Winter Internship Project
CARRIED OUT AT “NATIONAL ENGINEERING “NATIONAL ENGINEERING INDUSTRIES LTD. JAIPUR [RAJASTHAN] [RAJASTHAN]” In Taper Roller Department On Project Study of Different Parameters of Taper Roller Bearings Submitted towards the partial fulfilment of Bachelor of Technology In Mechanical engineering 2013-2017 From School of Mechanical Engineering Lovely Professional University Punjab
Submitted By Manish Kumar Registration No. – No. – 11307508 11307508 Section- 1304
ACKNOWLEDGEMENT
As the technologically advancement will enable us to get the environment we desire. The basic beatitude, bliss, euphoria & our endeavour to achieve complete and perfect knowledge in the field we choose that accompany the successful completion of any task would not be complete without the expression of appreciation of simple virtues to the people who made it possible. So, with reverence honour I acknowledge all those guidance and encouragement has made successful completion of training. I am thankful to Mr. Rajesh Sharma, Taper Roller Department, NEI Ltd., Jaipur for his constant cooperation and able guidance & without his support this work would not have been so understable. I am also thankful to Mr. Gurkeerat Singh, Department Head, Taper Roller Department, NEI Ltd., Jaipur for his constant motivation and able support to guide us throughout the training. I am also thankful to Mr. Vineet Sharma, Head, HR, NEI Ltd., Jaipur for providing us an opportunity to train and work with with their esteemed organization. organization. I am also thankful to Mr. Nitin Chauhan, Assistant Professor, School Of Mechanical Engineering, Mechanical Department, Lovely Professional University, Punjab who is always mentor to us.
I am also very thankful to all respected persons who have directly or indirectly helped me in my earnest effort to accomplish this training.
PREFACE
The Engineering curriculum is designed in such a way that student can grasp maximum knowledge and can get practical exposure to the corporate world in minimum possible time. Engineering schools of today realize the importance of practical knowledge over the theoretical base. The research report is necessary for the partial fulfilment of engineering curriculum and it provides p rovides an opportunity to the researcher in understanding the industry with special emphasis on the development of skills in analysing and interpreting practical problems through the application of engineering theories and techniques. It is a new platform of learning through practical experience. It gives the learner an opportunity to relate the theory with the practice, to test the validity and applicability of his classroom learning against real life engineering situations. Working under this project I have gained the knowledge about whole bearing industry. Here I have learnt about the use of bearing in different sectors and I have also gained knowledge about the application of No. of bearings in a single vehicle and how a supply chain management plays a vital Role in the success of the economy and various other industries.
Table of Contents S. No. 1 2
Contents Chapter: One Introduction Company Profile
Page No. 7 8-15
Chapter: Two 3 4 5 6 7
History & Evolution of Bearings Classification of Bearings Failure of Bearings Indian Bearing Industry Global Bearing Industry
17-18 19-20 21-23 24
Chapter: Three 8 9 10 11 12 13 14 15 16 17 18
Flow of Material in Bearing Industry Bearing Materials Bearing designation Taper Roller Bearings Process Flow chart of Cup Process Flow chart of Cone Process of Heat Treatment Process of Grinding Roller Manufacturing Cage Manufacturing Assembly
26 27 27 28-31 31-32 32 33-37 37 37-38 39 40-41
Chapter: Four 19 20 21 22 23
Research Methodology Projects Undertaken Conclusion Summary Bibliography
43 43-64 65 66 67
Chapter: One Introduction & Company Profile
INTRODUCTION The current size of the global bearings industry stands at whopping `3 trillion, as per data released by Industry experts. With the Indian economy undergoing rapid industrialization, the industry has doubled in the last five years and has registered annual gains well above the global average of ~35%. With increased infrastructure and industrialization, at least, this trend should continue for next five years. India is among the fastest growing markets for bearings. Close to 40% of the total demand is fulfilled through imports with the balance being met by indigenous products. As the Indian infrastructure develops and the industry modernizes, we can see tremendous opportunities opening up for the bearings industry. In the near future, customers will look for better and cleaner technologies, hence necessitating necessitating aftermarket services including maintenance of equipment, reliability monitoring, remanufacturing so as to keep their equipment running efficiently and for long. Moreover, the Indian economy which is driven largely by the domestic demand was not only spared of the worst of the downturn but also very ver y well placed to make the most of the upturn. As the government increases its thrust on the infrastructure build, the economic growth will accelerate. National Engineering Engineering Industries Ltd.oneof Ltd.oneof the largest manufacturer manufacturer of Ball and Roller Roller Bearin gs, Steel Balls and Axle Boxes complete with Roller bearing in India, which are being produced in factories factories at Jaipur and Newai. Bearings are manufactured for every possible application and requirement of modern engineering engineering industry and we continue to develop new sizes, keeping pace with rapid advancement in the Indian engineering industry. industry. NEI’s technical collaborations with the world’s leading conglomerates in the field of bearing bearing technology viz. M/s NTN Corporation of Japan, M/s BRENCO incorporated of USA have given a whole new dimension to the product range and a quality par excellence. NEI has already implemented implemented modern concepts of Total Quality Management and accredited QS9000 and TS16949 certification, NEI has also been awarded Association of American Railroads (AAR) for AAR certificate M-1003 for Cartridge Tapered Roller Bearing in Feb 04-05. NEI has also been awarded ISO-14001 certificate for its concern and commitment towards a cleaner environment. NEI has successfully implemented im plemented SAP-ERP to re-engineer and integrate business processes to conform to world class standards.
COMPANY PROFILE
National Engineering Industries Limited (NEI), the flagship company of US$ 1.6 Billion CK Birla Group, was founded in the year 1946 under the name of ‘National Bearings Company Limited’. Over its seven decade long history, it has gone from strength to strength on the back
of sound business practises, manufacturing capabilities and technology collaborations with Brenco (now Amsted Rail), NTN and Izumi. NEI is recognized recognized today as a pioneer brand in the Indian bearings bearings industry. NEI boasts boasts of four world class manufacturing facilities located at Jaipur, Newai (both in Rajasthan), Manesar (Haryana) and Savli (Vadodara). The company currently manufactures nearly 150 million bearings per annum. Its product range r ange currently comprises of bearings across categories such as Ball, Taper Roller, Double Row Angular Contact (DRAC), Cylindrical Roller & Spherical Roller Bearings. The company has specially equipped facilities to manufacture axle boxes for railway applications, Cartridge Taper Roller Bearings and Large Dia. Bearings for industrial applications. NEI is capable of developing bearings from 6mm bore to 2000mm outer diameter, over a 1000 sizes. NBC Bearings are widely used by manufactures of 2 &3 wheelers, cars, trucks, tractors, electric motors, railway wagon, coach and locomotives. NEI product range are also used in steel mills, heavy engineering plants, bulldozers, shovels, tillers and thermal power plants all across the country. NBC Bearings are exported to various countries like USA, Germany, Italy, Japan, South Africa, Saudi Arabia, Brazil, Peru, Guyana, Sri Lanka, Bangladesh, Pakistan, Nepal, Bhutan, Indonesia, Singapore, Turkey, Australia, China, Canada, Guatemala, Mexico, Malaysia, Nigeria, Argentina and and Columbia.
VISION NEI will be the best market driven Antifriction Bearing Company providing innovative products& service to achieve satisfaction of of customers and other stake holders by using world class technology and management practices and through employee commitment. NEI will diversify in allied precision engineering products and special purpose machine. MISSION NEI Ltd. is in the business of precision rolling bearings, providing technical services and seeking opportunities for new business consistent with its it s vision to
Provide product and services of world class quality. Meet customer requirements. Increase Shareholder value. Develop mutually beneficial supplier relationships.
Create opportunity for the employees to achieve their reasonable Aspirations. To serve the society by providing products and services of excellent quality, meeting consumer requirement, providing adequate return to shareholders and creating opportunity for the employees to achieve their aspirations.
TECHNICAL COLLABORATIONS a. Amsted Rail (Brenco Incorporated), USA: 1982 Onwards: For Cartridge Taper Roller Bearings used in Railway Wagons b. NTN Corporate, Japan: 1985 onwards: For Ball Bearings, Cylindrical and Spherical Bearings 1997 Onwards: For Taper Roller Bearings c. Isumi Kinzoku Kogya Co. Ltd., Japan 1996 Onwards: For re-manufacturing, retrofitting, and overhauling of grinding & super-finishing machines used on the races/tracks of bearings.
Milestones:
MANUFACTURING FACILITIES 1. JAIPUR PLANT
i.
Ball Bearings Precision Ball Bearings from 6mm bore to 75mm bore diameter are manufactured using 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 equ ipment’s. 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 sqm.
ii.
Steel Ball Precision steel balls (upto 25mm diameter) are manufactured on precision grinding and lapping machines to achieve a super finished surface, accuracy and roundness as per ISO standards. This division is spread over a covered area of 4,700 sqm.
iii.
Taper Roller Bearings Precision Taper Roller Bearings are manufactured manufactured in inch and metric series from a bore size of 15.875mm to 95.25mm with technology obtained from our earlier collaborator, Federal Mogul Corporation USA and now with NTN Corporation, Japan. These Bearings are used by all major automobiles manufacturers in the country as Original Equipment. This division is spread over an area of 11,652 sqm.
iv.
Railway Bearings a. 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 in locomotives manufactured by Diesel Locomotive Works, General Motors locomotives, Chittaranjan Locomotive Works, the ICF Broad and Meter Gauge Coaches, as well as various Wagon Builders. Over a million NBC bearings and boxes are in service with Indian
railways. The development of completely Indigenous axle boxes and bearings for the high speed Rajdhani Locomotives, the Yugoslavian and the Egyptian Railway Wagons are the highlights of the design capabilities at NEI. Today more than 100 types of axle boxes and bearings are being manufactured. b. Spherical Roller Bearings 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 t he collaborators.
c. Cartridge Taper Roller Bearings For fitment to the new BOX-IN Updated Wagons designed designed by the RDSO. NEI is the only manufacturer in the country to indigenise these bearings to a high percentage in collaboration with the t he 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. d. Large Diameter Bearings Self-sufficiency in steel is the call of the day and bearings are a crucial component of steel mills. NEI has the distinction of being one of the only ten manufacturers of these bearings in the world, who can manufacture large diameter bearings upto 200mm diameter. The largest l argest bearing manufactured by NEI for fitment to the plant mill of Rourkela Steel Plant was released by Mr. G.P. Birla in September 1985. This 4 Row Taper Roller Bearing measured 1300mm dia and weighed 4.39 tons. The large diameter bearings are mainly manufactured out of case carburising steel and 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 2000mm diameter with electronic sizing and numerical display. Production of these bearings started in 1975, and till date over 100 different types of special large diameter bearings have been manufactured and successfully used in various industries. The Large dia. Bearings division is spread over an area of 2508 sqm.
2. Newai Plant The plant was 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 and post process gauging, and centrally air conditioned assembly lines with auto gauging and test equipment’s for quality and reliability of the products. The plant is spread over
a covered area of 7,200 sqm. 3. Manesar Plant The Plant has covered area of 5,200 sqm 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 equipment’s.
4. Savli(Vadodara) Plant The recently commissioned plant is spread over an area of 80,937 sqm. This plant is designed and constructed to achieve IGBC Platinum Certification which is the highest Green rating available.
