training report for nbc

NEI Ltd (nbc) SKIT, JAIPUR

1 | T r a i n i n g R e p o r t - H I T E S H S H A R M A

A

Report on Practical Training

Taken at

“National Engineering Industries Limited, Jaipur”

From May 22to July 23, 2016

Submitted in partial fulfillment

for the award of the

Degree of Bachelor of technology in Department of Mechanical Engineering

of the Rajasthan Technical University, Kota

(Academic Session 2013-17)

Coordinators Submitted by

Mr. Manoj K. Sain Hitesh Sharma

Mr. Sudesh Garg (13ESKME036)

Department of Mechanical Engineering

Swami Keshvanand Institute of Technology, Management & Gramothan,



ACKNOWLEDGEMENT

Gratitude is the hardest of emotions to express and often one does not find adequate words

to convey all, that one feels. It has been my good fortune to come across many good hearted

people during my project activities.

I take this opportunity to express my deep sense of gratitude, thanks and regards towards

all of those who have directly or indirectly helped me in the successful completion of this

Industrial Training.

I must thank the organizations that allowed me to enter their workplaces, and all the

participants involved in the Training. I want to thank all the staff of National Engineering

Industries Limited and especially the training officer, Mr. Amit Kandari & my mentor at

Taper Roller Bearing Division Mr. Daman Singh. These people invested time and energy

into completing my Training. I am so appreciative of their efforts and I am determined to

share the knowledge that I have gained from them. I am grateful to all faculty members of

Department of Mechanical Engineering, SKIT, Jaipur who have helped me in the

successful completion of this report. I would like to thank Mr. Manoj K. Sain & Mr. Sudesh

Garg, for their guidance in completion of this Training Report.

Last but not the least I am indebted to my Parents who provided me their time, support and

inspiration needed to prepare this report.



Table of Contents

Chapter: 1 .................................................................................................................................................... 6

1. About The Company ........................................................................................................................... 6

1.1. Technical collaboration .............................................................................................................. 7

1.2. Major Customers ........................................................................................................................ 7

2. Plant at Jaipur: ...................................................................................................................................... 9

2.1. Ball Bearing: .............................................................................................................................. 9

2.2. Steel Ball: .................................................................................................................................. 9

2.3. Tapered Roller Bearing: ............................................................................................................ 9

2.4. Railway Bearing: ..................................................................................................................... 10

2.5. Large Diameter Bearing:......................................................................................................... 10

2.6. Research & Development At Jaipur : ..................................................................................... 11

2.6.1. Design & Development: ..................................................................................................... 11

3. Companies Mission and Vision:- .................................................................................................... 13

Chapter: 2 .................................................................................................................................................. 14

4. About The Training:- ........................................................................................................................ 14

4.1. Objectives of the Training ........................................................................................................ 14

4.2. Summary of Duties ................................................................................................................... 15

Chapter: 3 .................................................................................................................................................. 17

5. Introduction to Bearings .............................................................................................................. 17

5.1. Definition of Bearing ................................................................................................................. 17

5.2. Principles of Operation ............................................................................................................. 18

5.3. Motions....................................................................................................................................... 18

5.4. Loads .......................................................................................................................................... 18

6. Classification of Bearing ................................................................................................................... 19

6.1. Sliding Contact Bearing............................................................................................................ 20

6.1.1. Hydrodynamic bearing ..................................................................................................... 20

6.1.2. Hydrostatic Bearing .......................................................................................................... 21

6.2. Rolling Contact Bearing ........................................................................................................... 22

6.2.1. Ball Bearings .......................................................................................................................... 22

6.2.2. Roller Bearings ...................................................................................................................... 23



7. Material Used in Bearings ................................................................................................................ 24

8. Tapered Roller Bearing .................................................................................................................... 25

8.1. Components of Tapered Roller Bearing:-............................................................................... 25

8.2. Manufacturing of Tapered Roller Bearing: - ......................................................................... 25

8.3. Material Selection:- ........................................................................................................................... 26

9. Heat Treatment Process:- ................................................................................................................. 28

9.1. Working:-................................................................................................................................... 29

9.2. Testing after Hardening & Tempering Process:- ................................................................... 30

9.2.2. Rockwell Hardness Testing Procedure:- ............................................................................. 30

10. Grinding Process: - ........................................................................................................................... 32

11. Grinding Processes for CUP:- .......................................................................................................... 33

11.1. OD Grinding:- ....................................................................................................................... 33

11.2. Face Grinding:- ..................................................................................................................... 34

11.3. Track Grinding:- ................................................................................................................... 35

11.4. Track Super finishing (Honning):- ...................................................................................... 36

12. Grinding process for CONE:- .......................................................................................................... 37

12.1. Face Grinding:- ..................................................................................................................... 37

12.2. Cone Track Grinding:- ......................................................................................................... 38

12.3. Flange Grinding Process:- .................................................................................................... 39

12.4. Bore Grinding:- ..................................................................................................................... 39

12.5. Cone Track & Flange Super-Finishing:- ............................................................................ 40

13. Grinding Process For Roller:- ......................................................................................................... 41

13.2. Roller End Grinding:- .......................................................................................................... 41

13.3. Roller OD grinding ............................................................................................................... 42

13.4. Roller Honning process ........................................................................................................ 42

14. Assembly process .............................................................................................................................. 43

15. Applications ....................................................................................................................................... 45

Chapter: 4 .................................................................................................................................................. 46

16. Working Experience ......................................................................................................................... 46

Chapter: 5 .................................................................................................................................................. 47



17. Conclusion ......................................................................................................................................... 47

18. References .......................................................................................................................................... 48



Chapter: 1

1. About The Company

[1]

Figure 1. National Bearing Corporation Logo

National Engineering Industries Ltd., part of the 150 year old, multi-billion dollar C.K. Birla

group manufactures a wide range of bearings for automotive and railway industry as well as

for general industrial applications under the brand name NBC . NEI, founded in the year 1946

as a pioneer industry in the field of bearing manufacture, now manufactures nearly 80 Million

Bearings per annum in over 500 different sizes ranging from 6 mm bore to 1300 mm outer

diameter having capability to manufacture bearing up to 2000 mm. diameter.

