hitesh nbc report
TRANSCRIPT
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
ACKNOWLEDGEMENT
As a part of our graduation degree in engineering, I underwent training from 1june 2012 to
30june 2012 at NATIONAL ENGINEEERING INDUSTRIES LIMITED, JAIPUR for a period of 30
days.
I shall in my duties if I do not acknowledge thanks to Ms. Monika Joshi , Assistant
Manager(HR) of National Engineering Industries Limited, Jaipur with whose permission my
training in the factory was made possible.
I wish to express appreciation for taken keen interest taken by the engineers, workers of
different Departments in explaining of various machines and for important valuable
information regarding their operations etc.
I also acknowledge thanks to my fellow student for discussing various points during the
course of training which proved very useful in preparing this project.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
PREFACE
A very important element in curriculum of an Engineering student is the Practical Training.
We underwent practical training at NATIONAL ENGINEERING INDUSTIES LIMITED, JAIPUR
from 1-06-2012 to 30-06-2012. This is a part of total 30 days training program incorporated
in the curriculum of the Gyan Vihar College of Engineering & Technology for B.Tech. course.
As we are the students of Mechanical Engineering so the training at NBC has been
particularly beneficial for us. We saw the various procedures, processes and equipment
used in production of railway bearing which were studied in books.
The student wishing that private sector undertaking success so that it may flourish and
serve the nation which has reached 61 years of its independence and has to achieve many
goals.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
CONTENT
1.INTRODUCTION2.COMPANY PROFILE3.INTRODUCTION OF PRODUCTS4.MANUFACTURING PROCESS OF BEARING5.BALL BEARING DIVISION6.BEARING DESIGNATION7.ABOUT THE QUALITY IN NEL8.MY OBSERVATION9.CONCLUSION
10.REFERENCES
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
INTRODUCTION
THE GROUP
C.K.Birla group is a diversified conglomerate with interests spanning across industries such
as Cement, Consumer Electricals, Precision Bearings, Heavy Engineering Products, Paper,
Building products, Automobiles, Auto components, Healthcare, Education & ITES. With a
combined turnover of over US $ 1.8 billion and over 20,000 employees, manufacturing and
service footprint across India, and track record of successful partnerships with global
leaders; the CK Birla group strives to deliver enduring value to stakeholders. The group
extends social welfare activities to communities, especially, around its industrial units while
strengthening the social infrastructure through education and healthcare initiatives as part
of its social responsibility.
The group companies include
AVTEC Limited Birlasoft Limited GMMCO Limited Hindustan Motors Limited Hyderabad Industries Limited Indian Smelting & Refineries Limited Orient Paper and Industries Limited Special Engineering Services Limited Nigeria Engineering Works Limited Rivers Vegetable Oil Company Limited
http://www.avtec.in/http://www.birlasoft.com/http://www.gmmco.in/http://www.hindmotor.com/http://www.hil.in/http://www.indiansmelting.com/http://www.orientpaperindia.com/http://www.newclime.com/http://www.rivoc.com/http://www.rivoc.com/http://www.newclime.com/http://www.orientpaperindia.com/http://www.indiansmelting.com/http://www.hil.in/http://www.hindmotor.com/http://www.gmmco.in/http://www.birlasoft.com/http://www.avtec.in/ -
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
Education Institutions
Birla Institute of Technology Modern High School for Girls Rukmani Birla Modern High School
Healthcare Institutions
The Calcutta Medical Research Institute B. M. Birla Heart Research Centre
Arts and Science Centers
The CK Birla Groups not-for-profit initiatives cover Science, Temples, Art and Archaeology
and are aimed at building the social infrastructure in the communities we serve.
The B.M. Birla Science & Technology Centre, Jaipur, The B.M.Birla Planetariums at Jaipur,
Chennai and Hyderabad, B.M. Birla Museum, Ujjain, B.M. Birla Science Museum and the G.P.
Birla Observatory & Astronomical Research Centre, Hyderabad are institutions that seek to
get the mysteries of science and astronomy within the reach of the common man.