RESEARCH AND DEVELOPMENT a. Design & Development Complete in-house facility for design and development of all types of bearings and tools is available. The design of all types of bearings is done on Pro Engineering 3D Modelling & Analysis Software. Complete engineering & research facility is available to solve intricate problems with expert advice on design development, manufacturing, installation and maintenance of bearings. With the signing of the technical collaboration agreement with NTN Corporation, Japan and BRENCO Inc. of USA, the capability to offer the finest engineering services in the bearing industry has been enhanced. Services of teams of experienced engineers are available for selection of bearing as per application. b. Machine Building NEI has the technology to design, develop and manufacture special purpose CNC Grinding Lines, HT Lines, Material Handling Equipment’s and other special purpose machines which have been made for its captive use to keep pace with the latest technology. c. SAP-ERP In order to reengineer and integrate the Business processes for sales, production, materials and finance, NEI has successfully implemented SAP- ERP. By use of this Package, Package, their processes pr ocesses now conform to international standard.
Quality Management System ISO / TS 16949:2002
NEI has been awarded TS 16949: 16949: 2002 on 17th October, October, 2003- THE MARK OF EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by BVQI for design, development, manufacture manufacture & supply of Ball Bearing, Tapered Roller Bearing andCylindrical Roller Bearings. NEI Ltd. is the first bearing industry in India to have been recommended recommended for TS 16949: 2002.This certificate is awarded only to suppliers of automobile manufacturers. manufacturers. TS 16949: 2002 quality management system is based on ISO 9001:2000 in which many supplementary and additional requirements of automobile industries have beenincorporated.S implicity, effectiveness & efficiency of processes, error proofing and continuousimprovement continuousimprovement in processes thus become the highlight of TS quality management system. ISO 9001:2000
bearing division and railway bearing division which are manufacturingcylindrical manufacturingcylindrical Roller Bearings, Spherical Roller Bearings, Cartridge Tapered Roll er Bearings, Railway Rolling Stock and Spares has also been awarded to ISO 9001: 2000 on 9th October, 2003 by BVQI. NEI’s
large dia.
ISO 14001:1996
NEI was awarded awarded ISO 14001 certificates certificates by BVQI in the month of March 2000 for Environmental Management 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.
Chapter: Two Bearings & Bearings Industry
History & Evolution of Bearing An early type of linear bearing uses tree trunks laid down under sleds. This technology may date as far back as the construction of the Pyramids of Giza, though there is no definitive evidence. Modern linear bearings use a similar principle, sometimes with ball sin place of rollers. Tapered steering head bearings for a motorcycle. The first plain and rolling-element bearings were wood, but ceramic, sapphire, or glass were also used, and steel, bronze, other metals, ceramics, and plastic (e.g., nylon, polyoxymethylene, Teflon, and UHMWPE) are all common today. A pocket watch uses stones to reduce friction, and allow more precise timekeeping. Even old materials can have good durability. As examples, wood bearings can still be seen today in old water mills where the water provides cooling and lubrication.
BEARING Definition- A bearing is a device to allow constrained relative motion between two or more
parts, typically rotation 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. Plain bearings are widely used, and use surfaces in rubbing contact. Particularly with lubrication they often give entirely acceptable life and friction. On the other hand, low friction bearings are often often important for efficiency, to reduce reduce wear and to facilitate facilitate extended extended use use at high high speeds. speeds. Esse Essentially ntially,, a bearing bearing can reduc reducee friction friction by v i r t u e o f its shape, shape, by its its material material,, or by introducing and containing a fluid between surfaces or by separating the surfaces with an electromagnetic field. By shape, gains advantage usually usually by using spheres or rollers, or by forming flexure bearings.
By material exploits the nature of the bearing material used. (An example would be using
plastics that have low surface friction.) By fluids exploits the low viscosity of a layer of fluid, such as a lubricant or as a pressurized medium to keep the two solid parts from touching, or by reducing the normal force between them. By fields exploits electromagnetic fields, such as magnetic fields, to keep solid parts from touching. Combinations of these can even be employed within the same bearing. An example of this is where the cage is made of plastic, and it separates the rollers/balls, which reduce friction by their shape and finish.
Principles of Operation There are at least six common principles of operation:
• Sliding bearings, usually called "bushes", "bushings", "journal bearings", "sleeve bearings", "rifle bearings", or "plain bearings”. • Rolling-element bearings such as ball bearings and roller r oller bearings. • Jewel bearings, in which the load is carried by rolling the axle slightly off -centre. • Fluid bearings, in which the load is carried by a gas or liquid. • Magnetic bearings, in which the load is carried by a magnetic field. • Flexure bearings, in which the motion is supported by a load element which bends.
Motions Common motions permitted by bearings are: • Axial rotation e.g. shaft rotation • Linear motion e.g. drawer • Spherical rotation e.g. ball and socket joint • Hinge motion e.g. door
Loads Bearings vary greatly over the size and directions of forces that they can support. Forces can be predominately predominately radial, axial (thrust bearings) bearings) or moments perpendicular perpendicular to the main axis.
CLASSIFICATION OF BEARINGS Depending upon the direction of load to be supported :-Based on this criteria, the bearings
may be categorized into a) Radial Bearings:-These are also known as Journal Bearings. In these t hese bearings the main load is perpendicular to the axis of rotation of the moving elements. b) Thrust Bearings:-In these bearings the load acts along the axis of rotation. Depending upon the type of loading :-Based on this criteria, the journal bearings may be
categorized into. a) Bearing with a steady load, such as bearings of electric generators, and motors,
centrifugal pumps, or various blowers or fans. Such bearings are called POWER BEARINGS. b) Bearing with a variable or fluctuating load, such as main crankpin, wrist pin, or camshaft bearings in diesel engines. Depending upon the nature of contact between the working:-Based on this criteria they
may be categorized into two general classes, each with two sub-types. 1) Plain (Sliding Contact Bearings):-The primary motion between the bearing and the
moving element is the sliding one : a) Cylindrical bearing: can be made from a cast, solid bronze material. Cylindrical C ylindrical bearings can be available as plain bearings, cored bars or solid bars in the market. b) Thrust bearing: can be made from fr om porous bronze, oil impregnated type of bearing material. Thrust bearings can be available as plain bearings (also known as sleeve bearings), flanged bearings, thrust-bearings, cored bars, solid bars and plate stock. 2) Anti-Friction Bearings (Rolling Contact Bearings):- In these bearings, the contact
between the bearing bearing element is rolling instead of sliding as as in plain bearings. bearings. Since the rolling friction is very less as compared to the sliding friction, such bearings are also known as “Anti-friction Bearings”. 2.1) The rolling element bearings are classified into: a) Ball bearing: - In these t hese bearings, the rolling element is a spherical ball. b) Roller bearings: - In these bearings, the rolling element is a roller, which might be cylindrical, conical, spherical, or concave. 2.2) Depending upon the load to be carried, the rolling contact bearings may be categorized as: a) Radial Bearings: - In radial contact bearings, the load is primarily radial with only low magnitude thrust load. b) Thrust Bearings:-These bearings handle loads which are primarily thrust. c) Angular Contact Bearings:-These bearings are used where the loads are combined radial and high thrust, and where accurate shaft location is required.
Share
7
6
3
54
30
Ball Bearings
Taper Roller
Cylindrical
Needle
Spherical
Failures of Bearing Causes: Only 34% of bearings fail due to Fatigue, which is the basis of life calculation. Poor lubrication is the reason for 36% of premature bearing failure. Contamination is the reason for 14% of premature bearing failure. Poor installation is the reason for 16% of premature bearing failure. Common symptoms of failure: A. Overheated bearing B. Noisy bearing C. Vibration D. Shaft is jammed E. Bearing clearance has increased F. Lubricant has metallic debris G. Unsatisfactory equipment performance Failure Mode: Surface fatigue a. Subsurface fatigue b. Surface initiated fatigue Wear a. Abrasive wear b. Adhesive wear Corrosion a. Moisture corrosion b. Frictional corrosion i. Fretting corrosion ii. False brinelling Electrical Corrosion Plastic deformation Fracture
Indian Bearing Industry The Indian Bearing Industry is estimated at Rs30 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 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 comprises automotive railway and other Industrial users. The replacement market is dominated by unorganized Sector. ORGANISED SECTOR
The organized Sector comprises about 12 big Manufacturer, who contribute to more than50% of total turnover. Most of the big players are having either technical or financialwith International Manufacturer. International Collaboration gives access to besttech nology in the world. SKF Bearing is the major player in the Indian market with the largest market share followed by National Engineering Industry (NBC) and FAG Bearing India the two other major players.
Sectors 30 55 15
Organized
Unorganized
Imports
UNORGANISED SECTOR
The Unorganized Sector Include the Small Scale Manufacturer and Manufacturer of Spurious Bearing. The unorganized Sector Contribute to almost 15% of Total Industry turnover. The Unorganized Sector players have a strong regional presence and mainly cater to the needs of the replacement market. The direct employment provided by the above sectors is more than 12000 people. Indirect employment for Transportation, Tools, Containers, and Packaging etc. further helps
in providing
employment.
Threats & Limitations to Indian Market Increasing Competition in Domestic market. Very Low Volume of Direct Export. Weak Marketing Linkages. Raw Material Bank is not present. Low level of technology used by most of manufacturing Units. Quality of Bearing Manufactured in the Small Scale Industry (SSI) Sector does not meet the International Quality Standard. No R ecen ec entt up gr ad at i on i n Desi De si gn , Te ch no lo g y, Pr oc ess es s of Ma nu f act ac t ur i n g and Quality Control. Non-existence of highly skilled Man Power. Stiff Competition from China made Bearing. Increase in Illegal Imports. No Entry Barrier in the cluster Increase in Raw Material Prices. Government Rules & Regulations According to estimate an entrepreneur need to interact with 14 Govt. departments to get permission for manufacturing &exporting. Most of their time is spend in filling up forms and submitting paper as per their requirement. Therefore Govt. rules and regulation have to be liberalized& the the role of Govt. Department Department should be a facilitator facilitator rather than regulator. regulator.
Market Share
6
4 29
8 9
9 20 15
SKF
NBC
FAG
TATA
NRB
TIMKEN
ABC
HMT
Global Bearing Industry The global bearings market is generally seen as the worldwide sales of rolling bearings, comprising ball and roller bearing assemblies of various designs, including mounted bearing ket’s size in 2016 reached a value of units. SKF estimates that the global rolling bearing mar ket’s between SEK 340 and 360 billion. The industrial original equipment bearing markets accounted for almost 40% of world demand and included manufacturers of light and heavy industrial machines and equipment, as well as aerospace, aerospace, off-highway and railway vehicles. Sales through distributors (industrial distribution and the independent vehicle aftermarket) maintained around 30% of world bearing demand, of which around 25% is related to the vehicle service market and around 75% to the industrial market. The automotive original equipment bearing markets, including two and four wheelers, accounted for more than 30%. Europe accounts for 25% of the total world market with Germany alone accounting for almost 10%.The Americas now represent slightly more than 20% of global demand, of which the USA, Canada and Mexico together account for about 80%. In South America, Brazil is the major market and makes up more than 50% of regional demand. Asia’s share of the world bearing market grew the most year-on-year and accounted for more than 50% compared with less than 30% fifteen years ago. China’s share of the total world bearing market grew heavily to about 30%. Japan’s share of the world bearing market
accounts for slightly more than 10%. Other Asian markets with sizeable bearing sales account for about 10%, including India, Thailand, Indonesia, Taiwan and South Korea. The Chinese bearing market, which remains the largest of the emerging markets, is very fragmented, with the main international bearing companies accounting for about one third of the market, while the other two thirds of the market consists of a host of local manufacturers. Some of the largest include: Wafangdian (ZWZ), Luoyang (LYC), Harbin (HRB), Zhejiang Tianma (TMB), Wanxiang Qianchao, and C&U. The Indian bearing market accounts for less than 5% of the world bearing market. The players in that market include international manufacturers and several local manufacturers such as NEI, NRB, ABC and TATA. Radial deep groove ball bearings are the most common rolling bearing type, accounting for almost 30% of world bearing demand. Other major ball bearing types include angular contact ball bearings, self-aligning ball bearings, thrust ball bearings and automotive wheel hub ball bearing units. Roller bearings account for less than half of worldwide rolling bearing sales. Roller bearings are named after the roller shape, such as cylindrical roller bearings, needle roller bearings, tapered roller bearings and spherical roller bearings. All of these are available for loads acting across the shaft (radial bearings) and for loads that are parallel with the shaft (thrust bearings). The largest roller bearing family is the tapered roller bearing, with almost 20% of the world bearing market.