NEI is one of the largest domestic bearing manufactures with gross annual turnover of Rs.

1051 crore in 2010-11. The company exports bearings to more than 20 countries and is also

exporting to OEMs in Europe and USA. NEI has grown at a CAGR of 19% since 2007-08.

NEI manufactures a wide range of bearings namely ball and cylindrical roller bearings, double

row angular contact bearings, tapered roller bearings for automobiles, railways and industrial

applications and large diameter bearings for steel plants and rolling mills. The three plants

situated at Jaipur, Newai and Manesar manufacture these products with approx. 2300-strong

team, supported by a well-equipped R&D with bearing life testing facility.

NEI Ltd. has been awarded the coveted 2010 Deming Application Prize, by the Union of

Japanese Scientists and Engineers (JUSE), Japan, for achieving distinctive performance

improvement through the application of Total Quality Management (TQM).The Deming

medal confirms that our quality management systems are one of the best, globally .For our

customers, this means enjoying consistently superior products and assurance of highest quality

for every NBC bearings they use.



R&D is equipped to introduce new technology in the field of bearings and related products .All

functions from concept design to product launch are an integral part of R&D. The activity

begins from customer interaction by Application Engineering and QFD approach is used to

understand Customer requirements to translate into a useful product. It has a full-fledged test

center for endurance as well as application testing .The test lab is being expanded to double

the capacity in next four years.

Advanced functions like Tribology, Simulation, Materials Technology and Lubrication

technology have been added .The center relies on the associate strength that has vast experience

in the bearing industry. Academic excellence is being promoted by inclusion of specialists

from IIT’s and REC’s .The Centre will be a leading technology Centre in next 4 to 5 years.

1.1. Technical collaboration

o BRENCO Incorporated of U.S.A. Since 1982 - For Cartridge Tapered Roller Bearings

for Railroad applications.

o NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical & Spherical

Roller Bearings, JPU Bearings, Double Row Angular Contact Bearings, Hub

Bearings Since 1997 - for Tapered Roller bearings.

o Izumi Kinzoku of JAPAN Since 1996 for remanufacturing, retrofitting and

overhauling of grinding and Super-finishing machines for bearing races. [2]

1.2. Major Customers

1.2.1. Rolling Stock: -

DLW (Diesel Locomotive Work)

CLW (Chittaranjan Locomotive Works)

ICF (Integral Coach Factory, Chennai)

RCF (Rail Coach Factor, Kapurthala)

CIMMCO

BEML (Bharat Earth Movers, Bangalore)

TEXMACO

Hindustan Motors Ltd.

Maruti Udyog Ltd.

Mahindra & Mahindra



Automobiles-LCV: -

Ashok Leyland

Force Motors

Eicher Motors

Tata Motors

1.2.2. Automobiles-Two/ Three Wheelers:-

Bajaj Auto Ltd.

Hero Honda Motors Ltd.

Honda Motorcycle & Scooters India Ltd.

Suzuki Motorcycle India

Majestic Auto

Piaggio India Ltd.

Royal Enfield Ltd.

Yamaha Motors India Pvt. Ltd.

TVS

1.2.3. Tractors: -

Eicher

Escorts

HMT

International tractors

Mahindra & Mahindra

Punjab Tractors

TAFE

VST Tillers

1.2.4. Electric Motors & Pumps:-

Crompton Greaves

G.E. Motors

Kirloskar Electric

NGEF

MICO

1.2.5. Fans: -



Bajaj Electricals

Crompton Greaves

2. Plant at Jaipur:

[3]

Figure 2. NEI Jaipur Plant

2.1. Ball Bearing:

Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are manufactured on

state of the art manufacturing facilities with in-process and post-process gauging in

grinding and centrally air conditioned assembly lines with auto gauging and testing

equipments. The latest advanced techniques for manufacturing and Quality Assurance are

implemented to meet the rapid increase in demand for Quality, diversity of specifications

and new types of bearings.

This Division is spread over a covered area of 14,694 Sq. Meters.

2.2. Steel Ball:

Precision Steel Balls up to 25 mm diameters for NBC Bearings are manufactured on

precision grinding and lapping machines to achieve super finished surface, accuracy and

roundness as per ISO standards. This Division is spread over a covered area of 4,700 Sq.

Meters.

2.3. Tapered Roller Bearing:



Precision Tapered Roller Bearings are manufactured in Inch and Metric series from

15.875mm bore to 95.25mm bore with technology obtained from our earlier collaborator,

Federal Mogul Corporation, USA and now with NTN Corporation, Japan. These bearings

are used by all major Automobile manufacturers in the country as Original Equipment.


2.4. Railway Bearing:

2.4.1. Roller Bearing in Axle Box:

With the production of Roller Bearings and Axle Boxes since 1952, the company has fully

met the requirements of the Indian Railways (one of the largest systems of the world) by

designing and developing Axle Boxes and bearings for fitment to Locomotives

manufactured by Diesel Locomotive Works , Chittaranjan Locomotive Works, various

wagon builders, the ICF broad and meter gauge coaches. Over a million NBC bearings

and boxes are in service with the Indian Railways. The development of completely

indigenized Axle Boxes and bearings for the high speed Rajdhani Locomotive, the

Yugoslavian and Egyptian Railway wagons are the highlights of the design capabilities at

NEI.

On date more than 100 types of Axle Boxes & Bearings have been manufactured.

2.4.2. Spherical Roller Bearing:

The manufacturing of Spherical Roller Bearings was started in the year 1975-76 for

fitment to broad gauge and meter gauge passenger coaches with designs, technology,

machines and equipment procured from the collaborators.

