Ritik NBC

Industrial Training Report
Mechanical Engg. Deptt. RITM, Jaipur Page 1

A
Training Report
NATIONAL ENGINEERING INDUSTRIES LTD.
JAIPUR
Submitted in partial fulfillment of the
Requirements of the degree
Of
B. TECH MECHANICAL ENGINEERING
By
RITIK BHATNAGAR
(10ERDME037)
Under the guidance of
MR. T.S. CHOUHAN
(H.O.D MECHANICAL)

DEPARTMENT OF MECHANICAL ENGINEERING
Rajdhani Institute of Technology & Management
Sanganer Renwal Road, Jaipur, Rajasthan, India


PREFACE

As per the requirement of B. Tech. course, National Engineering Industries Ltd. (NEI), Jaipur
has been kind enough to permit me to complete my Practical Training under Ball Bearing
Division.
This report prepared during the practical training. Which is students first and greatest treasure as
it is full of experience, observation and knowledge.
The summer training was very interesting and gainful as it is close to real what have been studied
is all the years through was seen implemented in a modified and practical form.
The only fault was that the time available was short and there was much to learn, yet the things
learned shall never be oblivion and are of great aid in the near future.
The student wishing that gorgeous private sector undertaking success so that is may flourish and
serve the nation which has reached significant years of its independence and has to achieve many
goals.



ACKNOWLEDGEMENT

It gives to me tremendous pleasure in acknowledge the invaluable assistance to me by various
personalities In successful completion of this report. I express my gratitude towards Mr. Rohit
Sabu, President, and the entire management of NEI Ltd., Jaipur for giving me a chance to work
as a vocational trainee in their esteemed organization.

I wish to acknowledge my profound gratitude towards Mr.Thomas (Dy. Manager -HRM)
for giving me opportunity in this field.

I also wish to acknowledge my profound gratitude towards Mr. T.S. CHOUHAN (HOD OF
ME DEPARTMENT) and Mr. PUNEET JAIN they encouraging me at every step.

I would be a thankless child if I dont mention the name of my continuous source of energy
and inspiration i.e. that is my parents who always encourage and support me at every right step
in my life.



CONTENTS :
SR.NO. CHAPTER PAGE
1 INTRODUCTION 4
2 ABOUT NEI 7
3 BEARING AND ITS TYPE 8
4 COMPONENTS OF BEARING 15
5 MANUFACTURING PROCESS OF BALL BEARING 19
6 MANUFACTURING PROCESS OF BALL 37
7 PROBLEM STUDIED DURING TRAINING 46



CHAPTER 1

INTRODUCTION :

Any type of Economic Activity producing GOODs or SERVICES

It is part of a chain from raw materials to finished product, finished product to
service sector, and service sector to research and development.

It includes AGRICULTURE, MANUFACTURING and SERVICES

Industry varies over time and between different countries

Industrial linkage is:-

When one Industry depends on the output of another

This can cause problems if one industry has production problems or closes down

The CAR INDUSTRY is a good example each component (engine parts, lights,
body etc.) may be produced by a different company
Before it goes to the ASSEMBLY PLANT.



BEARING INDUSTRY GLOBAL SCENERIO :

The world Market of quality Bearing is very vast. The Big players of bearing
sector are present in U.S.A, Russia, Japan,China and Eastern Europe. Some of
leading bearing Manufacturers are: -
NSK Japan
NTN Japan
KOYA Seiko Japan
FAG Germany
SKF Sweden
NRB France
Timken USA

There are few of leading bearing manufacturer present in India. Most of the big
player is having either technical orfinancial Collaboration with leading Auto
Manufacturer.International Collaboration gives Access to best technologyin the
world.
GLOBAL COLLABORATION
COMPANY : COLLABORATION

FAG Bearing India : FAG, Germany
SKF India : SKF Sweden
NRB : Nadella, France
ABC Bearing Ltd. : NSK Japan
TIMKEN India : TIMKEN USA
Bimetal Bearing Ltd. : Clevite Corporation USA
Gabriel India : Suspension Italy


The Indian Bearing Industry, especially the companies having technical and
financial collaboration with Global player are Expected to garner higher pie in
export market.