Chapter: Three Manufacturing of Taper Taper Roller Bearings
Flow of Material in Bearing Industry
Material from outside Vendor Such as Races (Inner & Outer), Cages, retainers etc.
Store House for Size Inspection
Laboratory For Metallurgical inspection based on the norms set by R & D Department
Yes/No
Material is sent back to Vendor
Material is send to specific departments for further Operations
The following Operations are done: 1. Hardening or Heat Treatment 2. Rough Grinding (Face, O.D., Inner & Outer Track) 3. Finish Grinding (Face, O.D., Inner & Outer Track) 4. Inspection 5. Assembly
Bearing Materials MATERIAL OF BEARING COMPONENTS:
Balls, rollers and rings of rolling bearings are manufactured from bearing steel that has capability of being hardened to a high degree, at least at the surface. • Commonly used bearing steel SAE 52100/SUJ2 is rich in Chromium (through hardened) or SAE3310/ SAE4320 (case hardened steel). In both the cases the surface hardness achieved is 59~65 HRC. • In certain applications, stainless steel is also used where environment is corrosive e.g. chemical plants. •
Chemical Composition of SAE 52100:
Carbon- 0.95-1.1% Silicon- 0.15-0.35% Manganese- 0.5% (max) Molybdenum- 0.08% (max) Phosphorus- 0.012% (max) Silicon- 0.25% (max) Chromium- 1.3-1.6% (max) Nickel- 0.25% (max) (max) Bearing Designation in NBC Rolling bearing part numbers indicate Bearing type, Dimensions, Tolerance, Internal Construction & other related specifications. The Digits & Indications are:st ➢1 Digit – Bearing Bearing Type ➢2nd Digit – Width Width or Height Series ➢3rdDigit – Diameter Diameter Series ➢Last 2 Digits – Bore Bore Diameter
Taper Roller Bearings Tapered roller bearings consist of 2 basic components: the cup and the cone assembly. The cup is the outer ring and is a separate component. component. The cone assembly assembly is made up of the inner ring, rollers, and the cage.
The inner and outer ring raceways ring raceways are segments of cones cones and the rollers are tapered 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 geometry makes the motion the motion of the cones remain coaxial, with no sliding motion between the raceways and the OD of the rollers. This conical geometry creates a linear contact patch which permits greater loads to be carried than with spherical (ball) bearings, which have point contact. 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 the contact the contact patch and no differential scrubbing occurs. The rollers are stabilized and restrained by a flange on the inner ring, r ing, against which their large end slides, which stops the rollers from popping out due to the "pumpkin seed effect" of their conical shape. The larger the half angles of these cones the larger the axial force that the bearing can sustain. Tapered roller bearings are separable into a cone assembly and a cup. The non-separable n on-separable cone assembly consists of the inner ring, the rollers, and a cage that retains & evenly spaces the rollers. The cup is simply the outer ring. Internal clearance is established during mounting by the axial position of the cone relative to the cup, although preloaded installations without clearance are common.
Tapered roller bearings are based on the
observation that cones that meet at a point can roll over each other without slipping. In practice, sections of cones are used.
Taper roller bearing types and characteristics Single Row TRB Taper roller bearings can take both axial and radial loads. The axial load carrying capacity of the bearings is largely determined by the contact angle α as shown in the figure below. If the contact angle α is larger, then the axial load carrying capacity is higher and vice versa.
Taper roller bearings are designed in such a way that vertices of the cone for each roller and those for the inner and outer raceways coincides on the bearing axis or extensions of the raceways and rollers converge at a common point on the axis of rotation. This results in true rolling motion of the rollers on the raceways at every point along the rollers. The taper roller bearings support radial radial loads and axial axial loads from one direction only. only. The line contact contact between rollers and raceways provide the bearings with a high load carrying capacity. Steep angle taper roller bearing with exceptionally steep cone angle enables the bearings to take heavier axial load. The bearings are of separable type, enabling separate mounting of cups and cones. Since the taper roller bearings can absorb thrust loads in one direction only, these bearings should generally be installed as opposed mountings. The correct amount of radial and axial clearance is obtained by adjusting the two bearings against each other. Besides, double row and four row taper roller bearings are also widely used for heavy loads such as rolling mills. A single row taper roller bearing can be located endwise in one direction only.
Double Row TRB In Double Row Taper Roller bearings, NBC provides both back-to-back arrangement (using double row outer rings) and face-to-face arrangement (using double row inner rings). These are adjusted to fix the clearance values of each type. Only parts with identical manufacturing numbers can be used and they must be assembled according to their code numbers .
Four row TRB Four Row Taper roller bearings are made up of two double row inner rings and two double row outer rings. These bearings are used for heavy load capacity as in the roller necks of rolling mills. The life of large bearings is extended by using case hardened steel, hollow rollers and pin-type cages. cages.
Taper Roller Thrust NBC Taper Roller Thrust bearings include rollers that have conical sections. These bearings are designed primarily to support axial loads at contact angles between 30˚ and 90˚. These
bearing are suited for applications applications where extremely high high thrust loads like in crane hooks, coal pulveriser etc. These These bearings can be supplied supplied with a full complement of of rollers.
Applications Common uses for this tapered t apered roller bearings include:
Automotive wheel bearings; as well as in gearboxes, axle systems, and engines Agricultural machinery shafts and line shafts As steady rest rollers, strip levellers, or in combination with a rail element Helicopter transmissions Aircraft fuel pumps Process Flow Chart for Cup Turning
Heat Treatment
Face Grinding
OD Grinding
Track Grinding
Honing
Assembly
Process Flow Chart for Cone Turning
Face Grinding
Track Grinding
Flange Grinding
Bore Grinding
Honing
Assembly
Process of Heat Treatment Heat treatment of cups and cones of taper roller bearings are done on Chugai-Ro furnace and Wein’s troth furnace. The contact surfaces of the bearing rings and rolling elements are subjected to repeated high stresses, so they must maintain high precision and rotational accuracy. T o accomplish this, the rings and rolling elements elements must be made of a material that that has high hardness, resistant to rolling fatigue, wear resistant r esistant and has good dimensional di mensional stability. High carbon chromium bearing steel (SUJ 2) deep hardened by the hardening method &case hardening steel (SC/SCM/SNCM) with a hardened carburized outer layer are used for the rings and rolling elements of standard bearings. The most widely used and most suitable materials for rolling bearings are high carbon steels. The most commonly used of these steels is SUJ2. For bearings with large cross section dimensions SUJ3 or SUJ5 having good hardening properties are used. used. NBC uses high carbon steel for almost all of spherical spherical roller & cylindrical cylindrical roller bearings. For case hardening steel; Chrome Steel (SCr), Chrome Molybdenum Steel (SCM) and Nickel Chrome Molybdenum Steel (SNCM) are used because of its combination of ahard surface layer which has been carburized and hardened to an appropriate depth, and are relatively pliable inner core, case hardening steel has excellent excellent efficiency against against shock load. NBC uses case hardening steel for almost all of tapered t apered roller bearings. Since the life l ife of the bearing steel is determined by the purity of cleanliness of steel the above grade steels are low in non-metallic impurities & low in oxygen content because they are refined by a Vacuum degassing process & outside hearth smelting process. The Hardening of steel is achieved by heat treatment process in which the steelmicrostructure is manipulated by cycles of heating & quick cooling to obtain the optimum hardness hardness range for steel – usually usually on the order of 60 to 64 on Rockwell C Hardness Scale. When slowly quenched it would form Austenite & Pearlite which is a partly hard and partly soft structure respectively. Hardening of steel requires a change in structure from Body Centred Cubic Structure found at room temperature to Face Centred Cubic Structure found in Austenite Region. When Steel is suddenly Quenched Martensite is formed which is extremely strong and If steel is Quenched slowly then Pearlite is formed which is extremely Soft.
Working of Chugai-Ro Furnace 1. Input: Raw materials after turning is fed into the hopper of the Chugai-Ro furnace.
Chugai-Ro Furnace 1. Automatic Prewashing: It consists of no man. 3 preheaters at 60ºC +10/-20ºC are used to heat the materials. Cerfa clean (L2S) is used to remove the oil because the oil can stick to the job and then due due to heating marks marks can be left on the surface of the materials. Simple H2O cleaning is used to remove the excess of cerfa clean at 4-5 KPa Pressure for almost 1 hour. Then the jobs are sent forward where the blower dries the job and removes excess water from them. 2. Alignment: Then comes the rabbit conveyer which moves the jobs in batch wise for proper alignment because if jobs are not aligned properly then there can be production delay and if more number of jobs go in then they might get stuck and whole process has to be stopped and started all over again. 3. Heating: Heating Heating: Heating is done in the main furnace. Its capacity is 450 kg/hour. The furnace is thermally insulated using glass wool. The furnace consists of 4 zones. These zones control the amount of CO^2. If the CO2 is more it will lead to scaling and if less, then the hardness can get affected. Thus its control is very important. An inert atmosphere is maintained inside to prevent the air flow in and out to prevent oxidation. And thus for this we have an LPG connection which reacts with the H2 inside and thus a continuous flame curtain is produced which prevents the air to pass in or go out. And in the bottom side there is a water curtain which does the same process. Zone 1: Its function is to provide ambient temperature of approx. 840 ºC. Zone 2: In 2: In this the temperature varies from 830-850ºC according according to hardness to be achieved. Soaking of temperature takes place here.
Zone 3 & 4: 4: Its function is to maintain a constant temperature of around 830-850º C according to requirement. This is the most important zone.
4. Quenching: After the heating process we have the quenching process. process. Jobs are quenched quenched up to 105º C in Nippon 303 oil tank. Vapours made after the quenching process are not allowed to go back into the inert atmosphere by the oil curtain. A shell type heat exchanger is used to cool the hot quenching oil. 5. Post-washing: The quenched jobs are sent to the cooler fan to cool them and then to the post washing tank at temperature 22.5 22.5 ±7.5 ºC to remove the quenched quenched oil. 6. Tempering: It is the last process. Tempering is done at 170 ºC ±5ºC temperature for about 90 minutes to relieve the internal stresses. It reduces the hardness to about 3 HRC but increases the toughness.
