PROJECT REPORT

(Project Semester January-June 2012)

STUDY, ANALYSIS AND DESIGN OF SYSTEMS FOR OPTIMISATION OF THE CTRB LINE

Submitted By

SIDDHANT SHAH 09107056

Under the Guidance of

Dr. Alakesh Manna Associate Professor PEC University of Technology Chandigarh

Mr. Bipin Kumar Railway Bearings Division National Engineering Industries Jaipur

Department Of Mechanical Engineering PEC University of Technology, Chandigarh January to July, 2012

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DECLARATION

I hereby declare that the project work entitled STUDY, ANALYSIS AND DESIGN OF SYSTEMS FOR OPTIMIZATION OF CTRB LINE is an authentic record of my own work carried out at National Engineering Industries, JAIPUR as a part of the requirements of six months project semester for the award of degree of B.E. MECHANICAL ENGINEERING, PEC University of Technology (Deemed University), Chandigarh, under the guidance of Mr.Bipin Kumar and Dr. Alakesh Manna, during January to June, 2012.

SIDDHANT SHAH Student I D - 09107056

Date: ___________________

Certified that the above statement made by the student is correct to the best of our knowledge and belief.

Dr. ALAKESH MANNA

Mr. BIPIN KUMAR

LPE RAILWAY BEARINGS DIV

ASSOCIATE PROFESSOR
PEC UNIVERSITY OF TECHNOLOGY (D.U)

NEI, JAIPUR

CHANDIGARH

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ACKNOWLEDGEMENT

If you take responsibility for yourself you will develop a hunger to accomplish your dreams. -Les Brown

In this age of cutting edge technologies, the scenario of the race for the technology is like the more we try to chase the horizon; the more difficult it becomes to maintain the pace. And till the hope to over run the horizon survives, newer technologies will keep on emerging.

We live in an age of history where change is so speeded up, that we begin to see the present only when it has already disappeared. My training at NEI, Jaipur is somewhat similar to what is written above. No project work is ever the outcome of a single individuals talent of efforts. This project too is no exception. Many supervisors, colleagues, friends, well-wishers have contributed to my work, directly or indirectly, and made it possible to present it in its current form.

My tenure at NEI, Jaipur was highly eventful. Working with highly devoted employees will probably remain the most memorable experience of my life. Hence, this acknowledgement is a humble attempt to earnestly thank all those who were directly or indirectly involved in my project work and were of immense help to me.

First and foremost, I am grateful to Mr. Aman Bhargava (Head of Railway Bearing Department, NEI Jaipur) for showing trust and confidence in me and allowing me to work in the Railway Bearing Department, which enhanced my knowledge and gave me the best industrial experience.

To be in the right direction at right speed you require a spark and you can travel all through to your destination. The spark is the initiation of the path to your destination. And I am indeed very thankful to my project guide and mentor Mr. Bipin Kumar (Engineer, LPE Department, Rly. Brg. Div.) for guiding me all through my project.

I am very thankful to other members of the department, Mr. Ravishanker Gupta, Mr. Raghu, Mr. Rajat Mehrotra and Mr. Vikas Vir who gave me their support right till the end of the project, by providing me with the required information whenever asked.

I am also thankful to Mr. Thomas (Personnel and HRD) for giving me an opportunity to work in such a reputed organization.
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Lastly I would also like to thank my faculty in charge Dr. Alakesh Manna who provided valuable support and guidance at various stages.

I sincerely thank Prof Arun K Lal, Head of Department, Mechanical Engineering Department, PEC University of Technology, Chandigarh for giving me this opportunity to come for training and learn in the outside world.

Siddhant Shah 09107056 BE, Mechanical Engineering PEC University of Technology Chandigarh

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CONTENTS

1) INTRODUCTION TO THE COMPANY AND THE RAILWAY BEARINGS DIVISION About the CK Birla Group National Engineering Industries o o : Company Profile NEI : Jaipur Plant Railway Bearings o Cartridge Tapered Roller Bearing (CTRB) Parts Nomenclature Manufacturing

1 - 35

2) PROBLEM SOLVING PROJECT : CTRB CONE STAMPING Nature of the problem Objective Analysis Counter Measure What is PLC Benefits 36 46

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3) STUDY ANALYSIS AND DESIGN OF CNC HARD TURNING SYSTEM AS A SUBSTITUTE TO CTRB CUP OD GRINDING Material used in Cup Why is OD Grinding Required Generally Required Parameters Centreless Grinding The Current Setup CNC Turning Hard Turning o Introduction o Advantages o Machining Requirements o Surface Finish Conclusion and Final Notes o Cycle Time Comparison o Final Conclusion 47 80