BEARING INDUSTRY INDIAN SCENERIO :

The Indian Bearing Industry is estimated at Rs. 30 BillionApproximately. The Industry has
established a highlydiversified product range of around 1000 type of Bearing,having High
Volume Demand. As much as 70% of the total

Demand for common varieties and size of bearing is met by the domestic Industry, and the
remaining demand to the tune of 30% is imported essentially for Industrial Application
andspecial purpose.

The Indian bearing Industry can be divided in to theorganized sector and un-organized sector.
The organized sector primarily caters to the original equipment Manufacturer (OEM) Segment,
which predominantly comprises Automotiverailway and other Industrial users. The replacement
market is dominatedby unorganized Sector.



CHAPTER 2

ABOUT NEI:
National Engineering Industries(NEI) Ltd was established 150 year ago by multi-billion dollar
C.K. Birla group. It manufactures a wide range of maximum types of bearings bearings for
automotive and railway industry as well as for general industrial applications under the brand
name NBC . NEI was founded in the year 1946 as a pioneer industry in the field of bearing
manufacture. Now it manufactures nearly 80 Million Bearings per annum in over 500 different
sizes ranging from 6 mm bore to 1300 mm outer diameter, also having capability to manufacture
the bearings upto 2000 mm as outer diameter.

NEI is one of the largest domestic bearing manufacturing company 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 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.

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 they were enjoying the consistently superior products and assurance of highest quality
for every NBC bearings they use .
1.1 Products
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. These products with
approx. 2300-strong team, supported by a well-equipped R&D with bearing life testing facilities.
The products are:-
Ball Bearings
Tapered Roller Bearings
Cylindrical Roller Bearings
Axle Boxes Spherical
Roller Bearings
Cartridge Tapered Roller Bearings
Large Dia Special Bearings



CHAPTER 3

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

Types:-
There are many different types of bearings.
Type Description Friction
Stiffne
ss

Speed Life Notes
Plainbearing
Rubbing
surfaces,
usually with
lubricant;
some
bearings use
pumped
lubrication
and behave
similarly to
fluid
bearings.
Depends
on
materials
and
constructi
on, PTFE
has
coefficient
of friction
~0.05-
0.35,
depending
upon
Good,
provide
d wear
is low,
but
some
slack is
normall
y
present
Low to
very
high
Low to very
high -
depends upon
application
and
lubrication
Widely used,
relatively high
friction, suffers
from stiction in
some applications.
Depending upon
the application,
lifetime can be
higher or lower
than rolling
element bearings.


fillers
added
Rollingelementbe
aring
Ball or
rollers are
used to
prevent or
minimize
rubbing
Rolling
coefficient
of friction
with steel
can be
~0.005
(adding
resistance
due to
seals,
packed
grease,
preload
and
misalignm
ent can
increase
friction to
as much
as 0.125)
Good,
but
some
slack is
usually
present
Moder
ate to
high
(often
require
s
cooling
)
Moderate to
high
(depends on
lubrication,
often requires
maintenance)
Used for higher
moment loads than
plain bearings with
lower friction
Jewel bearing
Off-center
bearing rolls
in seating
Low
Low
due to
flexing
Low
Adequate
(requires
maintenance)
Mainly used in
low-load, high
precision work
such as clocks.
Jewel bearings
may be very small.
Fluid bearing
Fluid is
forced
Zero
friction at
Very
high
Very
high
Virtually
infinite in
Can fail quickly
due to grit or dust


between two
faces and
held in by
edge seal
zero
speed, low
(usuall
y
limited
to a
few
hundre
d feet
per
second
at/by
seal)
some
applications,
may wear at
startup/shutd
own in some
cases. Often
negligible
maintenance.
or other
contaminants.
Maintenance free
in continuous use.
Can handle very
large loads with
low friction.
Magnetic
bearings
Faces of
bearing are
kept
separate by
magnets
(electromag
nets or
eddycurrent
s)
Zero
friction at
zero
speed, but
constant
power for
levitation,
eddy
currents
are often
induced
when
movement
occurs,
but may
be
negligible
if
magnetic
Low
No
practic
al limit
Indefinite.
Maintenance
free. (with
electromagne
ts)
Active magnetic
bearings (AMB)
need considerable
power.
Electrodynamicbea
rings (EDB) do not
require external
power.


field is
quasi-
static
Flexure bearing
Material
flexes to
give and
constrain
movement
Very low Low
Very
high.
Very high or
low
depending on
materials and
strain in
application.
Usually
maintenance
free.
Limited range of
movement, no
backlash,
extremely smooth
motion
Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct
from the friction of the bearing.