Heating (850 C) (Austentization)
Quenc hing (115C)
Air Cooling
Martensite
Tempering Chilling 10
Tempered Martensite
(170C)
Features:
A charge throat is provided between the charge & the preheating zone to recover the heat of the return belt. A water seal tank device for the return for the belt is provided at the charge & of the furnace to prevent the air from entering the furnace & reduce the consumption of the atmosphere gas. Energy saving due to in-built INDO GAS generator. A cascade seal is adopted on the quench chute to prevent the fume from entering the hardening furnace & reduce the consumption of the furnace atmosphere gas.
Working of Wien’s troth furnace: The working of Wien’s troth furnace is same as Chugai-Ro but quenching is done in a salt bath. Hardenability is more in case of Wein’s troth as compared to Chugai-Ro.
Features:
Fully automated plant with multiple faults diagnostics programs through various POKAYOKE systems. Batch to batch variation in hardness is controlled. Precise temperature control within set temperature. Excellent microstructure, hardness profile. Controlled Retained Austenite (Within the given limit) Elevated type quenching resulted better quality Better distortion (Ovality) controlled thus improve quality of the jobs. Traceability of Batch history (Recipes. Alarms, etc.) Online data monitoring system through SCADA. The capacity is 1500 kg/hour.
Note: The jobs after heating in Wien’s troth furnace are bluish-grey or black in texture but in Chugai-Ro the texture is Brownish in colour.
Process of Grinding
The Next stage is grinding, in order to give the rings the right form and dimension. The operations occur in following Order: Face Grinding – It It is the first operation for both inner & outer rings. Both faces are ground simultaneously to give the final width. Outside / Centre less Grinding – Outside Outside diameter of inner ring is ground to final f inal dimension in centre less grinding machine. The final machining operations are carried out on parallel lines of grinding and finishing machines. Inner Rings have the bores & raceways ground while Outer Rings have the only the raceway ground. These operations are carried away by form dressed grinding wheels. After grinding Operation, Honing is done. After honing the rings are thoroughly washed with water based cleaning medium so Rings get perfectly cleaned cleaned before Assembly is done.
Theory of Roller Manufacturing: The Raw Material used (SUJ 2 Steel) for manufacturing of rollers is a specially formulated grade of Steel. The Material is Supplies by rod. It is then cut to length &width on Production Lathe. For Spherical Rollers or Tapered Rollers, The rod is then fed through a header. This cold forged process produce “slugs” at an incredibly high speed. Rod is fed from decoilersinto cold heading machines where it is cut into blanks and then pressed betweenhem ispherical dies or conical dies. For Cylindrical Rollers the above procedure is not done. The flash around the rollers produced during pressing is removed by filing plate’s in deburring machines. These rough shaped spherical rollers have a ring around the middle. The next process is to remove remove this ring by machining in rill-filing machine, machine, equipped equipped with one one fixed and one rotating cast iron rill-plate. Concentric grooves in the plate ensure that the whole roller surface is machined to same extent and thus a spherical form is achieved. The next process for Rollers is grinding in which rollers are grind in the order: Face, Face, O.D, and I.D. The grinding process is done in two phases; one prior to Heat Treatment (Rough Grinding) & one after the heat treatment process (Finish Grinding).Final inspection for size, form and surface finish is carried out on a sample basis by means of high resolution microscopes and other precision equipment equipment because a tiniest deviation even of of the order of 1 Å (10 -10 m) in the roundness r oundness of bearing element can have an impact on bearing quality. The rollers are then cleaned and dispatched for bearing assembly operation.
Cage Manufacturing
Theory of Cage Manufacturing: The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & Cold Annealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in Press Machine in Successive Operations: Blanking, Punching, Forming (Pocketing) rivet holes and visual inspection is carried for any deformity.
Theory of Roller Bearing Assembly Line: Finally the rings, Rollers & Cage which have been manufactured in different locations come together for semi – Automatic or Automatic Assembly. Raceways & Rings are Optically Inspected separately prior to assembly. By selecting suitable combinations of ring & Rollers sizes the required internal clearance is obtained. Rollers are fed into the cage which are together fed in between the Outer & Inner Raceway & are fitted together through pressing. After
washing, the final inspection sequence starts which consist of number of checks such as running accuracy, vibration level, outside and bore diameters and radial clearance of bearings. The bearings are then automatically washed, washed, coated coated with preservative, greased and fitted with with seals or shields before being packed.
Chapter: Four Projects Undertaken
RESEARCH METHODOLOGY Research can be defined as “a scientific and systematic search for pertinent information in any branch of knowledge‟. It is the pursuit of truth with the help of study, observation, comparison and experiment. Research is, thus, an original contribution to the existing stock of knowledge making for its advancement. advancement. TITLE OF THE STUDY
Title of the study is “Study of different Parameters of Taper Roller Bearings
”
DURATION OF THE PROJECT
The duration of the project is 4 months in i n N. E.I .Limited Jaipur from 5 th Jan’17 to 29 April’17. OBJECTIVES OF STUDY
The purpose of attending this training is to understand the different processes involved in the manufacturing of bearings and its applications in different areas. The study also includes the understanding of the industrial production processes and work culture present there.
Project 1: 1: Study of width and flange width expansion and contraction Description: The project includes study of width expansion and contraction in
cups and width and flange width expansion or contraction in cones after heat treatment on two furnaces namely Chugai-Ro and Wien’s troth. Data: The project related data taken during the study stud y are as follows:-
MATERIAL INSPECTION INSPECTION DATA – CP Job Jo b : 3220 32208 8
Process Turni ng
Date Date 09.01 09.01.1 .17 7 WIDTH
S.NO S.NO
W1
W2
Avg Widt h
Var
1
20
40
30
20
2
30
40
35
10
3
40
60
50
20
4
20
50
35
30
5
10
40
25
30
6
30
50
40
20
7
30
50
40
20
8
30
40
35
10
9
30
40
35
10
10
20
40
30
20
11
20
30
25
10
12
0
30
15
30
13
30
50
40
20
14
20
40
30
20
15
20
40
30
20
16
10
40
25
30
17
30
40
35
10
18
10
30
20
20
19
30
50
40
20
20
10
40
25
30
USL
-50
50
LSL
50
0
X
32.00
20.0
8.2
7.3
Pp
-2.04
1.38
Ppk
-3.34
Max
40
60
50
30
Min
0
30
15
10
MATERIAL INSPECTION INSPECTION DATA – CP Date
Process
Job Jo b : 3220 32208 8
AFTER HT
10.01.17
CHUGAI RO
WIDTH S.NO S.NO
W1
W2
Avg Widt h
Var
1
40
70
55
30
2
50
70
60
20
3
60
80
70
20
4
50
80
65
30
5
40
90
65
50
6
50
80
65
30
7
50
90
70
40
8
50
70
60
20
9
60
80
70
20
10
40
70
55
30
11
50
70
60
20
12
30
60
45
30
13
50
80
65
30
14
60
100
80
40
15
50
90
70
40
16
50
80
65
30
17
50
80
65
30
18
40
70
55
30
19
60
100
80
40
20
30
80
55
50
USL
-50
50
LSL
50
0
X
63.75
31.5
8.6
9.3
Pp
-1.95
0.66
Ppk
-4.43
Max
60
100
80
50
Min
30
60
45
20
MATERIAL INSPECTION INSPECTION DATA – CN Job Jo b : 3159 31594 4
Turning
Process
Date
Flang e WIDTH
11.01.17
WIDTH
S.NO
F1
F2
Avg
Var
W1
W2
Avg Width
Var
1
-10
10
0
20
-30
-20
-25
10
2
-20
0
-10
20
-10
0
-5
10
3
0
10
5
10
-20
-10
-15
10
4
10
20
15
10
-10
0
-5
10
5
0
10
5
10
-10
0
-5
10
6
0
10
5
10
-20
-10
-15
10
7
-10
0
-5
10
-20
-10
-15
10
8
-10
10
0
20
-20
-10
-15
10
9
10
20
15
10
-20
-10
-15
10
10
0
10
5
10
-30
-10 - 10
-20
20
11
0
20
10
20
-10
0
-5
10
12
-10
0
-5
10
-30
-20
-25
10
13
10
20
15
10
-20
-10
-15
10
14
-10
10
0
20
-40
-30
-35
10
15
-10
0
-5
10
-20
-10
-15
10