4) COST SAVING PROJECT Idea Present Status Suggestion Analysis/Calculation

81 82

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5) OPTIMIZATION OF CTRB LINE USING STATISTICAL PROCESS CONTROL The 7 Quality Tools Statistical Process Control Assignment 1: o To reduce rejection of wear ring due large bore 1. Overview 2. Flow Chart 3. Background/Scope 4. Brainstorming a. Sizematic and Gagematic Grinding 5. Cause Effect Diagram 6. Fact Verification 7. Actions Taken 8. Effect : Benefits Assignment 2: o To reduce scrap of CTRB Cup in finish width grinding 1. Objective 2. Operational Flowchart 3. Initial Study 4. Cause Effect Diagram 5. Fact Vetification I
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83 131

6. Cause Effect Diagram II 7. Fact Verification 8. Action Plan 9. Final Long Term Study

6) CONCLUSION

132

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LIST OF FIGURES
Figure Number 2.1 2.2 Top view of CTRB Cone, showing stamped characters Maximum difference in the depth of two letters within the same stamped part 2.3 2.4 2.5 2.6 Part to part variation of letter B before improvements Diagram for implementation of the counter measure Variation in 200 pcs after improvements The installation of switch in the stamping press(above) and explanation of its working (below) 2.7 Variation in depth of letter B in 200 pcs after installation of switch 2.8 Study of 200 pcs (the data for one specific letter B after the implementation of changed depth control mechanism 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Flowchart of CTRB Cup Line A CTRB Cup Centreless grinding Vee block method of measuring roundness Measurement of roundness by special instruments The arrangement in centreless grinding Inclusion of an angled work-blade Fig 3.8 : Mechanism of the peel grinding process 3.8 Mechanism of Peel Grinding 58 47 47 48 50 51 54 55 45 45 39 41 41 43 Description Page Number 36 38

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3.9 3.10

Peel grinding as used in Cup OD Grinding The Cincinnati Centreless OD grinding machine for rough OD grinding

59 61

3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23

OD Grinding, X-291 Finish OD Grinding of Cups Process of heat treatment in Cups Carburising of Cups Rotary hearth for cup hardening showing hard turning process and CBN inserts respectively Advantages of hard turning process Machining Requirements in case of Hard Turning Flow of processes in order to incorporate hard turning Hard turning with and without coolant Cutting tool geometry Observed variation of surface in a turning operation a close up on the surface characteristics obtained in grinding(left) and hard turning(right)

61 62 63 64 64 67 69 69 70 71 72 72 73

3.24 3.25 5.1 5.2 5.3

A graphical comparison of various cutting tool materials Generation of white layer while hard turning on hardened steel CTRB Wear Ring Flow Chart Wear Ring on the grind base Pareto Diagram showing time wise and problem wise scrap due to large bore

76 77 104 105 106,107

5.4

Process Capability sixpack of OOR(Out of Round) due to

107

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improper bore gdg 5.5 5.6 Fish bone diagram for large bore in wear ring Checking coolant nozzles for correct positioning(above) and checking guards/loading arm for play (below) 5.7 5.8 5.9 Installation of sensor (microphone for noise) The Marposs P7 amplifier control unit The various stage in precision grinding using Gagematic (above) and the settings for the same preset in the Marposs panel (right) 5.10 5.11 5.12 5.13 Marposs sensor, filter + amplifier unit after installation Old BEMCO Press Quenching done on the old Bemco press The new Simpletec press in use, having guiderails and double action 5.14 5.15 5.16 5.17 The decrease in scrap as a result of the various steps taken The Gardner X 173 machine with the robotic arm Operational flow chart of the CTRB Cup line Cause and Effect diagram for the problem of rejection in cup face grinding 5.18 5.19 5.20 5.21 5.22 Width Study chart for 100 cups Updated fish bone chart Finish turned dimensions for the CTRB Cup after modification The worker indication-cum-alert system installed Process Capability Sixpack after completion of the project 126 127 129 130 131 121 122 123 125 118 118 119 120 114 115 117 111 113

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LIST OF TABLES
TABLE NUMBER 3.1 5.1 5.2 5.3 5.4 Composition of SAE 8720 Inspection Standard vs Quality Standard Dimensional Requirements for W/R Bore GDG : Background checklist for large bore problem Fact Verification for the issues mention in the fish bone diagram DESCRIPTION PAGE NUMBER 48 96 105 106 112

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