TYPES OF BEARING:
1. Single Row Radial Ball Bearings
The initial technology was from Hoffman Manufacturing Company
Ltd., U.K. a collaboration, which continued for 20 years.

We offer a wide range of both metric and inch series deep groove ball
bearings, angular contact ball bearings, self-aligning ball bearings etc.

With our tie up with the world's leading bearing manufacturing
company NTN Corporation, JAPAN, we have gained access to the


most advanced ball bearing technology i.e. thermo mechanical bearings (TMB) and
tensioner bearings available today and our wide range of ball bearings is increasing under
this collaboration.

2. Single Row Radial Ball Bearing with Tapered Bore

The single row radial ball bearings with tapered bore are Identical to
single row radial ball bearings except that these have tapered bore which
is used for easier mounting and for the adjustment of radial clearance.
Dimensions of tapered bore diameter refer to small bore.

3. Single Row Angular Contact Ball Bearing

The single row angular contact ball bearings have higher axial load capacity than the single row
radial ball bearings. The radial load must always be less than axial load.The bearings can carry
axial load in one direction only andshould be adjusted against another bearing, if axial load
iscoming from both the directions.
Each bearing can be located endwise in one direction only.
4. Single Row Externally Aligning Ball Bearing

The single row externally aligning ball bearings are usedwhere accurate alignment cannot be
guaranteed betweenbearing positions. It can take radial loads. Axial loads can also be
accommodated.The shell housing must not be made an interference fit on their outside diameter.
If an interference fit is used, the shell housing may contract and prevent alignment.These
bearings can be located endwise in both the directions.

5. Double Row Self Aligning Ball Bearing



The double row self-aligning ball bearings have the common outer spherical race for both the
rows. This feature gives the bearings self-aligning properties. The bearings have the same
external dimensions as there equivalent single row radial ball bearings. They can take radial
loads and very light axial loads.They can be located endwise in both the directions.

6. Double Row Self-Aligning Ball Bearing withTapered Clamping Sleeve and
Nut

The double row self-aligning ball bearings with tapered clamping sleeve and nut are identical to
double row self-aligning ball bearing except that these have a tapered bore, which is used for
easier mounting and also a clamping sleeve and nut to clamp the bearings on the shaft. The
tapered bore is also used for the adjustment of radial clearance.

7. Thrust Ball Bearing

The thrust ball bearings are used for high axial loads at low speeds. These cannot operate at high
speed as it will give rise to centrifugal or radial forces which cannot be taken by the bearings.
They can be located endwise in one direction only.

8. Cylindrical Roller Bearing:

The cylindrical roller bearings have greater radial load capacity than ball
bearings of same external dimensions and are particularly suitable for
arduous duties. The bearing features a modified line contact between
rollers and raceways toeliminate edge stressing. These bearings have a
high radial load capacity and are suitable for high speeds. Due to
detachabledesign character they have advantage of mounting inner ring
and outer ring separately.


9. 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 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 tapered roller bearings support radial loads and axial loads from one
direction only. The line contact between rollers and raceways provide the bearings with a high
load carrying capacity. Steep angle tapered 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 tapered 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 tapered roller bearings are also widely used for heavy loads
such as rolling mills.

10. Spherical Roller Bearing

Spherical roller bearings are particularly suitable for carrying heavy loads. They
are usually of the double row design, both of the rows of the rollers having
common spherical raceways in the outer ring. This feature of this bearing has great
practical importance in those cases where it is difficult to obtain exact parallelism
between the shaft and housing both axes. So these bearings are suitable where misalignment can
arise from mounting errors or from deflection of the shaft.


CHAPTER 4

Components of Ball Bearing:-
There are four major parts to a standard ball bearing: the outer race, the rolling balls, the inner
race, and the cage or retainer.

