Professional Documents
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Introduction
1.1. Company profile
The renowned industrialist, late Shree B. M. Birla founded National Engineering
Industries Ltd., Jaipur in the year 1946 as a pioneer industry in the field of bearing
manufacture, under the name of "National Bearing Company Ltd."
The first bearing was manufactured in 1950 with a modest start of 30,000 bearings
in 19 sizes. The company is now manufacturing nearly 3.8 million bearings per
month in over 500 different sizes ranging from 6 mm bore to 1300 mm outer
diameter and has the capacity to manufacture bearings upto 2000 mm outer
diameter. At NEI, the development of bearings is a never ending job. With ever
increasing activities and grant of industrial licenses for other vital industries and
manufacturing of Roller Bearing Axle Boxes for Railway Rolling Stock, Steel Balls,
Tapered Roller Bearings, Spindle Inserts etc., the name of the company was
changed in 1958 to "National Engineering Industries Ltd." retaining its original
trade mark NBC.
The industry is spread over 118 acres of land in Jaipur and 56 acres in Gunsi
(Newai). This is the only unit in the country manufacturing wide variety and range
of bearings such as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical
Roller Bearings & Axle Boxes for Railway Rolling Stock including Spherical Roller
Bearings, Cartridge Tapered Roller Bearings and Large Diameter special Bearings
in separate fully equipped factories. The development of National Engineering
Industries Ltd., was pioneered with a theme Indigenization
and Self-reliance".
NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors, Electric
Motors, Railway wagon, Coach and Locomotive manufacturers as Original
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Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers
and Thermal Power Plants all across the country.
1.2. Milestones
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
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x.
1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for
Machine Retrofitting
xi.
xii.
xiii.
xiv.
Eicher Motors
Tata Motors
Automobiles-Two/ Three Wheelers: Bajaj Auto Ltd.
Hero Honda Motors Ltd.
Honda Motorcycle & Scooters India
Suzuki Motorcycle India
Majestic Auto
Piaggio India Ltd.
Royal Enfield Ltd.
Yamaha Motors India Pvt. Ltd.
TVS
Tractors: Eicher
Escorts
HMT
International tractors
Mahindra & Mahindra
Punjab Tractors
TAFE
VST Tillers
Electric Motors & Pumps: Crompton Greaves
G.E. Motors
Kirloskar Electric
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Ltd.
NGEF
MICO
Fans: Bajaj Electricals
Crompton Greaves
1.5. Manufacturing FacilitiesNBC has manufacturing facilities at Jaipur (established in 1946), Newai
(established in 1980) and Manesar (established in 2006). A fourth plant, a green
field project, at Savli in Gujarat will ship out its first bearing in November 2013,
ramping up production capacity to 150 million bearings per year once it is fully
operational.
Jaipur Plant
Newai (Gunsi) Plant
Manesar Plant
1.5.1. Newai (Gunsi) PlantEstablished in the year 1980-81 as an expansion project of NEI Ltd . The factory is
equipped with fully automated grinding lines with electronic in-process & postprocess gauging and centrally air-conditioned assembly lines with auto gauging and
test equipments for quality and reliability of the products, The plant is spread over a
covered area of 7,200 Sq. Meters.
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Fig1.2:
Newai (Gunsi) plant
1.5.2 Manesar Plant
NEI has set up its third Ball Bearing manufacturing plant in the fastest growing
industrial town of Manesar in Haryana. The plant is having a covered area of
5200 sq. meters. with the most advanced and sophisticated machines imported
from reputed manufacturers from Europe and Japan .This plant is equipped with
state of the art fully automated grinding lines, assembly lines and inspection
equipments.
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Chapter 2
NBC Jaipur
2.1. Introduction
This plant is located in the heart of Pink City of India, which is also famous for its
Tourists spots. Spread over a total area of 4,78,900 m2 and a covered area of 75,310
m2, Jaipur plant has state of the art manufacturing facilities and capable to
manufacture all types of Ball and Roller Bearings of NEI product range. . It has a
separate division to manufacture all these spread across large area. The plant at
Jaipur includesi.
ii.
iii.
iv.
v.
vi.
vii.
