industrial training presentation nbc

8/11/2019 Industrial Training Presentation nbc

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INDUSTRIAL TRAINING PRESENTATION

NATIONAL BEARING CORPORATION

PRESENTED BY :

SURAJ SINGH MEHTA

VEDANT SHARMA



CONTENTS• OBJECTIVES

• COMPANY PROFILE

• TECHNOLOGY AND R&D

• BEARINGS : TYPES

• TAPERED ROLLER BEARING

• MANUFACTURING PROCESS OF TAPER ROLLER

BEARING:

HEAT TREATMENT PROCESS

DIFFERENT PROCESS FOR CONEDIFFERENT PROCESS FOR CUP



OBJECTIVE

• The main objective of this training is to learn differentengineering processes and to develop skills and with thatattitude I had done my engineering training with NBCBearings Ltd.

• In this one month training period I had seen different workand key responsibility of various bearings department.Training was started with brief introduction program of NBCBearing Ltd. and plant visit of different department.

• It was such a great experience to learn various engineeringproduction methods used now a days & to better correlatethe theoretical knowledge with practical observations andunderstandings



COMPANY PROFILE• NBC Bearings Limited, a member company of C.K. BIRLA group of Companies - is a

leading player in the Indian Bearing industry. The company manufactures a verywide range of bearings conforming to the stringent international quality standards.

• NBC manufacturing plants, located at Gunsi (Newai) Rajasthan, Manesar Haryana& Jaipur - was incorporated in the year 1946. Its feature the most advancedmanufacturing technology.

• The company is certified to ISO/TS 16949, ISO 9001, and ISO 14001standards. NBCIndia is a leading OEM supplier to the automotive industry, mechanical andelectrical engineering industry, besides the Railways.

•Bearings produced at the EOU plant have gained ready acceptance and recognitionof customers located in India & Indian Sub Continent, Europe & Africa. NBC’s maincompetitors in bearing are SKF, TIMKEN, NRB, FAG and other local

FacilitiesThe company has three manufacturing facilities located at Jaipur, Newai and

Manesar. The company will be investing Rs 500 crore for expansion in existing facilitiesand the setting up of a fourth plant.The fourth plant at Savli, near Vadodara, is aboutto commence production. A machine building plant at Jaipur reconditions as well asassembles specific work units.The employee strength is 2500 across three plants.



MarketIt is the second-largest Original Equipment Manufacturer (OEM) bearings toall the leading companies of India and abroad . In addition, the companyexports bearings to more than 21 countries including OEMs in Europe andUSA.Being one of the largest exporters of bearings from India, around 50percent of its exports are for railways.

CapacityNBC’s current capacity is to make 100 million bearings annually across itsthree plants. NEI aims to double the production capacity in next sevenyears.The NBC brand commands a market share of 24% in the domesticmarket. Approximately 70% of NEI's sales are to original equipmentmanufacturers and 30% into the replacement market.

The turnover approximates 60% from the auto sector (OEM and aftermarket),30% for railway products and 10% from the low volume industrialapplications. The ability to meet customers’ needs from product conceptresulted in development of 60 new products in the year.



ClientsThe client portfolio includes Indian Railways, Hero MotoCorp, Maruti Suzuki,Tata Motors, Mahindra & Mahindra, Daimler AG, Bajaj Auto and HondaMotorcycle & Scooter India.

ProductsNEI manufactures bearings in about 1000 different sizes.The size of bearingsmanufactured by NBC ranges from 25 mm to 1.3 metre Outer Diameter.

Ball bearings

Steel ball bearings

Tapered roller bearingsRailway bearings

Large diameter bearings



Technology

NEI uses a heat treatment machine (furnace) from Chugairo,

Japan.

The grinding technology is sourced from Izumi of Japan, Nova of

Italy, LMT of Sweden and FMT of Italy.

NEI operates 22 grinding lines out of which 17 are used for Deep

Groove Ball Bearing (DGBB) and five are used for Double Row

Angular Contact (DRAC) Bearings.

NEI is also provided technical assistance by NTN (Japan) and

Amsted Rail (Brenco, USA).



BEARINGS

A bearing is a machine element that constrains relative motion between

moving parts to only the desired motion. The design of the bearing may, for

example, provide for free linear movement of the moving part or for free

rotation around a fixed axis; or, it may prevent a motion by controlling the

vectors of normal forces that bear on the moving parts. Many bearings also

facilitate the desired motion as much as possible, such as by minimizing

friction. Bearings are classified broadly according to the type of operation,

the motions allowed, or to the directions of the loads (forces) applied to the

parts



TYPES OF BEARINGS

• Rolling Contact Bearings – load is transferred

through rolling elements such as balls, straight

and tapered cylinders and spherical rollers.

• Journal (sleeve) Bearings – load is transferred

through a thin film of lubricant (oil).



Rolling Contact Bearings

Load is transferred through elements in rolling

contact rather than sliding contact.



Journal (Sleeve) Bearings

Load is transferred through a lubricant in sliding

contact



Tapered Roller Bearing• Tapered roller bearings are designed in such a way that vertices of the

cone for each roller and those for the inner and outer raceways coincideson the bearing axis or extensions of the raceways and rollers converge at acommon point on the axis of rotation. This results in true rolling motion ofthe rollers on the raceways at every point along the rollers.

• The tapered roller bearings support radial loads and axial loads from onedirection only. The line contact between rollers and raceways provide thebearings with a high load carrying capacity. Steep angle tapered rollerbearing with exceptionally steep cone angle enables the bearings to take

heavier axial load.• The bearings are of separable type, enabling separate mounting of cups

and cones. Since the tapered roller bearings can absorb thrust loads inone direction only, these bearings should generally be installed asopposed mountings. The correct amount of radial and axial clearance isobtained by adjusting the two bearings against each other.



