Professional Documents
Culture Documents
Submitted By
NIKHIL JAIN
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INDEX
Acknowledgement
Foreword
Introduction
Plant at Jaipur
Plant at Gunsi (Newai)
Plant at Manesar
Research and Development
Quality Management System
Collaboration
Products
Advances
Total Production Management
Bearing Designation
Rolling Bearing Construction And Classification
Heat Treatment Process
Laser Marking System
Ball Bearing Division
Ring Rolling Mill
Miscellaneous
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Foreword
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Introduction
National Engineering Industries Ltd., Jaipur was founded in the year 1946 as a
pioneer industry in the field of bearing manufacture by the renowned
industrialist, late Shri B.M. Birla, under the name of "National Bearing Company
Limited." 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, and
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
"Indigenisation 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 Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers,
Shovels, Tillers and Thermal Power Plants all across the country.
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(I) PLANT AT JAIPUR :
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.
This Division is spread over a covered area of 11,652 Sq. Meters.
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
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in service with the Indian Railways. The development of completely
indigenised 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.
For fitment to the new BOX-IN Uprated Wagons designed by the RDSO,
NEI is the only manufacturer in the country to indigenise 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
year 1984. These bearings are grease packed and require no field lubrication
for a period of 7 years.
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 dia 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.
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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.
Established 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 &
post- process 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.
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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RESEARCH & 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.
(b)Machine Building :
NEI has the capability of machine building to design, develop and manufacture
special purpose CNC Grinding Lines, HT Lines, Material Handling Equipments
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 equipments, resulting in upgraded
quality and improved productivity.
R&D Division is spread over a covered area of 2,007 Sq. Meters.
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QUALITY MANAGEMENT SYSTEM
ISO / TS 16949:2002
The recommendation was made by BVQI after 15 days of detailed audit in all
areas of NEI including our Gunsi plant.
TS 16949: 2002 quality management system is based on ISO 9001: 2000 in which
many supplementary and additional requirements of automobile industries have
been incorporated. TS quality management system in NEI starts with
identification of all customer requirements and ends with ensuring that all
customer requirements have been fulfilled. This also requires continuous
improvement in all areas.
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improvement in processes thus become the highlight of TS quality management
system.
ISO 9001:2000
NEI’s Large dia bearing division and railway bearing division which are
manufacturing Cylindrical Roller Bearings, spherical roller bearings, cartridge
tapered roller bearings, railway rolling stock and spares has also been awarded
to ISO 9001: 2000 on 9th October, 2003 by BVQI.
ISO 14001:1996
NEI’s everlasting concern for cleaner, pollution free environment has made the
NEI to go on the path of Environmental management System. NEI was awarded
ISO -14001 certificates by BVQI in the month of March 2000 for Environmental
Management System. NEI has done tremendous efforts in resource conservation,
recycling and thick plantation. The efforts at NEI have saved precious natural
resources like water, oil and power etc.
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Collaboration
Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and
Locomotives.
www.brencoqbs.com
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PRODUCTS
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.
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Corporation, JAPAN, these bearings are used by all major automobiles, truck
and tractor manufacturers in the country as original equipment.
Developed by NBC for the Indian Railways for use in rolling stocks. Excellent
performance even in the high speed Rajdhani locomotives, the Yugoslavian and
Egyptian Railway wagons.
A total of 34 different types of the axle boxes are turned out at the NEI plant in
Jaipur. Designs for high speed railway application are being developed together
with NTN. More than one million NBC axle boxes and roller bearings are in
operation with Indian Railways. We have the privilege of being the single largest
source of bearings to Indian Railways, which is one of the largest networks of its
kind in the world.
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CARTRIDGE TAPERED ROLLER BEARINGS
Successful Track record in the Railways for the past 30 years, these require no
field lubrication. Developed in collaboration with BRENCO Inc. USA, these
bearings are being used in all broad gauge wagons of Indian Railways.
Manufactured using the most modern facilities available in India, Quality steel
balls, upto 25 mm in diameter for NBC bearings are manufactured in precision
lines imported from NTN Corporation, JAPAN. NBC ball bearings are now
specially manufactured with high precision steel balls produced in ultra modern
plant equipped with high speed headers, electronically controlled flashing,
grinding, and lapping machines to ensure accuracies of sub-micron levels.
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LARGE DIAMETER BEARINGS
We have the distinction of being one of the few bearing companies in the
world to manufacture bearings upto 2000 mm outside diameter developed with
indigenous technology. Bringing Shri B.M. Birla's vision of self-reliance to
fruition, NBC large diameter bearings contribute to steel production and thermal
power generation in India.