Ball Bearing
Precision Ball Making
Tapered Roller Bearing
Railway Bearing
Research & Development
Large diameter bearings
SAP-ERP
2.2. Ball BearingThe 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.
Type of Ball Bearing:a. Radial Ball Bearing
b. Angular Contact Bearing
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Self-Aligning Two-Row
Ball Bearing
(a)
(b)
(c)
manufactured with latest advance techniques. The unit has advanced assembly line
with auto gauging and testing equipment. NEI has 22 automatic Grinding lines from
M/s. NTN & Izumi, Japan. All machines with in process & post process gauges to
ensure grinding accuracy. Use of High Quality coolants for consistent grinding
quality and surface finish. Complete automation by flex-link conveyor system. NEI
has automatic plant for Track Grinding, Bore Grinding and Honing, The latest
advanced techniques for manufacturing and Quality Assurances are implemented to
meet the rapid increase in demand for quality, diversity of specifications and new
types of bearings. The plant is spread over a covered area of 14,694 sq. meters.
2.3. Precision Ball Making
Precision Steel balls up to 25 mm diameter for NEI bearings are being manufactured
in a separate well equipped factory. Precision quality balls are manufactured on
precision Grinding & Lapping machines to achieve super finished surface, accuracy
and roundness as per ISO standards. The plant is spread over a covered area of
4,700 sq.mtr.
(b)
Fig 2.3 Tapered Roller Bearings
This plant with the most modern equipment was set up in the year 1968.
Manufactured at an ultra-modern plant, with technology obtained from our earlier
collaborators, Federal Mogul Corporation, USA and now with NTN Corporation,
JAPAN, these bearings are used by all major automobiles, truck and tractor
manufacturers in the country as original equipment. The above bearings are
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manufacture in inch & metric series form 15.857mm bore to 95.25mm bore. For
TRB NEI has Automatic Grinding Lines with in-process & post process gauges.
Complete automation by Flex link conveyor. Crowning provision on Inner (Cone) &
Outer (Cup). Complete Automatic Line for Roll Grinding, Super finishing,
Inspection and Sorting imported from NTN, Japan automatic checking & prevention
of inverted roller & roller missing. Automatic checking of stand height, noise and
run outs. Presently under modernisation and expansion plan the new latest state of
the art technology lines are installed. The plant is spread over a cover area of 11,652
sq. mtr.
2.5. Railway bearing
Railway Bearings included in three sections
a. Roller Bearing & Axle Boxes
b. Spherical Roller Bearing
c. Cartridge Tapered Roller Bearing
2.5.1 Roller bearing & axle boxes
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 Railway The development of completely indigenise axle boxes and
bearings for the high speed Rajdhani Locomotive and the Yogoslavia and Egyptian
Railway Wagons are the highlights of the design capabilities at NEI.
The most of the production of this type of bearing for Indian Railways, Production
of the bearing started in 1952, on date plant is producing 100 different types of Axle
Box bearing, over a million NEI bearings and boxes are in service with the Indian
railways. New Automatic Grinding and Assembly Line has been purchased for
manufacturing of Axle Unit Bearings (DRAC bearings) from M/s Izumi Kinzoku.
2.5.2. Spherical roller bearing
The manufacture 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
(a)
Fig 2.5 Railway Bearings
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(b)
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Chapter 3
Railway Bearing Department
(Spherical Roller Bearing)
3.1. Introduction
I did my training at Railway Baring Department (Spherical Roller Bearing) .This
division is spread over covered area of 4,855 Sq. Meters. 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 .Spherical roller bearing has bore
(minimum) 40 mm and outer diameter (maximum) 420 mm. These bearings are
used by Indian Railway in all zones in the country as original equipment as well as
in other countries such as U.S., China, and Indonesia.
rolling stocks where vibrations and shock loads are encountered. All NBC spherical
roller bearing are fitted with machined brass cages. Brass is the most preferred cage
material for bearing used in railways all over the world. NBC spherical roller
bearings for Meter Gauge and Broad gauge passenger coaches have symmetrical
roller design. Where as in case of bearing used in Broad Gauge EMU, rollers are of
asymmetric
design.