16
-10
10
0
20
-30
-20
-25
10
17
10
30
20
20
-20
-10
-15
10
18
-20
0
-10
20
-30
-20
-25
10
19
-20
0
-10
20
-20
-10
-15
10
20
-10
10
0
20
-10
0
-5
10
USL
-50
50
-50
50
LSL
50
0
50
0
X
2.50
15.0
-15.75
10.5
9.0
5.1
8.3
2.2
Pp
-1.86
2.27
-2.00
5.89
Ppk
-1.95
-2.64
Max
10
30
20
20
-10
0
-5
20
Min
-20
0
-10
10
-40
-30
-35
10
MATERIAL INSPECTION INSPECTION DATA – CN
HT (Chugai-Ro) (Chugai-Ro) Process After HT
Job Jo b : 3159 31594 4
Date:12.01.17 Date:12.01.17
Flang e WIDTH
WIDTH
S.NO
F1
F2
Avg
Var
W1
W2
Avg Width
Var
1
-10
10
0
20
10
20
15
10
2
0
-20
-10
20
30
50
40
20
3
-10
10
0
20
30
40
35
10
4
0
20
10
20
30
50
40
20 20
5
0
20
10
20
50
60
55
10 10
6
0
-20
-10
20
30
50
40
20
7
0
20
10
20
30
40
35
10 10
8
-10
10
0
20
30
40
35
10
9
0
20
10
20
40
50
45
10 10
10
0
20
10
20
30
40
35
10
11
-10
10
0
20
50
60
55
10
12
0
-20
-10
20
30
40
35
10
13
-10
10
0
20
30
40
35
10
14
-10
20
5
30
20
30
25
10
15
-20
10
-5
30
40
50
45
10
16
0
20
10
20
20
40
30
20
17
10
30
20
20
40
50
45
10
18
-10
20
5
30
20
30
25
10
19
0
-20
-10
20
30
40
35
10
20
-10
20
5
30
30
60
45
30
USL
-50
50
-50
50
LSL
50
0
50
0
X
2.50
22.0
37.50
13.0
8.5
4.1
9.7
5.7
Pp
-1.96
2.27
-1.72
2.16
Ppk
-2.06
-3.02
Max
10
30
20
30
50
60
55
30
Min
-20
-20
-10
20
10
20
15
10
MATERIAL INSPECTION INSPECTION DATA – CP Date 17.01.17 Job : 3200 32004X 4X Process Turning
Chugai-Ro
WIDTH Width Size S.NO
Avg
Variation
W1
W2
Size
1
-20
0
-10
20
2
-40
-30
-35
10
3
-30
-10
-20
20
4
-60
-20
-40
40
5
-20
10
-5
30
6
-20
0
-10
20
7
-40
-20
-30
20
8
-20
0
-10
20
9
-40
-10
-25
30
10
0
20
10
20
11
-30
0
-15
30
12
-20
0
-10
20
13
-30
0
-15
30
14
-20
0
-10
20
15
0
10
5
10
16
-20
0
-10
20
17
-30
-10
-20
20
18
-10
20
5
30
19
-40
-10
-25
30
20
0
20
10
20
USL
50
50
LSL
-50
0
X
-13.0
23.0
14.0
7.3
Pp
1.19
1.23
Ppk
0.88
Max
0
20
10
40
Min
-60
-30
-40
10
MATERIAL INSPECTION INSPECTION DATA – CP Date 18.01.17 Jo b : 32004X 32004X Proces Pro cess s AFTER HT
Chugai-Ro
WIDTH Width Size S.NO
Avg
Variation
W1
W2
Size
1
10
30
20
20
2
-20
-10
-15
10
3
-10
20
5
30
4
-40
10
-15
50
5
-10
30
10
40
6
0
20
10
20
7
-20
0
-10
20
8
10
30
20
20
9
-10
20
5
30
10
20
40
30
20
11
-10
20
5
30
12
0
20
10
20
13
0
30
15
30
14
10
20
15
10
15
20
30
25
10
16
0
20
10
20
17
-10
10
0
20
18
10
40
25
30
19
-20
20
0
40
20
20
40
30
20
USL
50
50
LSL
-50
0
X
9.8
24.5
13.4
10.5
Pp
1.24
0.81
Ppk
1.00
Max
20
40
30
50
Min
-40
-10
-15
10
MATERIAL INSPECTION INSPECTION DATA – CN CHUGAIRO Job : 32004X
Turning
Process
Date 18.01.17
Flange Size Flange Size S.NO
Avg
WIDTH Variation
Width Size
Avg
W1
W2
Size
Variation
F1
F2
Size
1
-10
40
15
50
0
20
10
20
2
-60
-20
-40
40
-10
20
5
30
3
-30
0
-15
30
0
20
10
20
4
-40
-20
-30
20
-10
10
0
20
5
-30
0
-15
30
10
30
20
20
6
-50
-30
-40
20
0
10
5
10
7
-20
0
-10
20
0
10
5
10
8
-10
10
0
20
-10
10
0
20
9
0
10
5
10
-10
0
-5
10
10
-40
-20
-30
20
0
10
5
10
11
-50
-20
-35
30
10
30
20
20
12
-40
-20
-30
20
0
10
5
10
13
-30
-10
-20
20
0
20
10
20
14
10
30
20
20
-10
0
-5
10
15
-10
10
0
20
-10
0
-5
10
16
-30
10
-10
40
-10
10
0
20
17
-40
0
-20
40
-10
30
10
40
18
-60
-40
-50
20
-10
10
0
20
19
-40
-20
-30
20
10
30
20
20
20
-50
0
-25
50
-20
20
0
40
USL
50
50
50
50
LSL
-50
0
-50
0
X
-18.0
27.0
5.5
19.0
18.9
11.3
7.9
9.1
Pp
0.88
0.68
2.10
1.13
Ppk
0.57
1.87
Max
10
40
20
50
10
30
20
40
Min
-60
-40
-50
10
-20
0
-5
10
MATERIAL INSPECTION DATA – CN CHUGAI-RO Job : 32004x
19.01.17 Process: After HT Date: 19.01.17 Flange Size Flange Size
S.NO
Avg
F1
F2
Size
1
-10
30
10
2
-60
-30
3
-30
4
WIDTH Width Size
Variation
Avg
Variation
W1
W2
Size
40
20
40
30
20
-45
30
10
50
30
40
-10
-20
20
20
40
30
20
-60
-30
-45
30
10
30
20
20
5
-30
0
-15
30
30
60
45
30
6
-40
-20
-30
20
20
30
25
10
7
0
20
10
20
10
30
20
20
8
0
20
10
20
10
30
20
20
9
-20
0
-10
20
10
20
15
10
10
-50
-30
-40 - 40
20
10
30
20
20
11
-50
-10
-30 - 30
40
20
50
35
30
12
-50
-30
-40 - 40
20
20
30
25
10
13
-60
-30
-45 - 45
30
20
40
30
20
14
-10
10
0
20
10
20
15
10
15
-10
10
0
20
0
20
10
20
16
-60
-30
-45 - 45
30
10
40
25
30
17
-50
10
-20
60
10
50
30
40
18
-70
-50
-60 - 60
20
20
40
30
20
19
-30
-10
-20 - 20
20
30
50
40
20
20
-10
-20
-15
10
0
40
20
40
USL
50
50
50
50
LSL
-50
0
-50
0
X
-22.5
26.0
25.8
22.5
21.3
11.0
8.6
9.7
Pp
0.78
0.73
1.93
0.95
Ppk
0.43
0.94
Max
0
30
10
60
30
60
45
40
Min
-70
-50
-60
10
0
20
10
10
MATERIAL INSPECTION DATA – CP Date 23.01.17
Process
Job Jo b : 3221 32213 3
Width Size
S.NO
Turning WIDTH Avg
Wiens Wiens troth Variation
W1
W2
Size
1
-20
0
-10
20
2
10
20
15 15
10
3
-20
50
15
70
4
50
60
55 55
10
5
-10
10
0
20
6
-10
0
-5
10
7
-20
0
-10
20
8
0
10
5
10
9
-20
10
-5
30
10
10
40
25
30
11
0
20
10
20
12
-10
40
15
50
13
-10
0
-5
10
14
-10
0
-5
10
15
-10
0
-5
10
16
-90
-50
-70
40
17
-100
-50
-75
50
18
-70
-50
-60
20
19
-20
-10
-15
10
20
-10
10
0
20
USL
50
50
LSL
-50
0
X
-6.3
23.5
31.1
16.9
Pp
0.54
0.52
Ppk
0.47
Max
50
60
55
70
Min
-100
-50
-75
10
Date Job Jo b : 3221 32213 3
30.01.17 Process Af t er HT WIDTH Width Size
S.NO
Avg
Wiens Wiens trot h
Variation
W1
W2
Size
1
40
90
65 65
50
2
60
100
80
40
3
40
90
65 65
50
4
90
110
100
20
5
30
50
40 40
20
6
40
70
55 55
30
7
30
50
40 40
20
8
50
80
65 65
30
9
30
60
45 45
30
10
40
90
65
50
11
50
80
65
30
12
40
90
65
50
13
30
90
60
60
14
40
90
65
50
15
30
60
45
30
16
-30
20
-5
50
17
-50
0
-25
50
18
-40
20
-10
60
19
20
40
30
20
20
40
70
55
30
USL
50
50
LSL
-50
0
X
48.3
38.5
30.7
13.9
Pp
0.54
0.28
Ppk
0.02
Max
90
110
100
60
Min
-50
0
-25
20
Material Inspection Data-CN 3159 31594 4 Proc ess Turni ng Date: Date: 06.02 06.02.17 .17 Wiens Troth Trot h
Job Jo b
Flange Size Flange Size
Avg
S.NO
F1
F2
Size
1
-50
0
-25
2
-30
-10
3
-10
4
WIDTH Variation
Width Size
Avg
Variation
W1
W2
Size
50
-50
-10
-30
40
-20
20
-10
10
0
20
20
5
30
-20
0
-10
20
0
10
5
10
-10
10
0
20
5
-10
0
-5
10
-10
10
0
20
6
-10
20
5
30
0
10
5
10
7
10
20
15
10
10
20
15
10
8
-10
10
0
20
0
10
5
10
9
0
10
5
10
0
10
5
10
10
0
10
5
10
0
10
5
10
11
20
30
25
10
0
10
5
10
12
-20
0
-10
20
-10
10
0
20
13
0
20
10
20
-10
10
0
20
14
-10
0
-5
10
0
10
5
10
15
-10
0
-5
10
-10
10
0
20
16
10
20
15
10
0
10
5
10
17
-20
-10
-15
10
-20
-10
-15
10
18
-30
-10
-20
20
-30
-20
-25
10
19
0
20
10
20
0
10
5
10
20
-20
0
-10
20
-10
10
0
20
USL
50
50
50
50
LSL
-50
0
-50
0
X
-0.8
17.5
-1.3
15.5
13.2
10.2
10.9
7.6
Pp
1.26
1.06
1.53
1.51
Ppk
1.24
1.50
Max
20
30
25
50
10
20
15
40
Min
-50
-10
-25
10
-50
-20
-30
10
Job
31594
Material Inspection Data-CN Process Af t er HT Wienstroth Flange Size
Flange Size
Avg
S.NO
F1
F2
Size
1
-70
-10
-40
2
-30
0
3
-20
4
Variation
Date
13.02.17
WIDTH
Width Size
Avg
Variation
W1
W2
Size
60
10
50
30
40
-15
30
20
40
30
20
0
-10
20
40
50
45
10
-20
0
-10
20
40
60
50
20
5
-20
0
-10
20
50
60
55
10
6
-20
10
-5
30
50
60
55
10
7
-10
20
5
30
60
70
65
10
8
-10
0
-5
10
50
70
60
20
9
0
10
5
10
40
50
45
10
10
-20
0
-10
20
50
60
55
10
11
0
20
10
20
60
80
70
20
12
-20
10
-5
30
40
60
50
20
13
-10
20
5
30
50
70
60
20
14
-20
10
-5
30
50
70
60
20
15
-10
10
0
20
50
60
55
10
16
0
20
10
20
50
60
55
10
17
-30
-20
-25
10
20
40
30
20
18
-40
-20
-30
20
20
30
25
10
19
10
20
15
10
40
50
45
10
20
-30
-10
-20
20
40
60
50
20
USL
50
50
50
50
LSL
-50
0
-50
0
X
-7.0
23.0
49.5
16.0
14.1
11.3
12.4
7.5
Pp
1.18
0.80
1.34
1.50
Ppk
1.02
0.01
Max
10
20
15
60
60
80
70
40
Min
-70
-20
-40
10
10
30
25
10
Summary of Cups
Job
32208
32004x
32213
Part
Cup
Cup
Cup
Hard on
Width
Width
Width
Chugai-Ro #1 Chugai-Ro #1 Wiens troth
Observed Parameter
Standard Parameter
Before HT
Min
Min
Max
After HT
Remarks
Max Min Max
-50
50
0
60
30
100
-41
59
-60
20
-40
40
-50
50
-100
60
-50
110
Expansion Found up to 40 µm Expansion Found up to 20 µm Expansion Found up to 50 µm
Summary of Cones
Job
31594
Part
Cone
Hard on
Width
Chugai-Ro #1
Flange Width
32004x
Cone
Width Flange Width
Chugai-Ro #1
Observed Parameter
Standard Parameter
Before HT
Min
Min
Max
After HT
Remarks
Max Min Max
-50
50
-40
0
10
60
-50
50
-10
20
-20
30
-40
60
-20
30
0
60
-50
50
-60
40
-70
30
Expansion Found up to 60 µm Expansion Found up to 10 µm Expansion Found up to 30 µm Contraction Found up to 10 µm
31594
Cone
Width
Wiens troth
Flange Width
-50
50
-50
20
10
80
-50
50
-50
30
-70
20
Expansion Found up to 60 µm Contraction Found up to 20 µm
Result: The result of this project shows that contraction and expansion of width
of cups and cones are in the defined standard limits of up to 50 µ m.