Fig. no. 1



BEARING RACE'S

The SSI Races Manufacturing Units of Jaipur areManufacturing outer & Inner Bearing Races in
Different sizes.According to the Demand in the market. The turned Races aresupplied in Soft
condition and remaining operation of Hardening, Tempering Grinding & Honing/polishing are
beingdone by the Bearing Manufacturer.
The Detail of type and size of Bearing Races are as under:-

S.No. Type of Bearing Races Inner Dia Ranger

1. Ball Bearing Races: 10mm to 80mm
2. Roller Bearing Races: 17mm to 100 mm
3. Cylindrical Roller Bearing Races: 20mm to 75 mm
4. Special type of Bearing Races for: 20mm to 75 mm
Transport Vehicles (Thrust Bearing)
5. Axle Box Bearing Races for Railway: 100mm to 200 mm
Passenger coaches and wagon



RAW MATERIAL:

The Races & Rolling elements of Bearing are subjected tostress on a very small contact surface
must be of such materialso 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:

Outer and Inner Races

The raw material used in the Manufacturing of bearingRaces is SAE 52100 high Carbon Chrome
bearing steel, whichhas composition similar to EN-31 (100 CR 6 As per BISspecification). The
raw material for Bearing Races is in the formof Rods & Seamless Hollow Tubes. This is a
SpheroidsAnnealed Steel. Approx. 80% of the Seamless Hollow tubes arepurchased by the
Industry from M/s. Indian Seamless Metal tubePUNE, while the rest of the tube used in the
cluster is importedmaterialThe Steel bar are purchased from M/s. Indian SeamlessSteel & Alloy
Pune & M/s. Mahindra Ugine Steel CompanyKHAPOLI (Maharashtra). Some of the units are
buying the steelscrap rod for manufacturing bearing races.
Bearing Races material and their heat treatment arerequired to be selected carefully, taking
account the mechanicalstrength and required life of the Bearing, so that each materialmay
perform at maximum capability.Approximate required composition for bearing races
areConstitute % Composition
Carbon 0.95 to 1.1
Chromium 1.4 to 1.6
Manganese 0.50 max.
Silicon 0.15 to 0.35
Sulphur 0.025 (Max.)
Phosphorous 0.05



CAGE'S

Cage is used to return balls at proper distance to preventthem from containing each other and to
prevent a temp.rise and resultant damage due to friction.
The Material for manufacturing cages is CRCA Strips ofC2015 Bearing grade steel having
carbon percentage at0.08% max. and Magnesium ranging from 0.25% to 0.45%

BALL'S

Steel Balls of grade 20, 16 &10 with close tolerance,smooth surface made by using SAE 52100
High CarbonChrome Bearing Steel.

REQUIREMENTS FOR BEARING PRODUCTION:

Raw material, Centre less lath machine, grinding machine, grinding wheels, roughing stone,
finishing stone, diamond to set curvature of grinding wheel, pp. gauge to measure the bore.



CHAPTER 5

MANUFACTURING PROCESS OF BALL 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 60
0
C, then send to a chamber where the material heated in
four chambers the first chamber has the temperature 840
0
C and further chamber contains the
850
0
C temperature. Then it dipped into an oil tank at temperature 25
0
C where the material get
quenched then it washed and then it tempered in water about 90 min. at temperature 105
0
C .
then dried and cooled in air. The hardened material is obtained.
The systematic flowchart is shown in following fig.



Reference: http//www.nbcprojectreport.com



Chugai Ro Heat Treatment Furnance
Reference: http//www.heattreatmentprocess.com

Heat Treatment

Raw Material
(Carbon Steel)

Carburizing
(Carbon Shield Layer increases Hardness)
(10 12 hrs.) (940
0
C) (GC Furnace)


Hardness I
(Revolving Furnace)
(920
0
C) (Time Dependent on Job)

Annealing
(6 hrs.) (650
0
C)

Shot Blasting

Hardening II
(Revolving Furnace)
(820
0
C) (Time Dependent on Job)

Sub-Zero Treatment
(-60
0
C) (Increases Toughness)


Tempering
(160
0
C) (4 hrs.)

Shot Blasting
(Wheel Abrator)

Hardness Inspection
(60 HRC)

After heat treatment following process are done to get a new ready to use ball bearing.