The Birla Temples at Hyderabad, Jaipur and Bhopal are archaeological marvels. The Birla
Archaeological & Cultural Research Institute, Hyderabad, Birla Institute of Art & Music,Bhopal, The B.M.Birla Archaeological Museum and Modern Art Gallery, Hyderabad and the
many renovation initiatives at renowned religious and historical places are a testimony of
the CK Birla Groups commitment to Art and Architecture.
http://www.bitmesra.ac.in/http://www.mhsforgirls.edu.in/http://www.rbmhsjaipur.com/http://www.cmri.in/http://www.birlaheart.org/http://www.nbcbearings.in/1CK-Birla-Group.htmhttp://www.nbcbearings.in/1CK-Birla-Group.htmhttp://www.birlaheart.org/http://www.cmri.in/http://www.rbmhsjaipur.com/http://www.mhsforgirls.edu.in/http://www.bitmesra.ac.in/ -
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
COMPANY PROFILE
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.
The three plants situated at Jaipur, Newai and Manesar manufacture these products
with approx. 2300-strong team, supported by a well-equipped R&D with bearing life
testing facility.
NEI Ltd. has been awarded the coveted 2010 Deming Application Prize, by the Union of
Japanese Scientists and Engineers (JUSE), Japan, for achieving distinctive performance
improvement through the application of Total Quality Management (TQM).The Deming
medal confirms that our quality management systems are one of the best ,globally .For
our customers, this means enjoying consistently superior products and assurance of
highest quality National Engineering Industries Ltd., part of the 150 year old, multi-
billion dollar C.K. Birla group manufactures a wide range of bearings for automotive and
railway industry as well as for general industrial applications under the brand name nbc
. NEI, founded in the year 1946 as a pioneer industry in the field of bearing
manufacture, now manufactures nearly 80 Million Bearings per annum in over 500
different sizes ranging from 6 mm bore to 1300 mm outer diameter having capability to
manufacture bearing upto 2000 mm. diameter.
NEI is one of the largest domestic bearing manufactures with gross annual turnover of
Rs. 1051 crore in 2010-11. The company exports bearings to more than 20 countries and
is also exporting to OEMs in Europe and USA. NEI has grown at a CAGR of 19% since
2007-08.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
The company having three plants situated in India these plants
with their specialties are:
(I) PLANT AT JAIPUR
(i). Ball Bearing
Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are
manufactured on state of the art manufacturing facilities with in-process and
post-process gauging in grinding and centrally air conditioned assembly lines
with auto gauging and testing equipments. The latest advanced techniques for
manufacturing and Quality Assurance are implemented to meet the rapid
increase in demand for Quality, diversity of specifications and new types of
bearings.
This Division is spread over a covered area of 14,694 Sq. Meters.
(ii). Steel Ball
Precision Steel Balls up to 25 mm diameters for NBC Bearings are manufactured on
precision grinding and lapping machines to achieve super finished surface, accuracy and
roundness as per ISO standards.
This Division is spread over a covered area of 4,700 Sq. Meters.
(iii). Tapered Roller Bearing
Precision Tapered Roller Bearings are manufactured in Inch and Metric series from
15.875mm bore to 95.25mm bore with technology obtained from our earliercollaborator, Federal Mogul Corporation, USA and now with NTN Corporation, Japan.
These bearings are used by all major Automobile manufacturers in the country as
Original Equipment.
This Division is spread over a covered area of 11,652 Sq. Meters.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
(iv). Railway Bearing
(a)Roller Bearing in Axle Box
With the production of Roller Bearings and Axle Boxes since 1952, the company has fully
met the requirements of the Indian Railways (one of the largest systems of the world) by
designing and developing Axle Boxes and bearings for fitment to Locomotives
manufactured by Diesel Locomotive Works , Chittaranjan Locomotive Works, various
wagon builders, the ICF broad and meter gauge coaches. Over a million NBC bearings
and boxes are in service with the Indian Railways. The development of completely
indigenised Axle Boxes and bearings for the high speed Rajdhani Locomotive, the
Yugoslavian and Egyptian Railway wagons are the highlights of the design capabilities at
NEI.
On date more than 100 types of Axle Boxes & Bearings have been manufactured.
(b)Spherical Roller Bearing
The manufacturing of Spherical Roller Bearings was started in the year 1975-76 for
fitment to broad gauge and meter gauge passenger coaches with designs, technology,
machines and equipment procured from the collaborators.
(c)Cartridge Tapered Roller Bearing
For fitment to the new BOX-IN Uprated Wagons designed by the RDSO, NEI is the only
manufacturer in the country to indigenise these bearings to a high percentage under
collaboration with the largest manufacturer of these bearings in the world. Production
of these bearings commenced in the year 1984. These bearings are grease packed and
require no field lubrication for a period of 7 years.
This Division is spread over a covered area of 4,855 Sq. Meters.