including material selection and processing with resultant physical properties. Lets
discuss material selection for spherical roller bearing at NBC
Bearing contains varying amount of carbon, iron, chromium, manganese,
phosphorus, sulphur, silicon etc. Each of these elements plays a role in making final
steel suitable for bearings. Chromium and carbon allows deep hardening. The
combination of chromium, carbon & iron helps to minimize failure. As they
increase the surface resistance to abrasion & wear increase. In short, proper
combination of all these elements make final bearing steel which is tough under
shocks, heavy loads & hard enough to withstand fatigue. Generally bearings are
made from bars. But now a day, many manufacturers are making bearings by
forging rings. The latest techniques adopted recently are the Vacuum Processing.
The bearing steel is made through vacuum processing, which assists rod to be clean
& free from defects & give substantially larger bearing life.
Table 3.1 Contents of impurities in a Raw material
ELEMENT
AMOUNT
Manganese
0.25 to 0.35
Silicon
0.025 to 0.35
Sulphur
0.025 max.
Phosphorus
0.025 max.
Nickel
0.025 max.
Copper
0.35 max.
Molybdenum
0.10 max.
3.3.1. Raw material for outer ring, inner ring and cages
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A spherical roller bearing contains the following partsMain parts of Spherical Roller Bearings are follows(i) Races (outer and inner)
(ii) Rollers
(iii) Cage
The demand on the steel industry to provide higher quality alloy steels promoted the
development of the cold charges in the basic material-lined, electric arc furnaces.
These furnaces let higher-and lower grade alloy scarps be mixed with plain carbon
scarp; economical operation and product quality are achieved through proper
selection and weight control of these materials. Knowing the exactly chemistry of
scarp charge reduce the consumption of more costly alloys that are added to the
melt and minimizes the introduction of undesirable tramp alloying elements. A
variety of steel and brasses are used for different components for bearings
depending upon the properties required in the final product.
Rollers
Races
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Cage
NBC was the first one in India who made the cartridge tapered roller bearing with
the help of BRENCO Incorporated of USA.
Ajanta turnings
Balaji engineering
Keshav engineering
Microtech engineering
e) Microtech rollers
The raw material first come in the inspection room and the following parts
inspectsa)
b)
c)
d)
Width size
ID(Track Size)
ID roundness
OD Size
OD roundness
Eccentricity (Bore to OD)
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g) Surface defects- free from damage, tool mark, black spot, rust, roughness,
burr etc.
h) Oiling
For inner ringa)
b)
c)
d)
e)
f)
g)
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Width size
Bore
Undercut size
Oil groove size
Surface defects
OD size
For SEMI-FINISH/FINISH ROLLEROD size
OD Ovality
OD Taper
Length
Recess Depth
Surface Roughness
Radius of large end
Radius of small end
Hardness
Oiling
For RETAINERa)
b)
c)
d)
e)
f)
g)
Total width
Small bore diameter
Pocket length
OD size at top
Sheet thickness at bore
Visual inspection
No. of pockets
to make it able to operate in automotive vehicle, railway etc. The processes through
which bearing has to go are shown in flow diagram below-
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Lets discusses each process with respect to these parts for simplicity of
understanding
while the core remains soft and tough as a ferritic and/or pearlite microstructure.
The carburizing is performed 940 to 980c in rotary hearth furnace with time of
10hrs. But carburizing is done for only cup and cone with Air: LPG =10:1 (Endo
Gas).
chambers are at 850 0C. After the hardening furnace bearing material (steel) is
converted into austenite form.
3.9. QuenchingQuenching is a process of cooling a metal at a rapid rate. This is most often done to
produce a martensite transformation. In ferrous alloys, this will often produce a
harder metal, while non-ferrous alloys will usually become softer than normal. To
harden by quenching, a metal (usually steel or cast iron) must be heated above the
upper critical temperature and then quickly cooled.
In NBC Oil is used in the quenching process and the oil is kept at a temperature of
250C. Agitator is used to stir the oil in the oil quenching tank.
