composition similar to EN-31 (100 CR 6 As per BIS
specification). The raw material for Bearing Races is in the
form of Rods & Seamless Hollow Tubes.

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

2 CAGE'S:
Cage is used to return balls at proper distance
to prevent them from containing each other
and to prevent a temperature rise and
resultant damage due to friction.
The Material for manufacturing cages is CRCA
Strips of C2015 Bearing grade steel having
carbon percentage at0.08% max. and
Magnesium ranging from 0.25% to 0.45%


MANUFACTURING PROCESS OF TAPER ROLLER BEARING:
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
Application for Rust Preventive
Ready For Dispatch to Assembly
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 600 C, then send to a
chamber where the material heated in four chambers the first chamber has the
temperature 8400 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.
flowchart of heat treatment
DIFFERENT PROCESS FOR CONE:-
Dimensions Checking
Before starting the grinding process, various dimensions of cone should be checked in
a machine or manually. Various dimensions to be checked are:
Flange diameter
Cone width
Cone track diameter
Bore diameter

Face Grinding
Face is the surface at side of the inner and outer race , face should be finished
indeed to get the desire width of the bearing and since the bearing is a
mating part and it has to be assembled somewhere in the machine where it
should be fit precisely. The face grinding is done in a machine where the faces
are grinded in between the grinding wheel.

OD (Outer Dia.) Grinding
OD is the circumferential surface of the outer race of the bearing. The OD should be
surface finished since the bearing has to be assembled in machine. It is obtain in an
OD grinding machine. In this machine the outer race is rotated between two grinding
wheel. The outer race is passed in machine three times to get highly finished as
follows:
1. Rough1
2. Rough2
3. Fine finish
Size Limit : 15 to 35 m
Target Size : +30 m

Flange Grinding
The flange should be surface finished since the bearing has to be assembled in
machine. It is obtain in the flange grinding machine. In this machine one grinding
stone is used to cut and grind the flange portion of cone.
NC Mode - AUTO
Feed Mode - AUTO
Override - 120% (used to change machine speed.)
Tool movement during grinding is in all three dimensional axes i.e. X, Y, Z axis.


Bore Grinding
Bore is the inner circumferential surface of the bearing. The bore
should be surface finished since the bearing has to be assembled in
machine. It is obtain in the bore grinding machine. In this machine
the grinding stone is moved in X and Y axis.
Size Limit : +4 m to -4 m.
TOOL movement during grinding is in only two dimensional axes i.e.
X, Z axis.

Auto Dimension Check
Various dimensions of cone are checked in this machine. This
machine includes various sensors for sensing the dimension of
cone. This machine use weight sensors and position sensors to
identify the position and weight of cone. All dimensions should be
checked in this machine.]
It automatically discards the work piece if its dimensions are not
compatible with pre-feed data.

The limitations of size are:

Size limit : +4 m to -4 m.
Taper : 5 m maximum
OOR : 5 m maximum
Chatter : 3 m maximum
Squareness : 5 m maximum


Honing Machine
Honing is an abrasive machining process that produces a precision
surface on a metal work piece by scrubbing an abrasive stone against it
along a controlled path. Honing is primarily used to improve the
geometric form of a surface, but may also improve the surface texture.
DIFFERENT PROCESS FOR CUP

OD Grinding
OD is the circumferential surface of the outer race of the bearing.
The OD should be surface finished since the bearing has to be
assembled in machine. It is obtain in an OD grinding machine. In
this machine the outer race is rotated between two grinding wheel.
The outer race is passed in machine three times to get highly
finished as follows:
Rough1, Rough2, Fine finish.
Size Limit : 15 to 35 m
Target Size : +30 m

Honing Machine
Honing is an abrasive machining process that produces a precision
surface on a metal work piece by scrubbing an abrasive stone
against it along a controlled path. Honing is primarily used to
improve the geometric form of a surface, but may also improve the
surface texture.

Assembly line:
Once respective CUP and CONE of corresponding bearing is
finished, they are sent in the Assembly line where these cup and
cone get assembled with retainers having rollers in them and after
some important test, they are finally packed and are ready for use.

Laser Printing Machine
It is a machine which is used for marking purpose of the company brand
and specification on respective cup or cone. This technology utilizes laser
beam for marking. The movement of laser beam is controlled by
automatic 3d table movement. The point on metal surfaces where these
laser beams hits leave marks as required. Names of few Laser Machine
which are installed in Taper Bearing Section are:
1. AKSHAR FIBER-PRO
2. SAJIAJANAND Laser Technology ltd

Roll Filling Machine:
It is an automatic machine which is actuated by pneumatic technology. In
this machine, first Retainer is placed on first station where rollers are
inserted at there respective position. Then they are sensed by position
sensor, actuated by pneumatic and then cone is fixed within cage.

Pressing Machine:
It is an automatic machine which is actuated by pneumatic and hydraulic
technology both. The Cone is pressed against Retainer with downstroke
powered by hydraulics and upstroke powered by pneumatics.

Weight check:
At this station, Weight of bearing is checked and if the weight is not
compatible with the given standard of weight limits, machine will reject
the workpiece sample.

Demagnetizer:
It is a machine which is used to remove magnetism induced during the
above process. It is done by impact hitting.
Washing:
Then the bearing is washed by fast stream of kerosene jet.

Noise checking:
The bearing is supposed to be produce low noise hence this
machine rotates the bearing at certain rpm and noise is
checked. The noise limit is nearby 0.1 Mpa.

Press checking:
At this station, the bearing is checked whether its assembly is
pressed properly or not.

Final checking
This machine has 2 or 4 stations where various dimensions of
final bearing are checked. If any bearing is found incompatible
with the given dimensions and tolerances, they are rejected by
the machine.
In ideal position 1, width of bearing, runout and commet or clearance
of bearing is checked. And at ideal position 2, bore size, taper and
roundness are checked.
All those bearings which does not have compatible size and tolerance
with the given data, they are rejected by the machine itself.
Ideal position 1 : width, run out, commet
Ideal position 2 : bore size, bore taper, bore
roundness


Oiling and Drawer Machine:
In this machine, bearing is subjected to a fast flowing
stream of coolant which is used to lubricate the bearing
parts. And then the excess oil is again sucked by the
machine.

Visual Inspection:
Now, the bearing is checked manually by the operators.
All the dimensions and surface properties are checked
and rejected workpiece are sent again for correction.

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

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