Hardening Procedure
Steel Material Carbon (0.9% - 1.10%)
HC Steel (High Carbon Steel)


Process

Hardening

Quenching

Tempering
Air
Cooling

Procedure

Heat the
Furnace
850-870
O
C

Fast cooling
60
0
C Oil
Quenching
180
0
C Salt Bath

Furnace
Heating
165
0
-180
0
C

Cool at Room
Temperature

Hardness

------

62 66 HRC

60 64 HRC

------

Time

35-60 min.
According to
the job

5-15 min.

150 min.

------

Hardening Procedure
Steel Material
LC Steel (Low Carbon Steel)



Fig. no. 2

Process

Carburizing

Hardening

Quenching

Tempering

Procedure

Carbon Furnace
heating at
940
0
C - 950
0
C

Furnace
temperature at
850
0
C

870
0
C

Fast cooling 60
0

C for oil
quenching only

Heat the
Furnace at
165
0
C-180
0
C

Hardness

.200 - .250

------

60 64 HRC

52 62 HRC

Time

8 10 hours

35-60 min.
According to
the job.

5-15 min.

120-180 min.

Salt Bath Furnace


Reference : http//www.superheatfurnance.com

Different process and Machines:-

Face Grinding:-Face is the surface at side of the inner and outer race , face should be
finished indeed to get the desire width of the bearing and since the bearing is a mating part and it
has to be assembled somewhere in the machine where it should be fit precisely. The face
grinding is done in a machine where the faces are grinded in between the grinding wheel.

OD(Outer Dia.) Grinding:-OD is the circumferential surface of the outer race of the
bearing. The OD should be surface finished since the bearing has to be assembled in machine. It
is obtain in an OD grinding machine in this machine the outer race is rotated between two
grinding wheel.The outer race is passed in machine two times to get highly finished. First rough
and second highly finished.

At G-12 line the different machines.
Job No. 6211
G-114 Outer race track grinding machine.

G-115 Outer race track honing machine.

G-103 Inner race bore grinding.



G-343 Inner race track grinding.

G-363 Inner race face grinding machine.

G-344 Inner race track honing machine.

Assembly Line:-

A-439 Auto inner outer race washing m/c.

A-440 Auto inner outer race measuring m/c.

A-441 Auto inner outer race combining m/c.

A-442 Auto cage assembly m/c.

A-443 Auto demagnetizing m/c.

A-444 Auto washing m/c for semi-finished product.

A-445 Shower cleans.

A-446 Auto inner outer diameter inspection and sensitivity checking m/c.

A-447 Auto radial internal clearance inspection m/c.

A-448 Auto washing and drying m/c.

A-449 Auto double side vibration testing m/c.

A-450 Auto Greasing and weighing m/c.


A-451 Auto shielding m/c.

A-452 Auto conservation oil spraying and visual inspection m/c.

Laser Marking System:

A Laser marking system marks a highly visible mark on the job without touching it.

Job Number
NBC INDIA
Date Code

Important parts
a) Marker
b) Controller
c) Water-cooled Unit
d) Filter Kit
e) Console
f) Control Panel
g) Mechanical Handing System

The Laser is produced with the help of a diode which is focused on the job by using a lens. The
Laser beam produces a external high thermal energy; this thermal energy marks a dark mark on
the job extra thermal energy is then absorbed through the cooling system.


Thus, in this form the laser beam produced from a diode marks a dark mark on the job. With
the help of the machine customer requirements like; customer code, part number etc. can be
marked according

GRINDING
Centre less Grinding

Fig. no 3
Centerless grinding is a method of material removal through grinding, similar to centered
grinding except for the absence of the spindle. It has high throughput, i.e. a large number of parts
can be manufactured in a short time.
The workpiece is set up between the regulating wheel (or back up wheel) and the grinding wheel,
and is supported by the work blade (or work rest). The work rest is located between the wheels.
The work is placed upon the work rest, and the latter together with the regulating wheel is fed
forward forcing the work against the grinding wheel. Axial movement of the work past the
grinding wheel is accomplished by tilting the regulating wheel at a slight angle from horizontal.
An angular adjustment of 0 to 8 or 10 degrees is provided in the machine for this purpose.