Project 2: Study of ovality and taper in case of 32010X cup Description: The study includes checking of ovality (Out of Roundness/OOR)
and taper in 32010X cup after each process of heat treatment, grinding and finishing and suggest for preventive measures if needed. Data: The project related data are as follows:-
Materi Material al Inspect ion Data-CP Data-CP Job: 32010X HT S.No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
OOR Side A Side B 30 20 40 60 30 30 30 40 50 40 100 110 60 80 100 100 60 70 30 30 50 40 70 70 110 120 70 70 110 100 30 30 80 100 100 110 70 60 20 20 70 90 150 120 20 20 120 140
Taper
105 30 30 75 25 85 130 180 85 140 35 80 85 80 75 50 50 115 65 30 40 185 130 90
After Face Face Grinding OOR Taper Side A Side B 20 10 165 20 60 90 30 20 85 20 30 95 40 50 85 50 120 175 60 60 200 100 100 250 60 60 130 30 20 215 50 40 95 70 60 135 110 110 120
100 40 80 80 70 30
70 20 100 80 60 30
135 130 110 150 115 100
140 20 130
100 20 130
250 200 130
After Rough OD Grinding OOR Taper Side A Side B 20 20 140 60 50 75 40 30 75 30 30 120 60 50 65 110 110 110 70 70 170 90 110 220 30 60 145 40 40 190 50 30 80 70 70 120 50 110 80 80 70 115 100 80 120 30 30 80 100 130 85 110 100 145 70 60 105 30 20 45 90 80 65 150 120 215 30 20 165 20 150 55
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
90 40 70 50 70 30 90 20 90 30 80 70 80 40 60 160 40 60 20 40 30 50 90 80 90 30 30 50 100 130 30 60 80 10 30 50 150 60 60 170 60 30 90 100 100 120 70 30 100 90 70 60
20 20 60 40 80 30 80 20 120 30 90 60 100 40 50 170 50 80 50 40 20 30 100 100 80 30 40 50 200 130 30 70 110 10 30 60 150 100 50 200 50 30 80 80 100 140 100 60 90 60 70 50
95 60 125 35 135 100 65 30 85 100 65 165 120 10 55 125 75 100 45 120 155 90 95 70 115 80 115 50 50 100 140 35 115 70 110 65 100 50 75 85 125 60 55 40 100 90 95 95 135 55 120 115
90 40 70 50 80 40 70 10 90 40 70 60 80 40 40 70 60 70 30 50 20 40 100 80 70 40 60 50 100 140 50 50 110 40 60 50 150 80 60 190 90 30 90 130 110 120 100 20 100 60 100 70
70 40 170 40 80 40 70 20 120 60 70 50 120 40 50 70 50 80 40 50 20 50 90 110 70 40 60 60 130 150 50 60 110 30 40 80 160 80 60 210 80 30 90 120 110 150 100 80 110 60 90 50
210 110 120 95 200 160 130 85 145 170 110 215 180 60 105 130 135 155 115 180 100 155 155 135 150 130 180 115 155 155 180 95 160 115 170 115 145 100 130 140 175 100 120 95 160 145 160 160 185 120 175 160
100 50 100 50 100 40 80 20 100 40 90 60 30 40 60 160 60 70 60 50 50 60 90 100 100 30 60 40 120 140 50 70 110 20 60
80 50 90 40 90 50 80 30 120 40 80 40 100 40 40 160 70 70 50 50 40 50 90 110 90 30 50 50 120 140 60 80 120 30 40
180 100 155 65 175 145 120 55 120 140 85 200 165 30 80 170 115 130 135 150 185 145 130 105 135 10 155 105 140 130 165 55 145 95 140
150 90 70 200
160 100 70 210
125 65 110 115
30 100 140 110 130 100 40 90 70 110 90
40 70 120 110 150 100 70 30 80 100 60
95 105 70 120 110 140 135 120 95 145 145
77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Min Max
140 70 60 60 80 100 50 150 30 40 40 100 20 50 30 20 50 50 50 30 70 60 30 80 10 170
70 70 100 50 150 100 60 100 20 30 30 70 40 100 30 40 50 20 50 50 80 60 20 110 10 200
135 80 180 125 65 130 75 125 65 85 95 85 130 75 70 130 100 115 70 120 175 100 65 155 10 185
60 100 40
50 100 50
95 200 175
130 50 160
120 60 170
165 115 135
50 20 70 30 90 30 30 30 40 50 50 60 80 20 110 10 190
40 30 80 30 110 30 40 70 30 60 40 60 90 20 120 10 210
155 155 125 170 110 120 175 140 165 95 165 210 145 130 205 60 250
60 100 50 80 130 70 70
90 100 40 80 120 60 160
105 180 155 130 135 105 65
70 30 60 40 80 40 40 50 50 60
30 30 90 20 50 40 40 70 40 50
100 120 105 170 125 80 160 130 135 85
60 80 30 100 20 200
70 90 30 110 20 210
185 125 100 185 10 220
Out of Round Workpieces Problem Workpieces out-of-round
Possible Cause Insufficient stock to allow rounding up after clean-up.
Correction Leave more stock for grinding, or improve concentricity of stock. Excessive clamping pressure Reduce clamping force to causes distortion in minimum. workpiece. Wheel too hard or too fine Use proper grade of wheel. causes excess grinding pressure. Interrupted cuts over Decrease feed and traverse keyways, oil grooves, valve rates. Use largest wheel parts, etc. possible. Hard areas in workpiece. Decrease feed and traverse speeds, change work speed. Out of balance workpieces. If possible, counterbalance the workpiece. Lack of rigidity in machine Check all hold down screws elements or fixtures. for rigidity. Worn Tyco/way bearings Check Bearing surfaces.
Worn or broken headstock spindle bearings. Check jaws worn, unstable chuck.
Check headstock spindle bearings. Replace Replace as needed. needed. Replace worn parts or change chucks.
Workpieces not ground straight Problem Workpieces not ground straight, Taper, concavity, or convexity apparent in workpieces.
Possible Cause Shape being dressed into the grinding wheel. Work heating and expanding during grinding.
Correction Check for worn diamond or dresser out of alignment. Increase cutting fluid flow. Decrease feed and traverse rates. Wheel pressure springing Decrease feed and traverse thin workpieces. rates. Decrease amount of feed per cut. Use steady rest. Grinding wheel passes off Shorten table traverse to workpiece at end of traverse. prevent wheel wheel from leaving workpiece. Balance over travel wheel on both ends. Incorrect dwell at end of Change the amount of dwell. traverse. Machine not level. Check level of machine base. Relevel Relevel if necessary. necessary.
Result: The result of this experiment shows that out of roundness of the job is
in the defined standard limit of less less than 200 µm. µ m.
Project 3: Study of effect of change in tempering temperature Description: The study includes the effect of change in tempering temperature
in the heat treatment process on the different parameters of cups and cones. Data: The project related data taken during the study are as follows:
Tempering Temperature=170 ºC
Processing Processing Condition ondi tion Zone Zone 1 840.3°C Hardening Zone Zone 2 845.2°C Furnace Zone Zone 3 844.8°C Temp. Zone Zone 4 845.3°C Tempering Zone Zone 1 170.2°C Furnace Zone Zone 2 169.8°C Temp. Zone Zone 3 170.1°C Prewasher Temp. Quenching Tank Temp. 122.7°C 10+ Agitator Position
MATERIAL INSPECTION DATA - CP Job :
Process:
30211
BORE
WIDTH W1
W2
Var
S.NO
DA T E : -
Turning
Avg Width
LARGE FACE
03.04.17
OD
Avg
OOR
SMALL FACE
Avg
OOR
B1
B2
Side A
Side A
B3
B4
Side B
Side B
Taper
LARGE FACE
Avg
OOR
SMALL FACE
Avg
OOR
O1
O2
Side A
Side A
O3
O4
Side B
Side B
Taper
1
0
10
5
10
-10
10
0
20
-50
-10
-30
40
30
10
30
20
20
10
30
20
20
0
2
20
40
30
20
10
30
20
20
-10
10
0
20
20
30
40
35
10
20
30
25
10
10
3
0
10
5
10
-20
10
-5
30
-40
0
-20
40
15
10
40
25
30
0
40
20
40
5
4
30
40
35
10
0
20
10
20
-20
0
-10
20
20
0
20
10
20
0
20
10
20
0
5
20
30
25
10
0
30
15
30
-10
20
5
30
10
10
40
25
30
-10
40
15
50
10
6
20
30
25
10
-30
20
-5
50
-50
0
-25
50
20
10
40
25
30
10
30
20
20
5
7
30
40
35
10
-10
30
10
40
-30
10
-10
40
20
0
40
20
40
0
50
25
50
5
8
10
30
20
20
-20
50
15
70 -5-50
30
-10
80
25
0
60
30
60
-20
9
30
40
35
10
30
40
35
10
0
20
10
20
25
0
20
10
20
-20
10
10
20
15
10
10
30
20
20
-10
10
0
20
20
20
40
30
20
11
30
40
35
10
10
30
20
20
-10
10
0
20
20
20
40
30
12
20
30
25
10
10
30
20
20
-10
10
0
20
20
10
30
13
10
30
20
20
-10
20
5
30
-30
0
-15
30
20
30
14
0
10
5
10
10
30
20
20
-10
10
0
20
20
15
10
30
20
20
0
40
20
40
-20
20
0
40
16
0
10
5
10
10
30
20
20
-10
10
0
17
0
10
5
10
10
30
20
20
0
20
18
10
20
15
10
10
30
20
20
-20
19
10
20
15
10
10
20
15
10
20
10
30
20
20
-30
20
-5
21
0
10
5
10
10
30
22
10
30
20
20
0
23
0
10
5
10
24
0
20
10
25
0
10
26
10
27
30
100
30
5
50
5
0
30
15
30
15
20
10
30
20
20
10
20
20
-10
30
10
40
10
40
35
10
-10
30
10
40
25
30
40
35
10
-10
30
10
40
25
20
30
60 45 45
30
-10
20
20
30
40
35
10
-20
30
5
50
30
10
20
10
30
40
35
10
0
30
15
30
20
0
-10
20
30
20
30
25
10
-20
30
5
50
20
-10
10
0
20
15
30
40
35
10
0
30
15
30
20
50
-50
10
-20
60 15 15
10
60 35 35
50
-10
20
20
-10
10
0
20
20
30
40
35
10
-10
30
10
40
25
20
10
20
-20
0
-10
20
20
20
40
30
20
-20
20
0
40
30
0
20
10
20
-10
10
0
20
10
20
40
30
20
0
40
20
40
10
20
0
30
15
30
-20
10
-5
30
20
30
50
40
20
-10
40
15
50
25
5
10
0
20
10
20
-30
10
-10
40
20
30
40
35
10
0
20
10
20
25
20
15
10
10
30
20
20
-10
10
0
20
20
30
40
35
10
0
30
15
30
20
20
30
25
10
10
30
20
20
-10
10
0
20