(v). Large Diameter Bearing
Self-sufficiency in steel is the call of the day, so is the importance of bearings in Steel Mills
Equipment. NEI has the distinction of being one of the ten manufacturers of these bearings
in the world, who can manufacture large diameter bearings up to 2000 mm diameter.
The largest bearing manufactured by NEI for fitment to the Plate Mill of Rourkela Steel Plant
was released by Mr. G.P. Birla in September 1985. This 4-Row Tapered Roller Bearing
measures 1300 mm dia and weigh 4.39 tons.
The large diameter bearings are mainly manufactured out of case carburising steel, heat
treated on special equipment and furnaces developed by NEI. Precision grinding is done to
close tolerances on CNC Twin Spindle Programmable Berthiez Machine for bearings ranging
from 500 to 2000 mm diameter with electronic sizing and numerical display.
Production of these bearings started in 1975 and to date over 100 different types of special
large diameter bearings have been manufactured and successfully used, saving considerableforeign exchange for the country.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
(II) PLANT AT GUNSI (NEWAI)
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.
Meters.
(III) PLANT AT MANESAR
NEI has set up its third Ball Bearing manufacturing plant in the fastest growing industrial
town of Manesar in Haryana. The plant is having a covered area of 5200 sq. meters. 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.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
COMPANY DEFINITION
Industry can be defined as:
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:
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.
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
- SKF Sweden
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.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
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 industries and other mechanical
Industrial users. The replacement market is dominated by unorganized Sector.
NATIONAL ENGINEERING INDUSTRY LIMITED(NEI)
Bearing in India started with the setting up of manufacturing unit in JAIPUR by the Birla
Group in 1946 under the name of "National Bearing Company Ltd."
The 1st Bearing was manufactured in 1950 with a modest start of 30 thousand bearing in 19
Sizes. The Bearing Races (Soft) was Manufactured by the Tiny Unit in the Small Scale Sector
at Jaipur during 1970 on Job Work basis.
It is a view to utilize the end piece of the Stainless steel tube which could not be fed to the
Multi operation of National Engineering Industries Jaipur.
There after there is a continuous growth of this Industry and now it has grown to a level that
Almost All the Leading Manufacturer of the country are procuring Soft Bearing Races fromJAIPUR. The National Engineering Industries procure lakhs of Ring every month from these
Bearing Race Manufacturing Unit.
The other leading manufacturer like S.K.F., FAG, TATA Bearing, NBC are also procuring the
Bearing races from Jaipur. In addition to above, the Small Scale Units manufacturing Bearing
in the state of Rajasthan, Delhi, Gujarat and Punjab also purchasing Bearing Races and
components from Jaipur.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
QUALITY MANAGEMENT
ISO / TS 16949
NEI extensively embarked upon system improvement and implemented modern concepts of
Total Quality Management. NEI has been awarded TS 16949: 2002 on 17th October, 2003-
THE MARK OF EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by BVQI for design,
development, manufacture & supply of Ball Bearing, Tapered Roller Bearing and Cylindrical
Roller Bearings. NEI Ltd. is the first bearing industry in India to have been recommended for
TS 16949: 2002.
This certificate is awarded to only suppliers of automobile manufacturers. NBC bearings are
used by all major auto OE customers in India like Maruti Udyog, Hero Honda, Bajaj Auto,
Bajaj Tempo, TVS Motors, Ashok Leyland, Tata Motors, Hindustan Motors, Yamaha Motors,
Eicher Limited, Eicher Motors, Mahindra & Mahindra Auto & Kinetic Motors etc.
In addition customers like Eicher Tractors, Punjab Tractor, Escort Tractor, International
Tractors, New Holland Tractors, Electric & Pump Motors, Crompton & Orient Fans and many
more in Automobile, Electric Motors & Pump, Fans, Conveyors, Steel Plants, Thermal Plants
also use NBC bearing regularly.
The recommendation was made by BVQI after 15 days of detailed audit in all areas of NEI
including our Gunsi plant.
TS 16949 quality management system is based on ISO 9001 in which many supplementary
and additional requirements of automobile industries have been incorporated. TS quality
management system in NEI starts with identification of all customer requirements and ends
with ensuring that all customer requirements have been fulfilled. This also requires
continuous improvement in all areas.
Every process is critically studied and performance indicators for measuring output of those
processes defined. Measurement of efficiency and effectiveness of every process only
decides how ably the process has been performed. Simplicity, effectiveness & efficiency of
processes, error proofing and continuous improvement in processes thus become the
highlight of TS quality management system.