From the figure 4.3, we can find that when we rapidly cool austenite form then
martensite will form and it will have more hardness in comparison to austenite
form. Then through the conveyor job is sent to the washing tank which is held at a
temperature near about 220C. The conveyor speed is 400 mm/Min. Then drying is
done with the help of air.
3.10 TamperingMartensite formed during the quenching process is extremely hard and brittle, and
lack toughness. Thus these steels are not suitable for some baring applications
requiring impact resistance; hence a secondary heat treatment process called
tempering is carried out on quenched steel to achieve the necessary toughness and
ductility by marginally sacrificing hardness. This process also relives the internal
stresses thus improving the ductility . The tempering temperature is about 200 C
for 2.5 hrs. The above mentioned time and temperatures during heat treatment
explanations are for cup, cone, and wear rings.
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small amount of material. In grinding, an abrasive material rubs against the metal
part and removes tiny pieces of material. The abrasive material is typically on the
surface of a wheel or belt and abrades material in a way similar to sanding. On a
microscopic scale, the chip formation in grinding is the same as that found in other
machining processes. The abrasive action of grinding generates excessive heat so
that flooding of the cutting area with fluid is necessary.
During the grinding operations coolant is used regularly. Coolant is mixture of
water and oil. In coolant percentage of oil 3.5% and rest is water. For O.D grinding
in N.E.I. Ltd. HOCUT B-60 oil is used.
The objectives of cooling is arei.
ii.
.O
D
G
in
drg aceG
F
rindg R
ailG
rndg F
lanegrid B
reG
o
g
d
in
Fig3.8: process sequence
(a) O.D. grindingOD 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
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grinding wheel. The outer race is passed in machine three times to get highly
finished as follows:
1. Rough1
2. Rough2
3. Fine finish
(b) Face grindingAfter hardening process the first of grinding is face grinding and this process is
done on facing wheel grinding machine by manual feeding of cup and cone. Facing
wheel grinding machine grind the face of races at an average speed of 225 races
per hour with maximum capacity of 550 races per hour. After facing inspection of
dimension also checked to ensure to quality of grinded face.
(c)Flange grindingThe flange should be surface finished since the bearing has to be assembled in
machine. It is obtain in the flange grinding machine. In this machine one grinding
stone is used to cut and grind the flange portion of cone.
NC Mode
AUTO
Feed Mode
AUTO
Override
Tool movement during grinding is in all three dimensional axes i.e. X, Y, Z axis.
(d) Bore grinding-
Bore is the inner circumferential surface of the bearing. The bore should be
surface finished since the bearing has to be assembled in machine. It is obtain in
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the bore grinding machine. In this machine the grinding stone is moved in X and
Y axis.
Size Limit
+4 m to -4 m.
TOOL movement during grinding is in only two dimensional axes i.e. X, Z axis.
(e) Honing machine (super finishing)
Honing is an abrasive machining process that produces a precision surface on
a metal work piece by scrubbing an abrasive stone against it along a controlled
path. Honing is primarily used to improve the geometric form of a surface, but
may also improve the surface texture.
FaceGrindg
O.DGrindg
RailGrndg
Track is the path on which rollers will move so track of the cup should be
grinded properly. So that rollers will move smoothly.
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B o d y G r in g
F a c e G ri n d g
(c) Roller super finishing (honing)Mostly one or two stage super finishing machines are used for rollers. The rollers
are supported and driven by control wheels. The stone oscillates across the O.D.
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LATHE m/c,
ii.
SHAPER m/c,
iii.
BORING m/c,
iv.
PLANNER m/c,
v.
DRILLING m/c,
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vi.
MILLING m/c,
vii.
Universal type,
viii.
used
b.
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Demagnetize Washing
Chapter 4
Learning and Suggestions
4.1. LearningThis training is very fruitful to me. I got immense knowledge of the industry
environment as I worked in the Taper Roller Bearing department. Besides that
outcomes of the training are pointed out beneath-
4.1.1. Effect of quenching mediumWe are using oil in quenching process but we can also use water, Brine solution or
air for quenching purpose. As we know that water has high thermal conductivity
and air has the least. So if we use water then cooling of the austenite steel will be
very fast and due to this crack will be formed on the surface of the steel or
material. If we use air that it will not remove the heat fast because it has low
thermal conductivity and it will not serve the purpose.