2.4.3. Cartridge Tapered Roller Bearing:

For fitment to the new BOX-IN Up rated Wagons designed by the RDSO, NEI is the only

manufacturer in the country to indigenize these bearings to a high percentage under

collaboration with the largest manufacturer of these bearings in the world. Production of

these bearings commenced in the year1984. These bearings are grease packed and require

no field lubrication for a period of 7 years.


2.5. Large Diameter Bearing:



Self-sufficiency in steel is the call of the day, so is the importance of bearings in Steel

Mills Equipment. NEI has the distinction of being one of the ten manufacturers of these

bearings in the world, who can manufacture large diameter bearings up to 2000 mm

diameter.

The largest bearing manufactured by NEI for fitment to the Plate Mill of Rourkela Steel

Plant was released by Mr. G.P. Birla in September 1985. This 4-Row Tapered Roller

Bearing measures 1300 mm diameter and weigh 4.39 tons.

The large diameter bearings are mainly manufactured out of case carburizing steel, heat

treated on special equipment and furnaces developed by NEI. Precision grinding is done

to close tolerances on CNC Twin Spindle Programmable Berthiez Machine for bearings

ranging from 500 to 2000 mm diameter with electronic sizing and numerical display.

Production of these bearings started in 1975 and to date over 100 different types of special

large diameter bearings have been manufactured and successfully used, saving

considerable foreign exchange for the country.

The Large Diameter Bearings Division is spread over a covered area of 2,508 Sq. Meters.

2.6. Research & Development At Jaipur :

2.6.1. Design & Development:

Complete in-house facility for design development of all types of bearings and tooling is

available. The design of all types of bearings is done on Pro-Engineer 3D Modeling &

Analysis Software.

Complete engineering and 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 & BRENCO Inc of USA, the capability to offer finest engineering services in the

bearing industry has enhanced. Services of team of experienced engineers are available for

selection of bearing as per application.

2.6.2. Machine Building :



NEI has the capability of machine building to design, develop and manufacture special

purpose CNC Grinding Lines, HT Lines, Material Handling Equipment and other special

purpose machines which have been made for its captive use to keep pace with latest

technology.

A well-equipped electronic design, development laboratory with all testing facilities

supports the Machine Building Division.

Machine Building has the capability and supports the Manufacturing Divisions by

overhauling and retrofitting of the existing equipment, resulting in upgraded quality and

improved productivity. R&D Division is spread over a covered area of 2,007 Sq. Meters.



3. Companies Mission and Vision:-

3.1. Mission

Grow in the business of anti-friction bearings and other allied engineering products

and services

To deliver superior value to our customers, suppliers, shareholders, employees and

society at large

Pursue excellence through Total Quality Management

3.2. Vision

To become a preferred anti-friction bearings supplier in domestic market and focus

on select export markets.

To enhance our presence in allied engineering products & services

To attain gross turnover of INR 50 billion by 2020.



Chapter: 2

4. About The Training:-

Practical training refers to students’ work experience in an engineering-practice

environment to familiarize themselves with professional engineering practices prior to

graduation. The Rajasthan Technical University prescribed 8 weeks continuous practical

training for all undergraduate engineering programs. All engineering students must

complete at least 60 days of Practical training as one of the requirements to be awarded a

Bachelor of Technology. It is a mechanism to integrate engineering practices in the

curriculum to achieve the overall Programs Outcomes and Graduates Attributes

So for the above cause I requested a training session of 60 days at National Engineering

Industries Limited from the duration 23 May 2016 to 22 July 2016. My request of training

program was accepted and I was allocated the project “Study of bearing manufacturing

process and its application” under the supervision of Mr. Daman Singh Sir of,

Maintenance Department, Taper Roller Bearing, NEI Ltd.

From Day 1 (23/5/2016) I began my training and started understanding Bearing

Manufacturing Process and on the last day (22/07/2016) I completed my training by

submitting the report of the work I completed in the finite duration.

4.1. Objectives of the Training

Through the Practical training, students will be able:-

To apply engineering knowledge learned in classroom in real industrial/Laboratory

situations.

To get the knowledge of advanced tools and techniques and expose to professional

engineering practices in the industry.

To understand the role and responsibilities as well as code of ethics that engineers should

uphold.

To develop awareness about general workplace behaviors and build interpersonal and team

skills.

To prepare professional work records and reports.



4.2. Summary of Duties

As mentioned above during the training period of 60 days (23, May -22, July, 2016) I was

enrolled with the Taper Roller Bearing division in National Bearing Industries Limited, Jaipur,

where I was awarded the project “Study of Bearing manufacturing process and its application”

in which I have to study How Bearings are manufactured?

Following is the Chronology of work schedule:-

Table 1. Chronology of work schedule in the practical training

Month Date topic

MAY 23 Orientation

MAY 24 study of design concept and components of bearing

MAY 25 study of raw material used in bearing manufacturing and its properties

MAY 26 study of heat treatment process and its importance in bearing manufacturing

MAY 27 Study of Chugai-RO Furnace



JUNE 1 study of Rockwell Hardness test and its importance

JUNE 2 Study of Abrasive Machining Process

JUNE 3 Study of Abrasive Grinding Wheel

JUNE 6 Study of O.D. Grinding machine and O.D Grinding Process

JUNE 7 Study of O.D. Grinding machine and O.D Grinding Process

JUNE 8 Study of Face Grinding machine and Face Grinding Process

JUNE 9 Study of Face Grinding machine and Face Grinding Process

JUNE 10 Study of coolant used in Grinding process

JUNE 13 Study of Cone Grinding & Finishing Processes







JUNE 20 Study of Cup Grinding & Finishing Processes





JUNE 27 Study of Roller Grinding and Finishing Processes




JULY 1 Study of Roller Grinding and Finishing Processes

JULY 4 Study of Bearing Assembly Process ( Manual )





JULY 11 Study of Bearing Assembly Process ( Automatic )





JULY 18 Study of Misc. processes and Parameters of Bearing Manufacturing Processes




JULY 22 Training Completion and Report Submission

The project has been successfully completed in the due time and the report as demanded by NEI,

has been submitted and the report consist of following information regarding Bearing

Manufacturing process. In the submitted report all the major sections of Taper Roller Bearing

Manufacturing are mentioned in the deepest form.