NEI is complying latest version of ISO/TS16949 standard.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
ISO 9001
NEIs Large dia bearing division and railway bearing division which are manufacturing
Cylindrical Roller Bearings, spherical roller bearings, cartridge tapered roller bearings,
railway rolling stock and spares has also been awarded to ISO 9001: 2000 on 9th October,
2003 by BVQI.
NEI is complying latest version of ISO 9001 standard.
ISO 14001
NEIs everlasting concern for cleaner, pollution free environment has made the NEI to go on
the path of Environmental management System. NEI was awarded ISO -14001 certificate by
BVQI in the month of March 2000 for Environmental Management System. NEI has done
tremendous efforts in resource conservation, recycling and thick plantation. The efforts at
NEI have saved precious natural resources like water, oil and power etc.
NEI is complying latest version of ISO 14001 standard.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
AWARDS
NEI has been awarded with many Biz-awards in its tenure till date. Some of recent
awards won by the company are :
1. Winner of DEMING PRIZE 2010.2. Grand Award for Cost in 2009-10 from Honda Motorcycle & Scooter
India Pvt. Ltd.
3. Award for TPM Excellence Category-A in 2009.4. Vendor Performance Award in 2008-09 for Overall Commendation.5. Certificate of Appreciation in 2008 from Maruti Suzuki India ltd.6. Award for Challenge India Support (Engine Group) in 2003-04 from7. Excellence Award in 2003 from IES.8. The 4India Pro User Award 20029. Award for Excellence in 2001-02 from MICO Bosch Group.10.Excellence in Performance in 2001-02 from Motors industries Co. ltd.11.
The 3India Pro User Award 2001.
12.Indian Pro User Award 1999.13.Winner of Certificate of Excellence in Industrial Equipment Category
from PTC.
The company is now preparing for the INDIAN MANUFACTURING EXCELLENCEAWARD 2011(IMEA).
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
RESEARCH & DEVELOPMENT
R&D is equipped to introduce new technology in the field of bearings and related products
.All functions from concept design to product launch are an integral part of R&D . The
activity begins from customer interaction by Application Engineering and QFD approach is
used to understand customer requirements to translate into a useful product . It has a full
fledged test centre for endurance as well as application testing .The test lab is being
expanded to double the capacity in next four years.
Advanced functions like Tribology ,Simulation ,Materials Technology and Lubrication
technology have been added .The centre relies on the associate strength that has vast
experience in the bearing industry . Academics excellence is being promoted by inclusion of
specialists from IITs and RECs .The centre will be a leading technology centre in next 4 to 5
years.
NEI stands committed to an endless journey of continuous improvement through TQM.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
CLIENTS
1.2 wheelersBAJAJ AUTO
YAMAHA MOTORS LIMITED
KINETIC ENGINEERING
KINETIC MOTORS
HERO MOTOCORPS
ENFIELD INDIA
TVS MOTOR INDIA(P)LTD
HMSIL
MAJESTIC AUTO LIMITED
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
2.3wheelersBAJAJ AUTO
FORCE MOTORS
SCOOTERS INDIA
LIMITED
MAHINDRA &
MAHINDRA LTD.
ATUL AUTO
LIMITED
3.Cars, jeepsMARUTI UDYOG LIMITED
HINDUSTAN MOTORS
FORCE MOTORS
MAHINDRA & MAHINDRA LTD.
ASHOK LEYLAND
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
4.TRACTORSESCORTS
FORCE MOTORS
EICHER MOTORS
MAHINDRA & MAHINDRA LTD.
PUNJAB TRACTORS
TAFE
NEW HOLLAND
VST TILLERS
FORCE MOTORS
EICHER MOTORS
HINDUSTAN MOTORS
MAHINDRA & MAHINDRA LTD.
TATA MOTORS LTD
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
HMT TRACTORS
SONALIKA
International Tractors Ltd
5.RAILWAYSINDIAN RAILWAYS
I.Production Units for Locomotive and passenger coaches:
Chittaranjan Locomotive Works Diesel Locomotive Works Diesel Loco Modernization Works Intergral Coach Factory
Rail Coach Factory
II.All Zonal Railways
III.Wagon Builders
BESCO Ltd. Bharat Wagon and Engg.Ltd. Bharat Wagon and Engg.Ltd. Braithwarte & Compay Limited Bridge & Roof Burn Std. Company Limited Hindustan Engineering Industries JESSOP & Co. Ltd. Modern Industries Ltd. Texmaco Limited Titagarh Wagon Ltd.