20
30
40
35
10
-20
40
10
60
25
28
20
30
25
10
-10
10
0
20
-40
10
-15
50
15
10
30
20
20
-20
40
10
60
10
29
10
20
15
10
0
50
25
50
-30
40
5
70 20 20
10
60 35 35
50
10
60
5
30
-20
10
-5
30
0
30
15
30
-30
0
-15
30
30
20
50
35
30
0
USL
50
50
50
50
50
50
50
50
LSL
-50
0
-50
0
-50
0
0
X
17.17
13.0
13.8
27.0
-5.83
31.67
11. 0
5. 3
9.5
13.4
9.92
Pp
1.51
2.31
1. 75
0.57
1.68
Ppk
0.99
1. 26
80
60
60
70
25
40
70
70
20
10
20
40
15
50
50
50
50
-50
0
-50
0
0
19.67
29.67
22.00
15.83
42.33
14.50
16.42
5.07
8. 19
13.49
8.52
18.88
9.32
0.37
1.99
2. 03
0.69
1.96
0.14
1.27
1.48
40
25
0
0. 83
1.34
Max
30
40
35
30
30
50
35
70
0
40
10
80
30
30
60
45
60
20
80
40
100
30
Min
-20
10
-5
10
-30
10
-5
10
-50
-10
-30
20
10
0
20
10
10
-20
20
0
10
0
MATERI MAT ERIAL AL INSPECTION INSPECTION DATA - CP Job :
Process:
30211
BO R E
WIDTH W1 W2 S.NO
Avg Width
DAT E: E: -
After Heat H eat Treatmen Treat mentt (Chu gai-Ro )
Var LA RGE FACE B1
A vg
OD
OOR SMALL FACE Avg
B2 Si S ide A Side A B3
04.04.17
B4
OOR Taper LARGE FA CE
Side B Side B
O1
O2
A vg
OOR SMALL FA CE
Side A Side A
O3
O4
Avg
OOR
Taper
Side B Side B
1
40 60
50
20
10 60 60
35
50 -9 -90
-60 -7 -75
30
110
60
140
100
80
-10
50
20
60
80
2
40 4 0 60
50
20
30
90
60
60 -8 -80
-10 -4 -45
70
105
80
140
110
60
0 60 60
30
60
80
3
20 40
30
20
0
30
15
30 -9 -90
-70 -8 -80
20
95
60
80
70
20 10 10
30
20 20
20
50
4
50 70
60
20
-10 60 60
25
70 -10 -1000
-50 -7 - 75
50
100
30
100
65
70 -4 -40
30
-5
70
70
5
40 4 0 60
50
20
40
80
60
40 -4 -40
0
-20
40
80
100
130
115
30
30 70 70
50
40
65
6
60 120
90
60
10 40 40
25
30 -11 -1100
-60 -8 -85
50
11 1 10
70 70
90
80
20 -2 -20
0
-10
20
90
7
50 70
60
20
0
90
45
90 -1 -110
0
-55
110
100
40
140
90
100
-20
70
25
90
65
8
50 70
60
20
-30 12 120
45
150 -140
-10
-75
130
120 0
170
85
170
-80
100
10
180
75
9
60 6 0 80
70
20
50
90
70
40 -8 -80
-40 -6 - 60
40
130
40
90
65
50 -2 -20
20
0
40
65
10
30 30 50
40
20
60
90
75
30 -5 -50
-20 -3 - 35
30
110
10 100
130
115
30 10 10
40
25 25
30
90
11
50 50 70
60
20
50
80
65
30 -8 -80
-40 -6 -60
40
125
90
120
105
30
0
40 20 20
40
85
12
60 8800
70
20
20 80 80
50
60 -8 -80
0
-40
80
90
80
110
95
30
10 50 50
30
40
65
13
40 6600
50
20
20 50 50
35
30 -9 -90
-70 -8 -80
20
115
70
110
90
40 -3 -30
20
-5
50
95
14
40 8800
60
40
20 12 1 20
70
100
-50 50 50
0
100
7700
70
140
105
70
10 90 90
50
80
55
15
20 20 40
30
20
60
100
80
40
0 60 60
30
60
50
10 100
15 1 50
125
50
60
130
95
70
30
16
40 140 90 90
100
40
150
95 110 110
-40
110
35
150 60 60
90
170 13 130
80
30
120
75
90
55
17
30 5500
40
20
10 80 80
0
-40
80
85
40
130
85
90
-30
50
10
80
75
18
50 100
75
50
40
140 90 90
100
100
25
150 65 65
90
180 13 135
90
20 13 130
75
110
60
19
70 90 80 80
20
0
70
35
70 -9 -90
-20 -5 -55
70
90
50
100
75
50 -3 -30
30
0
60
75
20
40 7700
55
30
-40 40 40
0
80 -10 -1000
-20 -6 -60
80
60
50
120
85
70
-10
60
25
70
60
21
40 6600
50
20
10 50 50
30
40 -5 -50
10 -2 -20
60
50
60
90
75
30
20 50 50
35
30
40
22
50 8800
65
30
20 90 90
55
70 -8 -80
0
-40
80
95
80
120
100
40
-10
50
20
60
80
23
30 7700
50
40
0
80
40
80
-70 30 30
-20
100
60
60
120
90
60
0 70 70
35
70
55
24
30 5500
40
20
0
100
50
100 -6 -60
-40 -5 -50
20
100
60
140
100
80
10 80 80
45
70
55
25
40 6600
50
20
0
60
30
60 -12 -1200
-50 -8 -85
70
11 1 15
60 60
90
75
30 -4 -40
10 -1 -15
50
90
26
40 40 60
50
20
50
80
65
30 -3 -30
0
-15
30
80
80
110
95
30
30 50 50
40
20
55
27
30 30 50
40
20
60
140 10 100
0
80
100
100
180 14 140
80
20
110
65
90
75
28
40 6600
50
20
-20 50 50
15
0
-50
100
65
40
100
70
60
-20
60
20
80
50
29
30 5500
40
20
10 12 120
65 110 110
60
5
110 60 60
60
170
115 11 1 10
10 14 140
75
130
40
30
30 5500
40
20
0
30
60 -10 -1000
-50 -7 -75
50
105
50
130
90
80 -2 -20
10 10
60
80
USL
80
50
130
100
130
100
50
150
100
150
100
50
LSL
-20
0
30
0
30
0
0
50
0
50
0
0
X
60
45
70 -8 -80
80
-50
-40 40 40
70 -1 -100 -50
40
54. 83 27. 0
50. 0 66. 0
-40. 00 70. 00 90.00
95.83
61. 00
29. 00
65.33 66. 83
15.5
17. 0
24. 6 30. 2
35.16 36. 77 23.30
20.60
32. 63
27. 74
34.11 16. 48
Pp
1.07
0. 45
0. 68 0. 37
0.47
0. 81
0.40
0.60
0.34
-0.34
Ppk
0.54
0. 27
-0.66
0.27 -0.57
0. 74
-0.25
Max 70 140
90
100
60
150
100
150
0
110
35
150
13 1 30
10 100
180
140
170
60
140
95
180
95
Min 20 40
30
20
-40
30
0
30
-140
-70 -7
-85
20
50
0
80
65
20
-80
0
-15
20
30
Tempering Temperature=190ºC Processing Processing Condi tion Zone Zone 1 Hardening Zone Zone 2 Furnace Zone Zone 3 Temp. Zone Zone 4 Tempering Zone Zone 1 Furnace Zone Zone 2 Temp. Zone Zone 3 Prewasher Temp. Quenching Tank Temp. Agit Ag it ator at or Positi Po siti on
840.5°C 850.1°C 856.1°C 850.1°C 190.1°C 189.9°C 190.1°C
115.2°C 2
MAT ERIAL INSPECTION INSPECTION DATA - CP Job :
Process:
30211
BORE
WIDTH W1
W2
V ar
S.NO
DAT E: -
Turning
Avg Width
LARGE FACE
10.04.17
OD
Avg
OOR
SMALL FACE
B1
B2
Side A
Side A
B3
Avg
OOR
B4
Side B
Side B
Taper
LARGE FACE
Avg
OOR
SMALL FACE
Avg
OOR
O1
O2
Side A
Side A
O3
O4
Side B
Side B
Taper
31
0
20
10
20
0
20
10
20
-20
0
-10
20
20
20
40
30
20
10
30
20
20
10
32
10
20
15
10
10
30
20
20
-20
10
-5
30
25
20
40
30
20
10
30
20
20
10
33
0
20
10
20
-20
20
0
40
-30
10
-10
40
10
30
34
10
20
15
10
0
20
10
20
-20
0
-10
20
20
20
40
30
20
0
20
10
20
20
35
10
20
15
10
10
30
20
20
-10
10
0
20
20
0
20
10
20
-10
10
0
20
10
36
20
30
25
10
10
30
20
20
0
20
10
20
10
20
40
30
20
10
30
20
20
10
37
20
30
25
10
10
30
20
20
0
20
10
20
10
40
50
45
10
30
40
35
10
10
38
0
20
10
20
10
30
20
20
-10
10
0
20
20
20
40
30
20
10
30
20
20
10
39
0
10
5
10
0
30
15
30
-30
0
-15
30
30
40
60
40
20
30
25
10
10
30
20
20
-20
10
-5
30
25
30
41
10
30
20
20
10
30
20
20
0
20
10
20
10
20
40
30
20
10
30
42
20
30
25
10
0
20
10
20
-20
0
-10
20
20
20
50
35
30
20
40
43
-10
10
0
20
-30
50
10
80 80
-60
30 30
-15
90
25
0
44
0
20
10
20
0
20
10
20
-20
0
-10
20
20
30
50
40
20
30
40
35
10
5
45
20
30
25
10
10
30
20
20
-20
0
-10
20
30
30
40
35
10
10
30
20
20
15
46
-10
10
0
20
10
30
20
20
-20
0
-10
20
30
30
40
35
10
10
30
20
20
15
47
10
30
20
20
0
20
10
20
-30
-10
-20
20
30
30
40
35
10
20
40
30
20
5
48
10
20
15
10
-10
10
0
20
-40
-20
-30
20
30
30
50
40
20
30
40
35
10
5
49
10
30
20
20
0
30
15
30
-20
10
-5
30
20
30
50
40
20
10
40
25
30
15
50
20
30
25
10
-10
30
10
40
-40
0
-20
40
30
10
50
30
40
0
50
25
50
5
51
0
10
5
10
0
40
20
40
-20
20
0
40
20
20
40
30
20
10
40
25
30
5
52
20
30
25
10
10
30
20
20
-20
10
-5
30
25
20
40
30
20
10
30
20
20
10
53
20
30
25
10
0
20
10
20
-10
10
0
20
10
20
30
25
10
20
40
30
20
5
54
20
30
25
10
10
30
20
20
-10
10
0
20
20
20
40
30
20
20
40
30
20
0
55
10
20
15
10
-20
10
-5
30
-40
-10
-25
30
20
10
40
25
30
10
40
25
30
0
56
10
30
20
20
10
40
25
30
-10
20
5
30
20
20
50
35
30
10
40
25
30
10
57
10
20
15
10
-20
10
-5
30
-40
-10
-25
30
20
20
40
30
20
30
40
35
10
5
58
20
30
25
10
-10
10
0
20
-20
0
-10
20
59
20
30
25
10
-20
20
0
40
-50
10
-20
60
60
20
30
10
30
-10
10
60
50
70
45 45
50 50 40
35
30
20
20
20
20
70
30
-5 -50
50
50 40
40
35
35 35
30
30
10
15
10
5
20
20
10
30
20
5
-5
10
20
40
30
20
0
30
15
20 20
0
50
25
50
-10
50
20
20
40
10
30
90
30 60
40
15 5
25
10
20
20
0
20
20
30
20
20
20
10
USL
50
50
50
50
50
50
50
50
50
50
50
50
LS L
-50
0
-50
0
-50
0
0
-50
0
-50
0
0
X
17.33
13 . 3
12.8
26 . 3
-7.83
28.33
20.67
32.83
23.00
23.67
25.33
9 . 83
8. 1
4. 8
8. 7
12. 5
10.48
14.87
6.66
7. 51
12.36
9.91
16.34
7 . 37
Pp
2.07
2.55
1. 92
0.63
1.59
0.49
1.47
2. 22
0.73
1.68
0.50
1 . 82
Ppk
1.35
0.00
1. 43
1.34
0. 76
0 . 89
Max
20
30
25
20
10
50
25
80
0
30
10
90
30
40
70
50
70
30
50
35
90
40
Min
-10
10
0
10
-30
10
-5
20
-60
-20
-30
20
10
0
20
10
10
-50
10
-5
10
0
MATERIAL INSPECTION DATA - CP Job :
Process:
30211
B OR E
WIDTH W1 W2 S .NO
Avg Width
DATE:TE:- 15.04.17
After Aft er Heat Treat T reatmen men t (Chug (Ch ug ai-Ro) ai-Ro )
V ar LA RGE FA CE B1
A vg
OD
OOR S MALL FACE A vg
B 2 Si S ide A S ide A B 3
OOR Taper LARGE FACE
B 4 Si S ide B S ide B
O1
O2
Avg
OOR S MALL FACE
Side A S ide A
O3
O4
A vg
OOR
Taper
S i d e B S i de B
31
4400 60
50
20
10 10 1 00
55
90 -1 -110
-20 -6 -65
90
120
60
150
105
90
-10
90
40
100
65
32
3300 60
45
30
30
100
65
70 -1 -100
-30 -6 -65
70
130
60
140
100
80
-10
70
30
80
70
33
3300 60
45
30
30
90
60
60 -1 -100
-30 -6 -65
70
125
100
150
125
50
30
80
55
50
70
34
4400 60
50
20
30
80
55
50 -1 -100
-50 -7 -75
50
130
70
120
95
50 -1 -10
40 15 15
50
80
35
4400 70
55
30
40
100
70
60 -8 -80
-20 -5 -50
60
120
50
110
80
60
-10
60
25
70
55
36
50 100
75
50
20 12 1 20
70
100
-25
130
95
60
130
95
70
10
100
55
90
40
37
5500 80
65
30
30
100
65