Chapter: 3 5. Introduction to Bearings

Figure 3. A Taper Roller Bearing

5.1. Definition of Bearing

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 very 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 important for efficiency, to reduce wear and to facilitate

extended use at high speeds. Essentially, a bearing can reduce friction by virtue of its shape,

by its material, or by introducing and containing a fluid between surfaces or by separating

the surfaces with an electromagnetic field.

By shape, gains advantage 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 fluid 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

5.2. 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 bearings.

Jewel bearings, in which the load is carried by rolling the axle slightly off-center.

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.

5.3. 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

5.4. Loads

Bearings vary greatly over the size and directions of forces that they can support. Forces can

be predominately radial, axial (thrust bearings) or moments perpendicular to the main axis.



6. Classification of Bearing

According to nature of relative motion between two contacting surface

Figure 4. Classification of Bearing

There are numerous different kinds of bearings that are designed to handle radial load,

thrust load, or some combination of the two. Because different applications require

bearings that are designed to handle a specific kind of load and different amounts of weight,

the differences between types of bearings concern load type and ability to handle weight.



6.1. Sliding Contact Bearing

6.1.1. Hydrodynamic bearing

Load supporting high pressure fluid film is created due to the shape and relative

motion between the two surfaces.

Figure 5. Hydrodynamic Bearing Mechanism



6.1.2. Hydrostatic Bearing

The load supporting fluid film is created by an external source, like pump.

Figure 6. Hydrostatic Bearing Mechanism



6.2. Rolling Contact Bearing

6.2.1. Ball Bearings

Ball bearings are extremely common because they can handle both radial and thrust

loads, but can only handle a small amount of weight. They are found in a wide array

of applications, such as roller blades and even hard drives, but are prone to deforming

if they are overloaded.

Figure 7. Ball Bearing Diagram



6.2.2. Roller Bearings

Roller bearings are designed to carry heavy loads—the primary roller is a cylinder,

which means the load is distributed over a larger area, enabling the bearing to handle

larger amounts of weight. This structure, however, means the bearing can handle

primarily radial loads, but is not suited to thrust loads. For applications where space

is an issue, a needle bearing can be used. Needle bearings work with small diameter

cylinders, so they are easier to fit in smaller applications.

Figure 8. Roller Bearing



7. Material Used in Bearings

Bearing reliability begins with the material from which the product is made. The material

selection can have a dramatic impact on a bearing’s ability to meet the application

requirements. Additionally, the heat-treatment process that accompanies material selection

largely dictates durability by its impact on several bearing characteristics, including

hardness profile, bearing microstructure, final raceway surface finish and residual stress.

Traditionally, Bearings have been produced from low carbon, carburizing grades of steel.

The introduction of carbon during manufacture, and the high alloys in the steel, assures the

proper combination of a hard, fatigue-resistant case and a tough, ductile core. Benefits of

casehardened bearings include:

Residual compressive stresses in the surface that retard propagation of fatigue cracks.

An enhanced ability to endure heavy shock loads as a result of the tough, ductile core.

Improved debris resistance due to the metallurgical characteristics of the surface

Tapered roller bearings have a spherical surface ground on the large ends of the rollers.

The radius of this surface is slightly less than the apex length (distance from the roller

large end to the apex). The roller large end makes point contact with the cone large rib

when under light load. Under heavier load, this contact area becomes elliptical. The roller

rib interface geometry promotes hydrodynamic lubrication in the contact area. The seating

force of the roller against the rib is normally small and therefore contact stresses are

relatively low. This is true whether pure radial load or pure thrust load is involved.



8. Tapered Roller Bearing

They are uniquely designed to manage both thrust and radial loads on rotating shafts & in the

housings.

The taper angle allows the bearing to handle a combination of radial and thrust load.

8.1. Components of Tapered Roller Bearing:-

The CONE (or inner ring)

The CUP (or outer ring)

The TAPERED ROLLER

The RETAINER or CAGE

Figure 9. Taper Roller Bearing Parts

8.2. Manufacturing of Tapered Roller Bearing: -

Following steps are taken while manufacturing a Tapered Roller Bearing on Industrial

Scale.

Material Selection

Machining

Heat Treatment for Hardening

Grinding & Finishing

Assembling & Packing



8.3. Material Selection:-

For bearing manufacturing process SAE 52100 grade steel is used. Which has following

composition:-

Table 2: Composition of Material In SAE 52100

Element Percentage

Carbon 0.98 - 1.1

Chromium 1.3 - 1.6

Iron Balance

Manganese 0.25 - 0.45

Phosphorus 0.25

Silicon 0.15- 0.35

Sulphur 0.025 max

Table 3. Material Property

Principal

Design

Features

52100 is a high carbon, chromium containing low alloy steel

that is through hardening and noted in particular for use as

bearings.

Applications Principal applications are those for bearings in rotating

machinery.

Machinability Machinability of 52100 alloy is good by conventional methods.

A spherodizing anneal at 1200 F before machining will improve

the overall machinability of the alloy.



Forming

52100 may be formed by all conventional methods,

including cold forging or stamping and hot or cold upset

forming.

Welding

No data given. This is a high carbon alloy typically used in

bearing applications where welding is not applicable or

appropriate.

Heat

Treatment

Heat treatment consists of heating to 1500 F followed by an

oil quench for through hardening of the alloy. A normalizing

heat treatment at 1600 F and slow cooling, to relieve

machining stress, may be employed prior to the 1500 F and

quench treatment.