• Designed to withstand high radial loads, high thrust loads, and

combined loads at moderate to high speeds. They can also

withstand repeated shock loads.



RAW MATERIAL:

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

CUP AND CONE:

The raw material used in the Manufacturing of bearing Races

is SAE 52100 high Carbon Chrome bearing steel, which hascomposition similar to EN-31 (100 CR 6 As per BISspecification). The raw material for Bearing Races is in theform of Rods & Seamless Hollow Tubes.



• Approximate required composition for bearingraces are Constitute % Composition

• Carbon 0.95 to 1.1

• Chromium 1.4 to 1.6

• Manganese 0.50 max.

• Silicon 0.15 to 0.35

• Sulphur 0.025 (Max.)

• Phosphorous 0.05



• 2 CAGE'S:

• Cage is used to return balls at proper distanceto prevent them from containing each other

and to prevent a temperature rise andresultant damage due to friction.

• The Material for manufacturing cages is CRCA

Strips of C2015 Bearing grade steel havingcarbon percentage at0.08% max. andMagnesium ranging from 0.25% to 0.45%



MANUFACTURING PROCESS OF TAPER ROLLER BEARING:

Forged rings (De-scaled) as raw material (SAE 52100 steel)

Turning Operation

Centre Less Grinding

Heat Treatment

Hardness Testing

Rough Grinding

Finish Grinding

Honing & Super Finishing



Washing

Application for Rust Preventive

Ready For Dispatch to Assembly

Heat Treatment Process:-Heat treatment process is the process of hardening the soft material. The row material is

soft material and it has to be hardened before grinding, and hardening increase the life

of bearing.

Hardening is done in a special furnace named CHUGAIRO furnace.

The soft machined material is feed in the furnace and washed at 600 C, then send to a

chamber where the material heated in four chambers the first chamber has thetemperature 8400 C and further chamber contains the 8500 C temperature.

Then it dipped into an oil tank at temperature 250C where the material get quenched

then it washed and then it tempered in water about 90 min. at temperature 1050 C .

then dried and cooled in air. The hardened material is obtained.



flowchart of heat treatment



DIFFERENT PROCESS FOR CONE:-

• Dimensions CheckingBefore starting the grinding process, various dimensions of cone should be checked ina 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 finishedindeed to get the desire width of the bearing and since the bearing is amating part and it has to be assembled somewhere in the machine where itshould be fit precisely. The face grinding is done in a machine where the facesare grinded in between the grinding wheel.



• OD (Outer Dia.) GrindingOD is the circumferential surface of the outer race of the bearing. The OD should besurface finished since the bearing has to be assembled in machine. It is obtain in anOD 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 asfollows:

1. Rough1

2. Rough2

3. Fine finish

Size Limit : 15 to 35 µm

Target Size : +30 µm

Flange GrindingThe flange should be surface finished since the bearing has to be assembled inmachine. 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 inmachine. It is obtain in the bore grinding machine. In this machine

the grinding stone is moved in X and Y axis.

• Size Limit : +4 µm to -4 µm.

• 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 ofcone. This machine use weight sensors and position sensors to

identify the position and weight of cone. All dimensions should bechecked in this machine.]

• It automatically discards the work piece if its dimensions are notcompatible with pre-feed data.



• The limitations of size are:

• Size limit : +4 µm to -4 µm.

•Taper : 5 µm maximum

• OOR : 5 µm maximum

• Chatter : 3 µm maximum

• Squareness : 5 µm maximum

Honing Machine

Honing is an abrasive machining process that produces a precisionsurface 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 beassembled in machine. It is obtain in an OD grinding machine. Inthis machine the outer race is rotated between two grinding wheel.The outer race is passed in machine three times to get highlyfinished as follows:

Rough1, Rough2, Fine finish.Size Limit : 15 to 35 µm

Target Size : +30 µm

• Honing Machine• Honing is an abrasive machining process that produces a precision

surface on a metal work piece by scrubbing an abrasive stoneagainst it along a controlled path. Honing is primarily used toimprove the geometric form of a surface, but may also improve thesurface texture.



• Assembly line:

•

Once respective CUP and CONE of corresponding bearing isfinished, 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 theselaser beams hits leave marks as required. Names of few Laser Machine

which are installed in Taper Bearing Section are:

1. AKSHAR FIBER-PRO

2. SAJIAJANAND Laser Technology ltd

R ll Filli M hi



• 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 areinserted at there respective position. Then they are sensed by positionsensor, 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 downstrokepowered by hydraulics and upstroke powered by pneumatics.

• Weight check:• At this station, Weight of bearing is checked and if the weight is not

compatible with the given standard of weight limits, machine will reject

the workpiece sample.

• Demagnetizer:• It is a machine which is used to remove magnetism induced during the

above process. It is done by impact hitting.



• Washing:• Then the bearing is washed by fast stream of kerosene jet.

•

Noise checking:• The bearing is supposed to be produce low noise hence this

machine rotates the bearing at certain rpm and noise ischecked. The noise limit is nearby 0.1 Mpa.

• Press checking:• At this station, the bearing is checked whether its assembly is

pressed properly or not.

• Final checking• This machine has 2 or 4 stations where various dimensions of

final bearing are checked. If any bearing is found incompatiblewith the given dimensions and tolerances, they are rejected bythe 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



• 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 themachine.

• 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.

industrial training presentation nbc

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