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.
Bearings And Bearing Metals: A Treatise Dealing with Various Types of Plain Bearings, the Compositions and Properties of Bearing Metals, Methods of Insuring Proper Lubrication, and Important Factors Governing the Design of Plain Bearings