Forging

The alloy may be supplied as forgings and also may be

subsequently forged at 2200 F down to 1700 F

Hot

Working

Hot working, such as upsetting, may be done in the range of

400 to 1000 F.

Cold

Working

The alloy has good ductility and may be cold worked in the

annealed or normalized conditions by conventional

methods.

Annealing

Anneal at 1600 F and slow cool to relieve machining or cold

working strains.



Aging

Not applicable to this alloy.

Tempering

Temper at 400 F.

Hardening

The alloy hardens from cold working or by heating and

quenching - see "Heat Treatment". It also may be carburized

at 1675 F and quenched after sufficient time for

carburization. A second heating to 1450 F and second

quench from that temperature should be used.

Physical Data :

Density (lb / cu. in.) 0.283

Specific Gravity 7.83

Specific Heat (Btu/lb/Deg F - [32-212 Deg F]) 0.114

Melting Point (Deg F) 2595

Thermal Conductivity 240

Mean Coeff Thermal Expansion 6.5

Modulus of Elasticity Tension 29

8.4. Machining: - In machining process, the steel grade raw material is given the shape of a

bearing element which are also called Races. These Races are made according to the load

and application of Bearing in its due life.

9. Heat Treatment Process:-

Heat treatment is a group of process to alter various properties of material (like strength,

ductility, hardness, brittleness, etc.,) by treating it at high temperature & pressure

conditions.



Machine Name- CHUGAI RO FURNANCE

Capacity- 450kg/hr

Fuel Type- L.P.G.

Process Involved:-

Prewashing

Hardening in furnace

Oil Quenching

Post Washing

Tempering in Furnace

9.1. Working:-

The material to be processed is received from the vendors.

On according to size & requirement of job the temperature of furnace is set and maintained

by the help of heater.

The heaters are used to raise the temperature of following units:-

Prewash Unit ( To 60+10/20 ◦C)

Hardening Furnace (To 840±20◦C)

Oil Quenching Tank (To 115±5◦C)

Tempering Furnace (To 170±5◦C)

Hot Air Blower’s (To 90±10◦C)

First the supply is been unloaded in the loading hopper.

The work pieces are now transferred to Pre-Wash unit, where in the action of water &

sulpha cleanser all the dirt & surface impurities are removed.

After prewashing, the jobs are then transferred to hardening furnace, through Rabbit

Conveyor.

Before hardening furnace, the jobs are made to dry under hot air blow of air which is forced

by a Hot Air Blower.

In the Hardening Furnace, the temperature of job is made to reach the set temperature of

about 840±20◦C in a fine span of time

After spending time in furnace & gaining its required temperature for hardness, the jobs

are then dropped into an Oil Quenching Tank which is preheated at a temperature of

115±10◦C.



In the Oil Quenching Tank, the temperature of the job is dropped from 840◦C to 110◦C.

this is done to avoid brittle fractures.

After Oil Quenching the job is cooled by the help of a Cooling Fan Unit, due to which its

temperature is made to drop before Post Washing Section.

In Post-Washing section, the job is again treated with the solution of water and sulpha

cleanser & its temperature is now dropped to 22.5±7.5◦C.

After Post-Washing section the jobs are then made to bass through a Hot Air Blower and

it is further sorted for Tempering Process.

In Tempering Furnace, the temperature of job is raised to arrange of 170◦C & it is a very

slow process. During this step, hold time is greater than in hardening process.

After tempering process, the jobs are collected & prepared for next process.

9.2. Testing after Hardening & Tempering Process:-

9.2.1. Rockwell Hardness Test: - Rockwell Hardness test is a method to determine the

degree of hardness of any specimen.

9.2.2. Rockwell Hardness Testing Procedure:-

In Rockwell hardness test, first the specimen is placed at the testing slab of machine.

Then with the help of hand lever provided the base, the slab is made to raise.

A diamond or ball inventor is made to indent the specimen till a small length.

After reaching the certain limit of indentation, predetermined load is applied on the

specimen.

After a span of time when the readings at the scale are stable, the load is removed.

After removing the load, the final hardness number of specimen can be gained from the

scale.



Figure 10. Rockwell Hardness Testing Machine

9.2.3. Load and Variables for R.H.T.-

Table 4: Load & Variable for Rockwell Hardness Test

Material Load Indenter Scale

Hard Job 150kg Diamond C

Soft Job 100kg Ball B



10. Grinding Process: -

Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.

In grinding process, the job is made to possess relative motion with respect to grinding

wheel, due to which material is removed from the surface of job and hence cutting

operation takes place. The removed metal is called as Sludge or Chip and it is removed

along with coolant.

10.1. Abrasive Grinding Wheel:- It is a wheel made up of abrasive particles bounded

together which is used for cutting, grinding or finishing metal or other objects.

[4]

Figure 11. Various Types of Abrasive Grinding Wheels

10.2. Abrasive Grinding Wheel Specification:-

Figure 12. Grinding Wheel Specification

PREFIX GRAIN TYPE GRAIN SIZE GRADE WHEEL STRUCTURE BOND TYPE SUFFIX



11. Grinding Processes for CUP:-

[5]

Figure 13. A Cup

For CUP following major are performed before sending it to assembly.

OD Grinding

Face Grinding

Track Grinding

Track Super-finishing (Honning)

11.1. OD Grinding:-

Figure 14. Centerless Grinding Process



OD Grinding is or Outer Diameter Grinding is a method of removing metal from outside

surface of cup till the limit asked by the consumer is gained. In the bearing manufacturing

process OD grinding is being performed by using Centre-less grinder.

In center-less grinding process the workpeice is held between two rotating wheels i.e.

grinding wheel and regulating wheel, which are rotating at different speeds (VGW>VRW).

This relative difference between the two wheel’s speeds provide the required cutting force

to remove the material from the workpeice.