Centerless grinding is classified into two types:
Throughfeed grinding - the workpiece is fed into the machine along the work blade
Plunge grinding - the workpiece is placed between the wheels on a work blade and the
grinding wheel is plunged into the workpiece.
Some of the benefits of centerless grinding include the ability to grind parts with geometries that
do not allow them to be OD ground, the ability to remove three, five and other odd numbered
lobing on the shaft of a part, and to maintain size beyond what is typically capable of an OD
grinder due to the low overall pressures spaced out along the workpiece.
An example of a centerless ground application is the outer diameter of the bearing races.

Mechanism:

Fig no 4


Types of Centerless grindings

Three Main Types of Grinding

Centerless grinding is similar to centered grinding except that there is no spindle. This allows
high through-put since parts can be quickly inserted and removed from the process. There are
three main types of centerless grinding:
1. Through-feed grinding.

2. In-feed grinding.

3. End-feed grinding.

Through-Feed Grinding

In through-feed grinding, the part rotates between the grinding wheel and a regulating wheel as
shown below.



Fig. no. 5

For through-feed grinding, one or both wheels of the centerless grinding machine are canted out
of the horizontal plane, as shown below. This imparts a horizontal velocity component to the
work piece, so that outside feed mechanisms are not necessary.

The grinding wheel is canted with respect to the other two axes so that a component of its surface
velocity pushes the part in the direction shown below. This auto feeding characteristic is useful
for rapidly processing many parts in quick sequence.

Because of the axial movement, through-feed parts can only have right circular cylindrical
ground surfaces. The wheel cannot be dressed to grind more complex shapes.

Below are parts produced with the through-feed centerless grinding process. As can be seen from
the quantities produced, through-feed grinding is primarily a mass-production process because of
its high throughput.



Fig. no 6

In-Feed Grinding

In-feed grinding differs from through-feed grinding in that the part is not fed axially so that the
ground surface does not need to be a right circular cylinder. The grinding wheel can be dressed
to accomodate the part. Once the work piece part is in place, the grinding wheel is fed in radially.

Because of the set up time involved for each part, in-feed griding does not have the high
throughput of through-feed grinding. In-feed grinding is illustrated below.



Fig, no. 7

End-Feed Grinding

In end-feed grinding, the part moves in axially between the grinding wheels, stops for grinding,
and then moves out again. The wheel can be dressed to form more complex shapes, but the part
can only get progressively smaller in diameter. End-feed grinding is illustrated below.

Fig. no. 8



CHAPTER 6
BALL MANUFACTURING PROCESS
Forged wire(De-scaled) as raw material
(SAE 52100 steel)

Heading Operation

Flashing

Grinding

Heat treatment

Hard Grinding

Tumbling

Lapping

Washing

Testing and Fine Inspection

Packing and launching


1. WIRE

Fig. no. 1



2. HEADING PROCESS:-

Heading is the process in which the wire of suitable dia is pressed b/w two dies one is
fixed and another is reciprocating moveable die. That die works at slider crank mechanism.
The process is known as heading due to formation of head and flash as the extra metal. The extra
metal remains due to passes between two dies. Use of head and flash is to assure that the
formed ball is completely filled and fully solid with metal.

Fig. no. 2


3.FLASHING:-

The flashing is the operation in which we remove the flash on the ball having head and flash. It is
also a grinding operation.The wheels are used are coarse grain type. The time taken in flashing
is18hrs approx.

Fig. no. 3
3. GRINDING:-
After flashing balls are send to grinding machines.Soft grinding process are used to finish the
ball to remove the major defect the balls are now begain to take shape but not fully finished.


Fig. no. 4
4.HEAT TREATMENT:-
The grinded ball are soft due to many operation like heading, flashing, grinding performed
earlier so by using Chugai RO furnace . The heat treatment is been done by which the balls are
hardened and the hardened balls capable to have loading at it for along time. Thegas used in heat
treatment is Indo Gas which is mixture of LPG & Air.In the heat treatment there are 3 steps.
Heating
Quenching


Tempering
The process time is approx 3 hrs.

Fig. no. 5
5.HARD GRINDING:-
The heat treated balls are then send to hard grinding where is the extra metal are remove. It is
also a similar operation like a soft grinding but the wheel used is harder than the soft grinding
machine. The process time is approx 3hrs.