4.1.2. Rockwell hardness test processBefore and after tampering to check the difference in hardness of bearing races that
comes in tampering process Rockwell Hardness Test is being used. The following
steps are to check the hardnessTable:4.1 According to material/job, we select the load indenter and scaleMaterial
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Load
Indenter
Scale
Hard job
150 kg
Diamond
C (Blake)
Soft job
100 kg
Ball (HCS)
B (Red)
1. Set the polished job (by Mb paper) and apply the load by hand lever
2. Hold the load for 10 seconds
3. Release the lever and note the scale reading
Note: The range of hardening of standard piece should lies between +1.5 to
-1.5
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(b)WaitingProcess which takes maximum time, identify that process (bottle neck process) and
try to reduce the process time to reduce the idle time of other processes which
depends on that.
(c)TransportationTry to minimize the distance between raw material and distance. This will save the
workers time and money and productivity will be increased. To do this a new
process can be stabilized or we can change the layout.
(d)InventoryRaw material should not be more than the demand. This stops the money in terms
of inventory.
(e)MotionCause of this- not placing tools at their proper place, it effects the motion of
worker. So there is loss of worker time and loss of machine production. For this we
should apply the work standard and design the work table according to need.
(f)Re-workCause- if product is not in proper size than there is need to again work on that. This
effects the loss of money, loss of worker and loss in production. For this we need to
understand the root of problem and try to make product correct in first time.
4.2 Flaking of rollers
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Corrective
Find the cause of heavy, load
Check internal clearance, regularly
Improve precision of journal and
housing
Improve operating conditions
Improve method of assembly and
handling
Check grease and greasing method
4.3 Comparisons between NBC Bearing and Bajaj BearingTable:4.3 Comparison between NBC Bearing and Bajaj Bearing
Type
Stake
NBC Bearing
11%
Bajaj Bearing
3.7%
Turnover(2012-13)
Quantity
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Range
Quality(Rejection)
1 PPM
6PPM
Customers
The comparison between NBC Bearing and Bajaj Bearing show that NBC bearings
is better than Bajaj Bearings in quantity wise and quality wise.
Chapter 5
5.3 Conclusion
Maximum of their work was done manually. While in railway bearing division, the
whole processing is automatic. But now days they are trying to set up new NOVA
CNC machines. It will reduce the human effort or will increase productivity up to a
large extent. This setting up of new nova machines will place the NBC at a position
to compete with other worldwide bearings mfg. co.
How an Industry works.
Learning of practical aspects of various dept. (Heat treatment, Grinding) in
railway bearings.
Got a brief idea about various heat treatment processes along-with their
industrial use.
Working of conventional machining process (grinding).
Industrial applications of all types of grinding and finishing processes.
Use of various gauges along-with applications of dial indicators in gauges.
How all the maintenance and inspections is done on in line processing or
after processing.
Various techniques of inspection methods.
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REFERENCES
BHANDARI V.B., Rolling Contact Bearing, Tata McGraw Hill
Education Private Limited, Fifth Reprint 2011.
RAO P.N, volume 2, Abrasive Processes, Tata McGraw Hill Education
Private Limited, Tenth Reprint 2011.
RAO P.N, volume 1, Engineering Materials, Tata McGraw Hill
Education Private Limited, Second Reprint 2009.
RAJVANSHI A.K., Manufacturing Processes, Genius Publications.
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http://www.nbcbearings.in/nbcpdf/Spherical_Roller_Bearings_catalatue_F i
na.pdf, on 15/06/2013
http://www.nbcbearings.in/nbcpdf/TechnicalCatalogue2012.pdf, on
15/06/2013
http://www.nbcbearings.in/nbcpdf/CTRBM.PDF, on 15/06/2013
http://www.nbcbearings.in/nbcpdf/SRBMM.PDF, on 15/06/2013
http://smartinvestor.business
standard.com/BSCMS/PDF/SKF_20080703.pdf
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