70 -8 -80
-10 -4 -45
70
110
60
120
90
60
20
80
50
60
40
38
2200 50
35
30
50
90
70
40 -8 -80
-40 -6 -60
40
130
90
140
115
50
20
70
45
50
70
39
3300 60
45
30
-10 10 100
45
110
-170
-40 -105
130
150
70
150
110
80
-40
70
15
110
95
40
60 120
90
60 0
140
70
1400 14
-140 -1 40
30
-55
170
125
50
150
100
100
-40
100
30
140
70
41
50 100
75
50 -1 -10
230
110 240 240
-150
140
-5
290
115 10 10
230
120
220
-60
170
55
230
65
42
4400 60
50
20
30
50
40
20 -1 -100
-80 -9 -90
20
130
80
100
90
20 20 20
40 30 30
20
60
43
30 3 0 60
45
30
50
150 100 100
100
0
-45
90
145
80
150
115
70
-10
80
35
90
80
44
4400 60
50
20
50
100
75
50 -1 -120
-70 -9 -95
50
170
80
150
115
70
0 60 60
30
60
85
45
5500 70
60
20
30
110
70
80 -1 -120
-40 -8 -80
80
150
60
140
100
80
-30
60
15
90
85
46
2200 40
30
20
50
100
75
50 -1 -100
-50 -7 -75
50
150
70
140
105
70
-10
60
25
70
80
47
6600 80
70
20
10 90 90
50
80 -1 -110
-40 -7 -75
70
125
60
130
95
70
10
80
45
70
50
48
4400 80
60
40
0
70
35
70 -1 -150
-90 -1 -120
60
155
60
140
100
80
-20
50
15
70
85
49
6600 80
70
20
60
90
75
30 -9 -90
-70 -8 -80
20
155
100
120
110
20 20 20
40 30 30
20
80
50
5500 70
60
20
30
50
40
20 -1 -100
0
-50
10 1 00
90
60
90
75
30
20
50
35
30
40
51
4400 60
50
20
60
120
90
60 -8 -80
-20 -5 - 50
60
140
90
160 12 125
70
0 60 60
30
60
95
52
5500 70
60
20
50
80
65
30 -8 -80
-40 -6 -60
40
125
90
110
100
20
20
50
35
30
65
53
4400 60
50
20
50
100
75
50 -1 -100
-40 -7 -70
60
145
60
120
90
60
10
70
40
60
50
54
50 90
70
40
40
120
80
80 -1 -130
-40 -8 - 85
90
165
40
150
95
110
-40
60
10
100
85
55
5500 70
60
20
30
100
65
70 -1 -110
-40 -7 -75
70
140
80
150
115
70
20
90
55
70
60
56
4400 60
50
20
40
100
70
60 -1 -110
-40 -7 -75
70
145
50
150
100
100
-40
50
5
90
95
57
4400 80
60
40
-10 10 100
45
110
-140
-30
-85
110
130
70
120
95
50
10
90
50
80
45
58
4400 60
50
20
-20 10 100
40
1200 12
-100 -1 00
30
-35
130
75 40 40
180
110 1 40 40
-30
110
40
140
70
59
4400 60
50
20
-10 80 80
35
90
-10 90 90
40
100
5
50
150
100
100
-20
80
30
100
70
60
4400 70
55
30 10 10
80 140 140
-80 70 70
-5
150 85 85
70
180
125 1 10 10
-20
100
40
120
85
USL
80
50
130
100
130
100
50
150
100
150
100
50
LS L
-20
0
30
0
30
0
0
50
0
50
0
0
56. 00 28. 0
64. 7
78.0
-60. 83 86.33 125.83
103. 17 75.00
33. 67
80. 00 69. 50
12. 6
11. 0
18. 4
44.1
32. 03 52.75 32. 19
12.70
39.11
14. 14
41. 85 16. 63
Pp
1 . 33
0 . 67
0 . 91
0. 17
0 . 52
1 . 31
0. 21
1 . 18
0 . 16
-0.39
P pk
0 . 64
X
150
-90 40 40
-90
0 . 63
0. 09 -0. 79
-0.95
1 . 23
-0.39
Max 60 120
90
60
60
230
110
240
-10
140
40
290
170
100
230
125
220
30
170
55
230
95
M i n 20 40
30
20
-20
50
35
20
-170 -1
-90 -9
-120
20
5
10
90
75
20
-60
40
5
20
40
Summary of Tempering Study
Parameters
TEMPERING TEMPERATURE 170°C
190°C
Min. Max. Min. Max. 20 14140 20 12120 30211 L.F. -40 150 -20 230 BORE 30~130µm S.F. -140 110 -170 140 L.F. 0 180 1010 230 O.D. 50~150µm S.F. -80 14140 -6-60 17170 HARDNESS 60/64 HRc 61~63 60~61 Width
CH#2
STD -20~80 µm
TEMPERING TEMPERATURE Parameters OOR (0~100) OOR (100~200) 30211 OOR (100~200) TAPER (0~50) TAPER (50~100) TAPER (Above100) TAPER (0~100)
BORE O.D. BORE O.D.
170°C 190°C 27 23 3 7 3 5 3 1 15 3 12 26 ALL ALL
Conclusion This report describes the NBC bearing industry and its technology. The industry is spread over 118 acres of land in Jaipur and 56 acres in Gunsi (Newai).This is the only unit in the country manufacturing wide variety and range of bearings such as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical Roller Bearings& Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings, Cartridge Tapered Roller Bearings and Large diameter special Bearings in separate fully equipped factories. 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 machines imported from reputed manufacturers from Europe and Japan .It has been long pursued policy and commitment of National Engineering Industries Limited (NEI) to adhere to highest standards of integrity – professional professional and financial – and and business ethics in the operation of its business. We believe that this organization has been handed handed to us by the various stakeholders in "trust” and we as professional managers are the "trustees" of those stakeholders. It is therefore our responsibility to ensure that the organization is managed in a manner that protects and furthers the interests of our stakeholders.
SUMMARY Bearings are mechanical devices employed to reduce friction between rotating equipment. Global bearings market is estimated at USD 60 billion, which is dominated by multinational companies like AB SKF (Sweden), Schaeffler Group (Germany), The Timken Company (USA) and Japanese companies like NSK, NTN and JTEKT. Indian bearing market is estimated at Rs 85 billion and it constitutes less than 4% of global bearing demand. In terms of consumption, about 60% requirement is catered through domestic production while remaining is met through imports. Industrial segment constitute major share of domestic bearing demand which is largely driven by general machines/motors, electrical equipment’s (fans/appliances) as well as heavy industries. Increasing automation in manufacturing units, thrust by Government’s ‘Make in India’ program, spending towards railways and metros will support
growth of manufacturing and engineering sector, which augurs well for bearing industry. Bearing industry is a technology and capital intensive industry, as end products finds application in critical applications like aviation, automobile engines, railways and others. Consequently, Consequently, all major players have technology tie-up with their parent (SKF, FAG, Timken) or with a foreign collaborator (NEI, NRB, ABC). Bearings are mainly manufactured m anufactured using high grade steel or alloy steel, which exposes them to global steel price movement. In general, raw material accounts for about t wo third of company’s cost structure or around 58% of bearing manufacturer’s revenue. While bearing manufacturers have relatively strong pricing flexibility
owing to technology knowhow and strong aftermarket presence; their profitability was also impacted during FY12-FY14 in the backdrop of increase in steel prices and weak demand. Out of bearing raw material cost, bearing rings/races constitute major share of raw material followed by that of rollers, cages and seals. Given that bearings find application in computer hardware to aerospace industry, the complexity of bearing ring varies with its applications, weight and size. The entry barrier are relatively lower for smaller bearing rings but technological knowhow as well as manufacturing capabilities becomes a differentiating factor as complexity/size of bearing increases. After witnessing flattish performance during FY12FY14, Indian bearing industry has witnessed healthy growth of 12.7% YoY during 9mFY15 supported by recovery in domestic automotive sector as well as improved off-take in industrial activity. Operating profitability of bearing manufacturers has also recovered in FY15, supported by benign commodity prices and improved operating leverage. With likely improvement in key end user industries like li ke energy/power (after coal block allocation), cement (higher infrastructure/road spending), automotive and railways, ICRA expects bearing industry to grow at healthy 12% CAGR over the medium term. The growth will be also supported by stable replacement demand, which provides comfort during slowdown in core industries.
BIBLIOGRAPHY The following books and websites were referred to during the making of the project report. 1. In house journals and magazines of NEI. 2. The MOVE (magazine of NEI) 3. www.nbcbearings.com 4. www.skf.com 5. www.scribd.com 6. http://www.99business.com/articles/bearing-industry-in-india.html
7.
https://en.wikipedia.org/wiki/Tap https://en.wikiped ia.org/wiki/Tapered_rol ered_roller_bearing ler_bearing
8.
http://www.arb-bearings.com/n http://www.arbbearings.com/news_detail.ph ews_detail.php?id=36 p?id=36
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http://www.grandviewresearch.c http://www.gran dviewresearch.com/industryom/industry-analysis/bear analysis/bearings-market ings-market
10. 10. http://www.engine http://www.engineersedge.co ersedge.com/bearing_ty m/bearing_types.htm pes.htm
11. 11. https://chugai.co.jp https://chugai.co.jp/en/pro_01 /en/pro_01_parts_04/ _parts_04/
