hitesh nbc report

Upload: saurabh-meena

Post on 14-Apr-2018

245 views

Category:

Documents


5 download

TRANSCRIPT

  • 7/29/2019 Hitesh Nbc Report

    1/51

    Page 1

    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.

  • 7/29/2019 Hitesh Nbc Report

    2/51

    Page 2

    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.

  • 7/29/2019 Hitesh Nbc Report

    3/51

    Page 3

    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

  • 7/29/2019 Hitesh Nbc Report

    4/51

    Page 4

    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/
  • 7/29/2019 Hitesh Nbc Report

    5/51

    Page 5

    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/
  • 7/29/2019 Hitesh Nbc Report

    6/51

    Page 6

    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.

  • 7/29/2019 Hitesh Nbc Report

    7/51

    Page 7

    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.

  • 7/29/2019 Hitesh Nbc Report

    8/51

    Page 8

    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.

  • 7/29/2019 Hitesh Nbc Report

    9/51

    Page 9

    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.

  • 7/29/2019 Hitesh Nbc Report

    10/51

    Page 10

    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.

  • 7/29/2019 Hitesh Nbc Report

    11/51

    Page 11

    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.

  • 7/29/2019 Hitesh Nbc Report

    12/51

    Page 12

    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.

  • 7/29/2019 Hitesh Nbc Report

    13/51

    Page 13

    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.

  • 7/29/2019 Hitesh Nbc Report

    14/51

    Page 14

    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).

  • 7/29/2019 Hitesh Nbc Report

    15/51

    Page 15

    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.

  • 7/29/2019 Hitesh Nbc Report

    16/51

    Page 16

    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

  • 7/29/2019 Hitesh Nbc Report

    17/51

    Page 17

    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

  • 7/29/2019 Hitesh Nbc Report

    18/51

    Page 18

    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

  • 7/29/2019 Hitesh Nbc Report

    19/51

    Page 19

    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

  • 7/29/2019 Hitesh Nbc Report

    20/51

    Page 20

    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

  • 7/29/2019 Hitesh Nbc Report

    21/51

    Page 21

    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.

  • 7/29/2019 Hitesh Nbc Report

    22/51

    Page 22

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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
  • 7/29/2019 Hitesh Nbc Report

    23/51

    Page 23

    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
  • 7/29/2019 Hitesh Nbc Report

    24/51

    Page 24

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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.

  • 7/29/2019 Hitesh Nbc Report

    25/51

    Page 25

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    26/51

    Page 26

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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.

  • 7/29/2019 Hitesh Nbc Report

    27/51

    Page 27

    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.

  • 7/29/2019 Hitesh Nbc Report

    28/51

    Page 28

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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)
  • 7/29/2019 Hitesh Nbc Report

    29/51

    Page 29

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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:

  • 7/29/2019 Hitesh Nbc Report

    30/51

    Page 30

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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%

  • 7/29/2019 Hitesh Nbc Report

    31/51

    Page 31

    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

  • 7/29/2019 Hitesh Nbc Report

    32/51

    Page 32

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    Bore finishing

    COMPUTERIZED NUMERIC CONTROL(CNC) M/C

  • 7/29/2019 Hitesh Nbc Report

    33/51

    Page 33

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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:

  • 7/29/2019 Hitesh Nbc Report

    34/51

    Page 34

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    Heat Treatment Process

    Chugai Ro Heat Treatment Furnance

  • 7/29/2019 Hitesh Nbc Report

    35/51

    Page 35

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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.

  • 7/29/2019 Hitesh Nbc Report

    36/51

  • 7/29/2019 Hitesh Nbc Report

    37/51

    Page 37

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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)

  • 7/29/2019 Hitesh Nbc Report

    38/51

    Page 38

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    39/51

    Page 39

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    40/51

    Page 40

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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.

  • 7/29/2019 Hitesh Nbc Report

    41/51

    Page 41

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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.

  • 7/29/2019 Hitesh Nbc Report

    42/51

    Page 42

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    43/51

    Page 43

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    44/51

    Page 44

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    (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)

  • 7/29/2019 Hitesh Nbc Report

    45/51

    Page 45

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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:-

  • 7/29/2019 Hitesh Nbc Report

    46/51

    Page 46

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    47/51

    Page 47

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    If

    Bar

    Slug cutting or shear cutting

    Up setting

    Pre - punching

    Finish Punching

    Rolling

    Forming and finish rolling

    Sizing and calibration

    Dimensional

    Inspection

  • 7/29/2019 Hitesh Nbc Report

    48/51

    Page 48

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    GRINDING MACHINE

  • 7/29/2019 Hitesh Nbc Report

    49/51

    Page 49

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    GRINDING

    Centre less Grinding

    Figure 2 Centreless Grinding

    Cone Track Grinding

  • 7/29/2019 Hitesh Nbc Report

    50/51

    Page 50

    GYAN VIHAR SCHOOL OF ENGINEERING & TECHNOLOGY ,JAIPUR

    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

  • 7/29/2019 Hitesh Nbc Report

    51/51

    Page 51

    Bearing Designation