ADVANCES
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Suspension Bearing developed for Indian Railways for WAG-9 Locomotive
Suspension tube kit assembly developed for Indian Railways for GM Locomotive
WDG-4
TPM
(Total Production Management)
(8 Pillars)
1. Focused Improvement
Developing machines for “High Equipment Effectiveness”
Quick process for developing new products
2. Autonomous Maintenance
Maintain Basic Conditions on shop floor and in Machines
All over participation through TPM circles
3. Office TPM
Local Analysis “Real Causes for Real Countermeasures”
Focus on Prevention
4. Quality Maintenance
Skill Development for uniformity of work practices on machines
Skill for zero accidents, zero defects and zero break down
Multi-Skilled employee in all departments
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5. Education and Training
To achieve zero accidents, zero health hazards at work
To maintain zero pollution plant and environment
6. Planned Maintenance
Improvement is Everyone Activity
Improvement is to eliminate production issues and Reduce cost
8. Development Management
Offices oriented for excellent support for manufacturing
Improving offices and man-hour efficiency
1S – Seiri – Clean Up
2S – Seition – Make Convenient
3S – Seiso – Maintain Cleanliness
4S – Seiketsu – Healthy Environment
5S – Shitsuke – Promote Good Habits
Bearing Designation
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Rolling Bearing Construction And Classification
Rolling bearings are generally composed of bearing rings, rolling elements and
cages. Several rolling elements are placed between two bearing rings and cages
prevent the rolling elements from contact and with such a structure, a smooth
rolling action becomes possible.
Rolling bearings are divided into radial bearings and thrust bearings, mainly
depending on the applicable load direction. Radial bearing mainly take radial
loads. Most types of radial bearings can also take thrust loads. Thrust bearings
generally take thrust loads only and not radial loads.
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Rolling bearings are largely divided into ball bearings and roller bearings in
accordance with the types of rolling elements, Roller bearings are further divided
depending on the shape of the roller into the cylindrical roller bearings, spherical
roller bearings and needle roller bearings. Ball bearings are divided into several
types, depending on the shape of bearing rings and the contact position between
the balls and the raceway.
The cages of rolling bearings are divided into pressed and machined ones with
the shapes differing according to the bearings types and conditions of use.
BEARING CLASSIFAICATION
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Owing to high degree of conformity between balls and raceways, the self
aligning capability of the deep groove ball bearings is small. This fact calls for
well aligned bearing mountings.
These bearings can be located endwise in both the directions.
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6. Double Row Self-Aligning Ball Bearing with Tapered Clamping
Sleeve and Nut
The double row self aligning ball bearings with tapered claming 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.
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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. A single row tapered roller bearing
can be located endwise in one direction only.
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Chugai – Ro Heat Treatment Furnance
Hardening Procedure
Air
Process Hardening Quenching Tempering Cooling
Hardening Procedure
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Steel Material
LC Steel (Low Carbon Steel)
Heat Treatment
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Raw Material
(Carbon Steel)
Carburizing
(Carbon Shield Layer increases Hardness)
(10 – 12 hrs.) (940 0C) (GC Furnace)
Hardness I
(Revolving Furnace)
(920 0C) (Time Dependent on Job)
Annealing
(6 hrs.) (650 0C)
Shot Blasting
Hardening II
(Revolving Furnace)
(820 0C) (Time Dependent on Job)
Sub-Zero Treatment
(-60 0C) (Increases Toughness)
Tempering
(160 0C) (4 hrs.)
Shot Blasting
(Wheel Abrator)
Hardness Inspection
(60 HRC)
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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 accordingly.
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Wire
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(High Chromium Steel)
Heading Machine
Flashing (Rough Grinding)
(Scale : 0.01-10mm) (High Grind Oil + H2O)
Soft Grinding
(Scale : 0.001-1mm) (High Grind Oil + H2O)
Heat Treatment
Work Hardening Tumbler
(60 HRC)
Hard Grinding (G2)
Finish Grinding (G3)
(Kerosene)
Rough Lapping (L1)
Finish Lapping (L2)
Ultra Sonic Washing Machine
(Kerosene)
Visual Inspection
Anti-Rust Oil Packaging
Maxi Grind Oil + H2O and High Grind Oil +H2O (Coolant)
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(l.d.b.)Ring Rolling Mill
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Miscellaneous
Bearing Components
1. Cage
2. Rubber Seal
3. Snarping
4. Dust Shield
5. Ball
Inspection/Testing
Analysis of Rejections
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Some Special Types of Bearings
DRAC Seals
A special Low torque high performance (LTHP) seal on both sides of the DRAC
Bearings prevent water ingress in the bearing and have low torque. It consists of
3-lips-Grease Lip, Dust Lip and Side Lip. A Stainless Steel Slinger is added to the
3-lip seal sliding part, which dramatically enhances rust resistance of the sliding
part of the lips. Side lip is added for improving the sealing performance.
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Lapping
Paste Composition
L1 L23
1500 gm
(Green Powder) 600 gm
(Cr2O3) +
(Chromium Oxide) 1 liter
+ (Honilo)
2 liter +
(Honilo) 1/4 liter
+ (Oleic Acid)
1 liter
(Oleic Acid)
GRINDING
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Cone Track Grinding
a) Cone Assembly
b) Cup
c) Spacer
d) Wear Ring
e) Grease Seal
f) Axel and Cup
g) Axel Cup Screw
h) Locking Plate
i) Backing Ring
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