During the whole process, a coolant, made from mixing Soluble Oil and DM Water, is

made to flow between the wheels & workpeice to prevent burning of metal on the surface.

Every first piece of the lot is made to subject to inspection for dimensional accuracy and if

it is passed than the process is continuous otherwise the cutting settings of the machine are

changed. These testing’s and inspection are done on comparisons basis with respect to a

standard specimen.

After OD Grinding Operation, the jobs are send for Face Grinding Operation at next

station.

11.2. Face Grinding:-

Face grinding is a process of removing material from the face of the cone and hence to also

finish its sides (Face).

In the process, the workpeice is first placed in loading hopper from where it gets sorted

towards the grinding machine.

In the Grinding Machine first the workpeice is loaded in carrier plate, which is use to hold

the job during grinding operation.

The upper and lower face cutting rate (metal removal rate) is set by the machine operator

& the machine removes the metal from the job according to it.

During whole process the job is cooled by a forced flow of coolant in the machine.

The first piece of the lot after grinding is subject to inspection on the basis of dimensional

accuracy, which is done by comparing the dimensions of the workpeice with accordance

to a standard sample.

After Face Grinding Operation, the jobs are send for Track Grinding Operation at next

station.



11.3. Track Grinding:-

Track grinding is a major aspect of whole process, as for, it’s major domination in

assembly.

Track Grinding is done by the help of abrasive grinding wheel.

The Grinding Wheel and Cup Track are positioned aligned to each other & due to their

relative motion, material is removed from the cup & hence its required tolerance is gained.

The cutting rate (metal removal rate) is set by the machine operator & after first job of the

is grinded the operator performs inspection and according to the results obtained by testing,

further amendments are made in machine settings.

11.3.1. General operation in Track Grinding:-

Loading

Dressing

Gage-in

Rapid/Quick feed

Rapid-I

Rapid-II

Rough Spark out

Approach

Fine Feed

Fine Spark Out

Table Out

Gage-out

Index back

Unloading

In the process of Track Grinding, First of all the given jobs are loaded in the machine through

loading hopper.

If required, the Dressing of Grinding wheel is done. As after so much of cutting operation, the

abrasive material in the grinding tool has to be taken out & this is done by a diamond shaped,

which cuts the abrasive surface of the grinding wheel.

After the dressing has been done, the job is set for gage-in which cuts a job & left a particular

grinding allowance for the machine this is a quick feed mechanism., the job is set against a



needle and quickly a portion of material is been cut. There after a particular grinding allowance

is taken out in a fine feed mechanism where the material is cut slowly.

Simultaneously, the cooling is continuous to pour on the job to prevent it from overheating.

After the cutting is done the job is unloaded from the machine, the loading/unloading is done

by the arm which is set a particular frequency.

11.4. Track Super finishing (Honning):-

After the track grinding process the jobs are the transferred to honning process, also known as

Super Finishing.

In this process the job’s track surface is been polished and make it super finished.

11.4.1. General operation in Honning:-

Loading

Clamping

Stone side advance ( Z-axis)

Stone down

Workpeice unit advance

Track Honning Finish

Stone side retract

Unclamping

Unloading

First of all, the job is loaded and is clamped in the machine. A white stone being

pressed against the job which polishes the surface of job, it polishes the track. In the

end, a super finished, polished and bright job is all we get. After the job is Super

Finished, it is send to assembly.



12. Grinding process for CONE:-

[6]

Figure 15. A Cone

For Cone component, the following processes are performed:-

Face Grinding

Cone Track Grinding

Cone flange Grinding

Cone Bore Grinding

Cone Flange & Track Super Finishing

12.1. Face Grinding:-

Face grinding is a process of removing material from the face of the cone and hence to also

finish its sides (Face).

In the process, the workpeice is first placed in loading hopper from where it gets sorted

towards the grinding machine.

In the Grinding Machine first the workpeice is loaded in carrier plate, which is use to hold

the job during grinding operation.

The upper and lower face cutting rate (metal removal rate) is set by the machine operator

& the machine removes the metal from the job according to it.

During whole process the job is cooled by a forced flow of coolant in the machine.

The first piece of the lot after grinding is subject to inspection on the basis of dimensional

accuracy, which is done by comparing the dimensions of the workpeice with accordance

to a standard sample.

After Face Grinding Operation, the jobs are send for Track Grinding Operation at next

station.



12.2. Cone Track Grinding:-

Track Grinding is done by the help of abrasive grinding wheel.

The Grinding Wheel and Cup Track are positioned aligned to each other & due to their

relative motion, material is removed from the cup & hence its required tolerance is gained.

The cutting rate (metal removal rate) is set by the machine operator & after first job of is

grinded the operator performs inspection and according to the results obtained by testing,

further amendments are made in machine settings.

General operation in Track Grinding:-

Loading

Dressing

Gage-in

Rapid/Quick feed

Rapid-I

Rapid-II

Rough Spark out

Approach

Fine Feed

Fine Spark Out

Table Out

Gage-out

Index back

Unloading

In the process of Track Grinding, First of all the given jobs are loaded in the machine

through loading hopper.

If required, the Dressing of Grinding wheel is done. As after so much of cutting operation,

the abrasive material in the grinding tool has to be taken out & this is done by a diamond

shaped, which cuts the abrasive surface of the grinding wheel.

After the dressing has been done, the job is set for gage-in which cuts a job & left a

particular grinding allowance for the machine this is a quick feed mechanism., the job is

set against a needle and quickly a portion of material is been cut. There after a particular

grinding allowance is taken out in a fine feed mechanism where the material is cut slowly.



Simultaneously, the cooling is continuous to pour on the job to prevent it from overheating.

After the cutting is done the job is unloaded from the machine, the loading/unloading is

done by the arm which is set a particular frequency.