BRENCO INC., USA
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
6.LARGE DIAMETER BEARINGMAHARASHTRA STATE ELECTRICITY BOARD
MADHYA PRADESH POWER GENERATION COMPANY LTD.
CHATTISGARH STATE ELECTRICITY BOARD
INDRAPRASTH POWER GENERATION CO. LTD.
RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD
TAMILNADU STATE ELECTRICITY BOARD
PUNJAB STATE ELECTRICITY BOARD
UTTAR PRADESH VIDYUT UTPADAN NIGAM LTD.
TATA POWER, MUMBAI
NATIONAL THERMAL POWER CORPORATION
STEEL PLANTS:
SAIL, BOKARO STEEL PLANT,BOKARO
SAIL,ROUERKELA STEEL PLANT, ROUERKELA
SAIL,DURGAPUR STEEL PLANT, DURGAPUR
SAIL,BHILAI STEEL PLANT, BHILAI
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
INTRODUCTION OF PRODUCT
A bearing is a device to allow constrained relative motion between two or more parts, typicallyrotation 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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TYPES OF BEARING
There are many different types of bearings.
Type Description Friction Stiffness
Speed Life Notes
Plain
bearing
Rubbing
surfaces,
usually with
lubricant; somebearings use
pumped
lubrication and
behave similarly
to fluid
bearings.
Depends on
materials
and
construction,
PTFE hascoefficient of
friction
~0.05-0.35,
depending
upon fillers
added
Good,
provided
wear islow, but
some
slack is
normally
present
Low to
very high
Low to very high -depends upon
application and
lubrication
Widely used,
relatively high
friction,
suffers from
stiction in
some
applications.Depending
upon the
application,
lifetime can
be higher or
lower than
rolling
element
bearings.
Rolling
element
bearing
Ball or rollers
are used to
prevent or
minimize
rubbing
Rollingcoefficient of
friction with
steel can be
~0.005
(adding
resistance
due to seals,
packed
grease,
preload andmisalignment
can increase
friction to as
much as
0.125)
Good,
but some
slack is
usually
present
Moderate
to high
(often
requires
cooling)
Moderate to high
(depends on
lubrication, often
requires
maintenance)
Used for
higher
moment
loads than
plain bearings
with lower
friction
Jewel
bearing
Off-center
bearing rolls in
seating
LowLow due
to flexingLow
Adequate
(requires
maintenance)
Mainly used
in low-load,
high precision
work such as
clocks. Jewelbearings may
http://en.wikipedia.org/wiki/Stiffnesshttp://en.wikipedia.org/wiki/Stiffnesshttp://en.wikipedia.org/wiki/Plain_bearinghttp://en.wikipedia.org/wiki/Plain_bearinghttp://en.wikipedia.org/wiki/Stictionhttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Jewel_bearinghttp://en.wikipedia.org/wiki/Jewel_bearinghttp://en.wikipedia.org/wiki/Jewel_bearinghttp://en.wikipedia.org/wiki/Jewel_bearinghttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Rolling_element_bearinghttp://en.wikipedia.org/wiki/Stictionhttp://en.wikipedia.org/wiki/Plain_bearinghttp://en.wikipedia.org/wiki/Plain_bearinghttp://en.wikipedia.org/wiki/Stiffness -
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
be very small.
Fluid
bearing
Fluid is forced
between two
faces and held
in by edge seal
Zero friction
at zero
speed, low
Very high
Very high
(usuallylimited to
a few
hundred
feet per
second
at/by
seal)
Virtually infinite
in some
applications, may
wear at
startup/shutdown
in some cases.
Often negligible
maintenance.
Can fail
quickly due to
grit or dust or
othercontaminants.
Maintenance
free in
continuous
use. Can
handle very
large loads
with low
friction.
Magnetic
bearings
Faces of bearing
are kept
separate by
magnets
(electromagnets
or eddy
currents)
Zero frictionat zero
speed, but
constant
power for
levitation,
eddy
currents are
often
induced
whenmovement
occurs, but
may be
negligible if
magnetic
field is quasi-
static
Low
No
practical
limit
Indefinite.
Maintenance
free. (with
electromagnets)
Active
magnetic
bearings
(AMB) need
considerable
power.