Fig. no. 6
6. Tumbling :- Tumbling is the process is which the hard grinded balls are washed in a
slower process in emulsion and at here the defective ball are removed from the lot.
7. Lapping :- It is also a metal removal process in which the balls are finished very well. The
metal removal is very less in order to microns. The wheels which are used are finer grain
sized and the friction agent between the balls is abrasive paste of hollino oil. The lapping
operations are of two types.
Lapping-1:- The lapping-1 is the process in which the diameter of balls is reduces in
order to micron. The finishing of balls are very high. The dB values, tally round, surface finish,
parameters are acheive. The process time is 36hrs
Lapping-2-3:- The lapping 2-3 is the operation in which the dia is not reduced so much but
the surface finish is increased very much. The polish is used instead of abrasive paste so
the friction is less. The process time 24hrs.



8.CLEANING:-
In this process the finished balls are washed in Kerosene Oil for approx 1hr.

Fig. no. 7
9.TESTING:-
In the testing we test each ball individually. Three test are performed at each ball
ECT eddy current test
EOT optical test
EVT vibration test
The test in case of failure the ball is rejected and the cause of failure is discontinuity
in internal structure.



10.FINE INSPECTION:-
In this segment the each ball is inspected by human eyes the surface defect are inspected by
that means.

Fig. no. 8
11.Packing & Launching:-
The finished OK tested balls are then packed in approx 5 Kg. weight per pack for assembly
section.



CHAPTER 7

Problem Studied During Training:-

Ball Bearing Grinding
Problem No. 1:-
G-1 Line Job No. 6213 (outer race of bearing)
Machine No. G-241
The abnormal lines were seen at the face of job. Initial prediction was that the backing plate is
damaged. The backing plate is part of machine which holds the job during grinding process at
rotates the job against the grinding wheel. The backing plate has worn out because it has friction
and relative motion between job, when it hold the job.
The backing plate has certain limit to wear about 3 mm. Scratches occur on the face of backing
plate which further produce the lines on the job face. The backing plate holds the job as shown in
fig.



Fig. no. 9
The backing plate supports the job at the back side.
The backing plate and the shoe and shoe fixture was replaced.
But the wowel was found in the job rotation, the shoe is the device which supports the job at
bottom and one side during the grinding process. And shoe fixture fixes the shoes.
The woweling was produced due to the carbide tip was damaged when the disassembling the
backing plate.

Problem No. 2:-
G-1 Line Job No. 6213 (Inner race track grinding)
Machine No. G-245
Inner race track grinding wheel changed because the wheel was has completed its life and not
able further use. Then it dressed for curvature setting as normally it dressed. But the black and
hot job obtained at outlet of machine. The prediction is that the dressing of wheel was not done
properly and curvature is not settled for job. Then prediction was that diamond has finished then
it was changed. New diamond setted and then dressed the grinding wheel but the curvature was
not right then and job was heated. Then again wheel dressed and job obtained satisfactory
But the diamond has to be changed very frequently, and curvature was not satisfactory. The
problem was that the diamond position was not right the right position is shown in the following
fig.


Fig. no. 10
Problem No. 3:-
G-1 Line Job No. 6213 (Inner race track grinding)
Machine No. G-245
The machine was taking more cycle time to grind the job. The machine was checked no problem
was found. Then the ovality checked of input job then it was found about 100 to 300 micron.
Then 100 random pieces were checked then it was found the ovality was more than the standard
limit. When the ovality is more the wheel has to remove more material
From job.Hence increased cycle time.
Ovality occurs when the job heat treated. And it can be controlled.



Fig. no. 11

Problem No. 4:-
G-1 Line Job No. 6213 (outer race track grinding)
Machine No. G-252
The track center of the outer race was found varied from the standard dimension. Initially the
lock nut to be adjusted, it was found that there was ply in the lock nut and the lock nut was
damaged due to hammering. The new lock nut was prepared in the tool room and fitted in the
machine. Now the track center adjusted.



Problem No. 5:-
G-12Line Job No. 6
211 (Inner race track Honing)
Machine No. G-343
Job rotation problem was found. It was due to the band in the window.
Window is the holding device for the honing stone and O ring. The band was due to
hammering action of the arbor.

Ritik NBC

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Industrial Training Report

Mechanical Engg. Deptt. RITM, Jaipur Page 1

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