12.3. Flange Grinding Process:-

Cone flange grinding is the process of removing excess material from the flanges of the

job, to make it under the required tolerance and design limits.

In the process an abrasive grinding wheel, which rotates at the extremities so the metal

could be removed from the end corners of the job.

At the end of the process the job is then send to Bore Grinding station.

12.4. Bore Grinding:-

Cone bore is made to reduce into required dimensions by removing excess material by the

help of an abrasive grinding wheel.

12.4.1. General Operations in Bore Grinding:-

Loading

Dressing

Gage-in

Rapid/Quick Feed

Rapid –I

Rapid –II

Rough spark out

Approach

Fine Feed

Fine spark out

Table out

Gaga-Out

Index back

Unloading

This process is also similar to other grinding processes but the difference between them is

that here size is of grinding wheel is lesser than the diameter of bore.



After successful operation of bore grinding, the job is moved to next station i.e, Track &

Flange Super-finishing operation

12.5. Cone Track & Flange Super-Finishing:-

In the process, cone’s track and flange sides are made polished by the process of Honning

with the help of a stone

12.5.1. General operations in process:-

Loading

Clamping

Stone side advance ( Z-axis)

Stone Down

Flange Unit advance

Finish Honning

Stone side retract (Z-axis)

Unclamping

Unloading

First of all, the job is loaded in the machine and it is clamped in it. After the clamping the

stone, which is used to polish the job is made to have contact with it. As the process starts,

the stone polishes the track and flange in the presence of Honning Oil.

In the end of the process a polished and ready job is what we get. After the required

inspection, then job is then send to the Assembly unit, where it will meet other component

to form the bearing unit.



13. Grinding Process For Roller:-

Roller are a major component of any bearing. They are specially designed to with stand

heavy load and thrust. They are manufactured from the same material by which other

component (i.e., Cup, Cone, Retainer) are made.

13.1. Basic operation in Roller Manufacturing and Finishing:-

Slug

Roller upset

Roller Soft Tumbling

Roller Hardening

Roller hard Tumbling

Roller rough O.D.

Roller Rough end grinding

Roller O.D. super finishing.

13.2. Roller End Grinding:-

Rollers are send to the end grinding machine where the end face of roller is grinded. The

machine consist of following important parts, namely-

Pressure Plate

Carrier Plate

Base Plate

Grinding wheel

First of all, rollers are arranged horizontally in a carrier plate facing outwards with its end

face.

The carrier plate is been supported by the base plate in a horizontal manner. This system

rotates clockwise in a direction and the grinding wheel grinds the jobs simultaneously.

Stones are also linked in the mechanism to polish the job, with polishing, oiling is too done

continuously.

So in this step end face grinding takes place along with Honning of the End Face.

After the end face grinding process, the roller are send to next station for O.D. grinding.



13.3. Roller OD grinding

After end face grinding operation, the roller are then subjected to OD grinding. The roller

are sent in vertical position and are supported by the base wheel, during grinding operation.

The dressing of grinding wheel is done to keep it ready for efficient grinding. After that

grinding operation start along with the passage of coolant to prevent the overheating.

This machine process work on the principle of center less grinding. The speed of both

grinding wheel and support wheel is not equal. Grinding wheel rotate faster than support

wheel.

After OD grinding process the roller are sent to next station for honing process, where

surface of rollers are super finished.

13.4. Roller Honning process

The honning process is the last step where roller are processed before assembling. In the

honning machine there are two types of wheel, i.e. first the regulating wheel and then feed

wheel.

Stones are used to polish the surface of rollers in presence of flow of honning oil.

The feed wheel produce a thrust and pressure the roller against the stone by which polishing

take place.

After this we get a finished OD grinding. And after this step roller are set for examination

under dimensional checks and further they are sent for assembly process.



14. Assembly process

It is the last and most important step in bearing manufacturing. In assembly process the basic

elements of bearing i.e. cone, roller, retainer and cup are linked together to form a whole unit.

Assembly process consists of following steps-

Washing

Dimension checking

Laser marking

Rough assembly

Press

Weight checking

Demag process

Washing and bearing

Noise and vibration test

Oiling

Packing

First of all the material are received from their respected finishing lines and are visually

inspected by the operators.

The operator make sure that all the component\elements are at their position before

assembly.

Washing- when the cone is received from super finishing /honning station it is a first

washed by a solution of water and sulpha cleanser and then it is forward for dimensional

analysis line.

Dimension checking- at this station, dimensions of cup /cone are checked by the machine,

where following aspects are matched according set tolerance limit

o Bore diameter

o Width of cone/cup

o OD of cup/topper for cone



Laser marking- if the element pass all the analysis then it is send for next station, where

various details are imprinted of the element, which provides the element /bearing its unique

identity.

o Detail marked on the element are-

Date and time of assembly

Serial number

Company name “nbc”

Rough assembly- in the process of rough assembly the elements- cone, roller and retainer

are linked together in standard manner.

o Eighteen rollers are made to bind together with a pair of cone and retainer.

Press- in this step, the linkage received from rough assembly is pressed by the machine at

a set thrust so to make the band and linkage stronger.

Weight checking- the combined weight of the linkage are measured and it is then

compared to the given limit. If the piece is in control than it is forwarded otherwise it is

sent for rework / scrap.

Washing- now the linkage is again washed in the presence of water and sulpha cleanser

solution to eliminates the presence of any dust particle.

Testing- after washing, the linkage is tested on various parameters to make sure about a

good working life. following tests are done/analyzed-

o Noise

o Vibration

o Free rotation

o Dimensional analysis

Cup-cone assembly- after testing, the linkage is now joined with the cup and bearing

assembly is completed.

Oiling- after completion of successful assembly the whole bearing is passed by shower of

oil, to lubricate it.

Sorting and packing- after oiling, the assembly is then again inspected for dimension and

then according to results, they are sorted out.

o After sorting out, they are packed in containers or boxes and ready to be shipped



15. Applications

While Engineered Surfaces have been successfully applied to a variety of components, our

first and most extensive experience is using these processes with anti-friction bearings.