Electro
dynamic
bearings
(EDB) do not
require
external
power.
Flexure
bearing
Material flexesto give and
constrain
movement
Very low LowVery
high.
Very high or low
depending on
materials andstrain in
application.
Usually
maintenance
free.
Limited range
of movement,no backlash,
extremely
smooth
motion
Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct
from the friction of the bearing.
Table 1: Types of bearing
http://en.wikipedia.org/wiki/Fluid_bearinghttp://en.wikipedia.org/wiki/Fluid_bearinghttp://en.wikipedia.org/wiki/Magnetic_bearingshttp://en.wikipedia.org/wiki/Magnetic_bearingshttp://en.wikipedia.org/wiki/Electromagnethttp://en.wikipedia.org/wiki/Eddy_currenthttp://en.wikipedia.org/wiki/Eddy_currenthttp://en.wikipedia.org/wiki/Electromagnethttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Flexure_bearinghttp://en.wikipedia.org/wiki/Flexure_bearinghttp://en.wikipedia.org/wiki/Frictionhttp://en.wikipedia.org/wiki/Frictionhttp://en.wikipedia.org/wiki/Flexure_bearinghttp://en.wikipedia.org/wiki/Flexure_bearinghttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Electrodynamic_bearinghttp://en.wikipedia.org/wiki/Electromagnethttp://en.wikipedia.org/wiki/Eddy_currenthttp://en.wikipedia.org/wiki/Eddy_currenthttp://en.wikipedia.org/wiki/Electromagnethttp://en.wikipedia.org/wiki/Magnetic_bearingshttp://en.wikipedia.org/wiki/Magnetic_bearingshttp://en.wikipedia.org/wiki/Fluid_bearinghttp://en.wikipedia.org/wiki/Fluid_bearing -
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PRODUCT RANGE
A BROAD RANGE BORN OF PRECISION
From a few mms to thousands of mms, from a few grammes to a few tonnes, the NBC range is
hard at work in some of the most critical areas of Indian industry.
BALL BEARINGS
The initial technology was from Hoffman Manufacturing Company
Ltd., U.K. a collaboration, which continued for 20 years.
We offer a wide range of both metric and inch series deep grooveball 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 technology i.e. thermo mechanical
bearings (TMB) and tensioner bearings available today and our
wide range of ball bearings is increasing under this collaboration.
TAPERED ROLLER BEARINGS
Manufactured at an ultra modern plant, with technology obtained
from our earlier collaborators, Federal Mogul Corporation, USA
and now with NTN Corporation, JAPAN, these bearings are used
by all major automobiles, truck and tractor manufacturers in the
country as original equipment.
SPECIFICATION
M244249A/N1060 (Bore 220.662 mm x OD 314.325 mm x Width
61.912 mm) Suspension Bearing developed for Indian Railways for
GM Locomotive WDG-4
N1059/M244210 (Bore 221.17 mm x OD 314.325 mm x Width
61.912 mm) Suspension Bearing developed for Indian Railways
GM Locomotive WDG-4.
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SPHERICAL ROLLER BEARINGS
Originally developed in collaboration with Swiss leaders FAG-SRO.
Vital for broad gauge and meter gauge coaches manufactured by
ICF, Chennai and RCF, Kapoorthala for the Indian Railways. Now
new sizes are being developed with the help of NTN Corporation,
JAPAN.
SPECIFICATION
22312D1 (Bore 60 mm x OD 130 mm x Width 46 mm)
22312KD1 (Bore 60 mm x OD 130 mm x Width 46 mm)
22314D1 (Bore 70 mm x OD 150 mm x Width 51 mm}
22314KD1 (Bore 70 mm x OD 150 mm x Width 51 mm)
22222 (Bore 110 mm x OD 200 mm x Width 53 mm)
22222KD1 (Bore 110mm x OD 200 mm x Width 53mm)
ROLLER BEARING AXLE BOXES
Developed by NBC for the Indian Railways for use in rolling stocks.
Excellent performance even in the high speed Rajdhani
locomotives, the Yugoslavian and Egyptian Railway wagons.
A total of 34 different types of the axle boxes are turned out at the
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NEI plant in Jaipur. Designs for high speed railway application are
being developed together with NTN. More than one million NBC
axle boxes and roller bearings are in operation with Indian
Railways. We have the privilege of being the single largest source of
bearings to Indian Railways, which is one of the largest networks of
its kind in the world.
CARTRIDGE TAPERED ROLLER BEARINGS
Successful Track record in the Railways for the past 30 years, these
require no field lubrication. Developed in collaboration with
BRENCO Inc. USA, these bearings are being used in all broad gauge
wagons of Indian Railways.
PRECISION STEEL BALLS
Manufactured using the most modern facilities available in India,
Quality steel balls, upto 25 mm in diameter for NBC bearings are
manufactured in precision lines imported from NTN Corporation,
JAPAN. NBC ball bearings are now specially manufactured with
high precision steel balls produced in ultra modern plant equipped
with high speed headers, electronically controlled flashing,
grinding, and lapping machines to ensure accuracies of sub-micron
levels.
LARGE DIAMETER BEARINGS
We have the distinction of being one of the few bearing
companies in the world to manufacture bearings upto 2000 mm
outside diameter developed with indigenous technology. Bringing
Shri B.M. Birla's vision of self-reliance to fruition, NBC large
diameter bearings contribute to steel production and thermalpower generation in India.
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
CYLINDRICAL ROLLER BEARINGS
NH318 (Bore 90 mm x OD 190 mm x Width 43 mm) Traction Motor Bearings
NU1964 (Bore 320 mm x OD 440 mm x Width 56 mm)
Suspension Bearing developed for Indian Railways for WAG-9 Locomotive
NH1044 (Bore 220 mm x OD 340 mm x Width 56 mm)
Suspension Bearing developed for Indian Railways for WAG-9 Locomotive
SUSPENSION TUBE KIT ASSEMBLY
Suspension tube kit assembly developed for Indian Railways for GM
Locomotive WDG-4
LARGE DIAMETER BEARING
Large dia. bearings are designed in such a way that vertices of the cone for each roller andthose 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 large dia. 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. Large Dia. Bearing enables the shafts to take heavier axial load.
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The bearings are of separable type, enabling separate mounting of cups and cones. Since
the Large Dia. 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.
Besides, double row and four row large dia. bearings are also widely used for heavy loads
such as rolling mills.
The inner and outer ringracewaysare segments ofconesand the rollers are also made with
a taper so that the conical surfaces of the raceways and the roller axes if projected, would
all meet at a common point on the main axis of the bearing.
This conical geometry is used as it gives a larger contact patch, which permits greater loads
to be carried than with spherical (ball) bearings, while the geometry means that the
tangential speeds of the surfaces of each of the rollers are the same as their raceways along
the whole length of thecontact patchand no differential scrubbing occurs. When a rollerslides rather than rolls, it can generate wear at the roller-to-race interface, i.e. the
differences in surface speeds creates a scrubbing action. Wear will degenerate the close
tolerances normally held in the bearing and can lead to other problems. Much closer to pure
rolling can be achieved in a tapered roller bearing and this avoids rapid wear.
The rollers are guided by a flange on the inner ring. This stops the rollers from sliding out at
high speed due to their momentum.
The larger the half angles of these cones the larger the axial force that the bearing can
sustain.
http://en.wikipedia.org/wiki/Race_(bearing)http://en.wikipedia.org/wiki/Race_(bearing)http://en.wikipedia.org/wiki/Race_(bearing)http://en.wikipedia.org/wiki/Cone_(geometry)http://en.wikipedia.org/wiki/Cone_(geometry)http://en.wikipedia.org/wiki/Cone_(geometry)http://en.wikipedia.org/wiki/Contact_patchhttp://en.wikipedia.org/wiki/Contact_patchhttp://en.wikipedia.org/wiki/Contact_patchhttp://en.wikipedia.org/wiki/Contact_patchhttp://en.wikipedia.org/wiki/Cone_(geometry)http://en.wikipedia.org/wiki/Race_(bearing) -
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Large Dia. Bearings have the following components: outer ring, inner ring, and roller
assembly (containing the rollers and a cage). The non-separable inner ring and roller
assembly is called the cone, and the outer ring is called the cup. Internal clearance is
established during mounting by the axial position of the cone relative to the cup.
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:
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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 HollowTubes.
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.
Bearing Races material and their heat treatment are required to be selected carefully, taking
account the mechanical strength and required life of the Bearing,
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
CAGE'S
Cage is used to return balls at proper distance to prevent them from containing each otherand 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%
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GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR
MANUFACTURING PROCESS OF LARGE DIA. 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
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Bore finishing
COMPUTERIZED NUMERIC CONTROL(CNC) M/C
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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 8400
C and further chamber contains the 8500
C temperature.