Timken research revealed that modifying the topography of a bearing’s contact surfaces

resulted in significant improvement in overall performance.

Inadequate lubrication, poor maintenance, extreme operating environments and vibration

can be detrimental to bearing performance. Engineered Surfaces enable bearings to better

resist these potentially damaging environmental factors.

Real-world benefits have been demonstrated in rugged applications that include bearings

used in aircraft landing gear, heavy equipment drive trains and industrial rolling mills.

In many applications tapered roller bearings are used in back-to-back pairs so that axial

forces can be supported equally in either direction.

Pairs of tapered roller bearings are used in car and vehicle wheel bearings where they must

cope simultaneously with large vertical (radial) and horizontal (axial) forces. Applications

for tapered roller bearings are commonly used for moderate speed, heavy duty applications

where durability is required. Common real world applications are in agriculture,

construction and mining equipment, axle systems, gear box, engine motors and reducers



Chapter: 4

16. Working Experience

National Engineering Industries Limited is one of the leading manufacturing industry in India. To

work with an organization like NEI is one of the best experience in my Course duration. Within

the 60 days of practical training the project guide helped me to understand the working of complex

systems of the organization. He insured that the students must kept aware of the functionality of

the organization. Following are the main point which I learned during my days in NEI which will

help me in upcoming days of my career.

To act as a student and be alert to learn every sort of thing which appears in form of daily

challenges and try to solve it with professional guidelines.

To maintain effective communication with both upper and lower level of hierarchy.

To develop certain set of procedures which we have to follow in routine to carry out

specific tasks.

To carry forward every information to the upper level of management so that no

misunderstanding could occur in the division.

To act as a member of the team and have a healthy relations with all the other team

members.

To attain ones responsibility in his absence without negligence of self-work and to not

leave the job without handling over the responsibilities to a person who is capable of

accepting it.

To work within the time period and guidelines as prescribed by the management.

To generate an efficacy toward meeting the goals.



Chapter: 5

17. Conclusion

The practical training is a best platform to polish ones knowledge of workings within a company

and also to test your compatibility with the practical knowledge of engineering we are gaining in

our studies. These 60 days trained me to work with my flaws and to sharpen my abilities to

demonstrate a better side of my performance.

These 60 days have improve my efficacy to work in practical environment for a given period of

time with full dedication, enthusiasm and energy. In any segment of day we could be called and

provided with tasks that have to be completed in the set of given time only.

The project guide are always tends to fill us with information with regards to our career and how

to set goals and achieve. He helps me to complete my report work and I am very thankful to him

for his painstaking efforts.

The report I am submitting in the institute carries all the major and minor segments I learned in

National Engineering Industries Limited, Jaipur.



18. References

[1] "About NBC," 4 August 2016. [Online]. Available: http://www.nbcbearings.com/who-we-are.html.

[2] AutoTech Review, "Auto Tech Reviews," National Engineering Industries- Setting Benchmark for Bearing of Tomorrow, p. 11, 17 December 2012.

[3] "Jaipur Plant," National ENgineering Industries Limited, [Online]. Available: http://www.nbcbearings.com/jaipur-plant.html. [Accessed 20 September 2016].

[4] "Radic.com," Radiac Abrasive, [Online]. Available: http://radiac.com/products/radiac-internal-grinding-wheel-system/. [Accessed 19 September 2016].

[5] "Bearings.Parts," [Online]. Available: http://www.bearings.parts/Timken-3920-Tapered-Roller-Bearing-Cup. [Accessed 19 September 2016].

[6] India Mart, [Online]. Available: http://dir.indiamart.com/gondal/tapered-roller-bearings.html. [Accessed 19 September 2016].

[7] "About NBC," National Engineering Industries Limites, [Online]. Available: http://www.nbcbearings.com/who-we-are.html. [Accessed 20 September 2016].

[8] "Reaserch & Development," National Engneering Industries Limited, [Online]. Available: http://www.nbcbearings.com/research-development.html. [Accessed 20 September 2016].

[9] "Ball Beaaring," National Engineering Industries Limited, [Online]. Available: http://www.nbcbearings.com/ball-bearings.html. [Accessed 20 September 2016].

[10] "Taper Roller Bearing," National Engineering Industries Limited, [Online]. Available: http://www.nbcbearings.com/taper-roller-bearings.html. [Accessed 20 September 2016].

[11] "Railway Products," National Engineering Industries Limited, [Online]. Available: http://www.nbcbearings.com/railway-Products.html. [Accessed 20 September 2016].

[12] "Special Bearings," National Engineerings Industries Limited, [Online]. Available: http://www.nbcbearings.com/special-products.html. [Accessed 20 September 2016].

[13] "Alloy Steel 52100," Metal Supliers Online, [Online]. Available: http://www.suppliersonline.com/propertypages/52100.asp. [Accessed 14 October 2016].

[14] R. Khurmi and J. K. Gupta, "Rolling Contact Bearing," in A textbook of Machine Design, New Delhi, EURASIA PUBLISHING HOUSE (PVT.) LTD., 2005, pp. 996-1020.



[15] "Speeds and Feeds," Global Engineer Harry, [Online]. Available: https://engineerharry.wordpress.com/category/main/education/seneca/machine-theory/. [Accessed 16 October 2016].

[16] P. N. Rao, Manufacturing Technology: Metal Cutting and Machine Tools, 3 ed., vol. 2, New Delhi: McGraw Hill Education (India) Private Limited, 2014.

[17] R. Rajput, A Textbook of Material Science & Engineering, 4 ed., New Delhi: S.K. Kataria & Sons, 2014.

[18] V. Bhandari, Design of Machine Elements, 3 ed., New Delhi: McGraw Hill Education (India) Private Limited, 2014.