Then it dipped into an oil tank at temperature 25
0
C where the material get quenched then itwashed and then it tempered in water about 90 min. at temperature 105
0C . then dried and
cooled in air. The hardened material is obtained.
The systematic flowchart is shown in following fig:
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Heat Treatment Process
Chugai Ro Heat Treatment Furnance
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Hardening Procedure
Steel Material
LC Steel (Low Carbon Steel)
Table 1 Hardening
Process Carburizing Hardening Quenching Tempering
Procedure
Carbon Furnace
heating at
940
0
C - 950
0
C
Furnace
temperature at
8500 C 8700 C
Fast cooling 600 C
for oil
quenching only
Heat the
Furnace at 1650
C-1800 C
Hardness .200 - .250 ------ 60 64 HRC 52 62 HRC
Time 8 10 hours 35-60 min.
According to the
job.
5-15 min. 120-180 min.
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Annealing
(6 hrs.) (6500C)
Shot Blasting
Hardening II
(Revolving Furnace)
(8200C) (Time Dependent on Job)
Sub-Zero Treatment
(-600C) (Increases Toughness)
Tempering
(1600C) (4 hrs.)
Shot Blasting
(Wheel Abrator)
Hardness Inspection
(60 HRC)
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After heat treatment following process are done:
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.
Size Limit : UCL +35 m
: LCL -35 m
Width Variation : 5 m
There are various semi-automatic face grinding machine installed in taper section for cone
1. DAISHO MACHINE
2. NISSEI MACHINE
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. Rough12. Rough23. Fine finish
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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.
M1 0.7 ID1 - X
M2 2.1 ID 2 - X
M3 -2 TAPER
M4 -0.2 ID1 - Y
M5 1.6 ID 2 Y
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M6 0.9 OVALITY
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.
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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-PRO2. 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 upstrokepowered 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.
DemagnetizerIt 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.
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Press checking:
At this station, the bearing is checked whether its assembly is pressed properly or not.
Final checkingThis 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.
Laser Marking System
A Laser marking system marks a highly visible mark on the job without touching it.
Job Number NBC INDIA Date Code
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Important parts
a) Markerb) Controllerc) Water-cooled Unitd) Filter Kite) Consolef) Control Panelg) Mechanical Handing System
The Laser is produced with the help of a diode which is focused on the job by using a lens.
The Laser beam produces a external high thermal energy; this thermal energy marks a dark
mark on the job extra thermal energy is then absorbed through the cooling system.
Thus, in this form the laser beam produced from a diode marks a dark mark on the job.
With the help of the machine customer requirements like; customer code, part number etc.
can be marked accordingly.
Ball Bearing Division
Wire
(High Chromium Steel)
Heading Machine
Flashing (Rough Grinding)
(Scale : 0.01-10mm) (High Grind Oil + H2O)
Soft Grinding
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(Scale : 0.001-1mm) (High Grind Oil + H2O)
Heat Treatment
Work Hardening Tumbler
(60 HRC)
Hard Grinding (G2)
Finish Grinding (G3)
(Kerosene)
Rough Lapping (L1)
Finish Lapping (L2)
Ultra Sonic Washing Machine
(Kerosene)
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Visual Inspection
Anti-Rust Oil Packaging
Maxi Grind Oil + H2O and High Grind Oil +H2O (Coolant)
Ring Rolling Mill
In this section ring blanks are produced with solid steels bars by forging process.
A systematic process of ring rolling shop may be as follows:-
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VIEW OF CALIBRATION PRESS:-
Figure 1 Calibration Press
Another flow chart for ring rolling operation may be drawn as follows:-
Raw material (Bar/slug)
Induction heatingIf
Bar
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If
Bar
Slug cutting or shear cutting
Up setting
Pre - punching
Finish Punching
Rolling
Forming and finish rolling
Sizing and calibration
Dimensional
Inspection
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GRINDING MACHINE
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GRINDING
Centre less Grinding
Figure 2 Centreless Grinding
Cone Track Grinding
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Causes of Step in Cone
a) Baking plate is not properly aligned in accordanceb) Width of Grinding Wheel is Lessc) Width of Cone Track is mored) Undercut Width is less.
Cartridge Roller Bearings Components
a) Cone Assemblyb) Cupc) Spacerd) Wear Ringe) Grease Sealf) Axel and Cupg) Axel Cup Screwh) Locking Platei) Backing Ring
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Bearing Designation