NEI Ltd.National Engineering Industries Ltd.

NEI Ltd. (National Engineering Industries Limited)

ACKNOWLEDGEMENT

At the outset we express our deep sense of gratitude to Mr. Ajay Pandey, Human Resource Department, N.E.I. and other staff members who have been the perennial source of inspiration and guidance in completion of this project.

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

National Engineering Industries Ltd. is the largest manufacturer of Ball and Roller Bearings, Steel Balls and Axle Boxes complete with Roller bearing in India, which are being produced in factories at Jaipur and Newai. Bearings are manufactured for every possible application and requirement of modern engineering industry and we continue to develop new sizes, keeping pace with rapid advancement in the Indian engineering industry.

NEI’s technical collaborations with the world’s leading conglomerates in the field of Bearing technology viz. M/s NTN Corporation of Japan, M/s BRENCO incorporated of USA have given a whole new dimension to the product range and a quality par excellence.

NEI has already implemented modern concepts of Total Quality Management and accredited QS9000 and TS16949 certification, NEI has also been awarded Assosiation of American Railroads (AAR) for AAR certificate M-1003 for cartridge Tapered Roller Bearing in Feb 04-05. NEI has also been awarded ISO-14001 certificate for its concern and commitment towards a cleaner environment. NEI has successfully implemented SAP-ERP to re-engineer and integrate business processes to conform to world class standards.

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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 :

(i). 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. (ii). 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. (iii). 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. This Division is spread over a covered area of 11,652 Sq. Meters. iv). Railway Bearing :

(a)Roller Bearing in Axle Box:

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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 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.

(b)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.

(c) Cartridge Tapered Roller Bearing:

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.

This Division is spread over a covered area of 4,855 Sq. Meters.

(v). 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

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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.

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.

(II) PLANT AT GUNSI (NEWAI) :

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. 

(III) PLANT AT MANESAR :

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

(a) 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.

(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.

(C) SAP – ERP :

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In order to reengineer and integrate the Business processes for sales, production, materials and finance, NEI has successfully implemented SAP- ERP. By use of this Package, our processes now conform to international standard.

QUALITY MANAGEMENT SYSTEM

ISO / TS 16949:2002

NEI extensively embarked upon system improvement and implemented modern concepts of Total Quality Management. NEI has been awarded TS 16949: 2002 on 17th October, 2003- THE MARK OF EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by BVQI for design, development, manufacture & supply of Ball Bearing, Tapered Roller Bearing and Cylindrical Roller Bearings. NEI Ltd. is the first bearing industry in India to have been recommended for TS 16949: 2002.

This certificate is awarded to only suppliers of automobile manufacturers. NBC bearings are used by all major auto OE customers in India like Maruti Udyog, Hero Honda, Bajaj Auto, Bajaj Tempo, TVS Motors, Ashok Leyland, Tata Motors, Hindustan Motors, Yamaha Motors, Eicher Limited, Eicher Motors, Mahindra & Mahindra Auto & Kinetic Motors etc.

In addition customers like Eicher Tractors, Punjab Tractor, Escort Tractor, International Tractors, New Holland Tractors, Electric & Pump Motors, Crompton & Orient Fans and many more in Automobile, Electric Motors & Pump, Fans, Conveyors, Steel Plants, Thermal Plants also use NBC bearing regularly.

The recommendation was made by BVQI after 15 days of detailed audit in all areas of NEI including our Gunsi plant.

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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.

Every process is critically studied and performance indicators for measuring output of those processes defined. Measurement of efficiency and effectiveness of every process only decides how ably the process has been performed. Simplicity, effectiveness & efficiency of processes, error proofing and continuous 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

(a) BRENCO Incorporated , U.S.A.

Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and Locomotives.www.brencoqbs.com

(b) NTN Corporation , Japan

Since 1985-For Ball Bearings, Cylindrical & Spherical Roller Bearings.Since 1997-For Tapered Roller Bearings.http://www.ntn.co.jp

(c) Izumi Kinzoku Kogyo Co. Ltd., Japan

Since 1996 - For re-manufacturing, retrofitting and overhauling of grinding and super finishing machines for bearing races.http://www7.ocn.ne.jp/~izk.co

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PRODUCTS

A BROAD RANGE BORN OF PRECISION

From a few mms to thousands of mms, from a few grams to a few tones, the NBC range is hard at work in some of the most critical areas of Indian industry.

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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TAPERED ROLLER BEARINGS

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.

SPHERICAL ROLLER BEARINGS

Originally developed in collaboration with Swiss leaders FAG-SRO. Vital for broad gauge and meter gauge coaches manufactured by ICF, Chennai and RCF, Kapoorthala for the Indian Railways. Now new sizes are being developed with the help of NTN Corporation, JAPAN.

ROLLER BEARING AXLE BOXES

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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.

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.

PRECISION STEEL BALLS

Manufactured using the most modern facilities available in India, Quality steel balls, upto 25 mm in diameter for NBC bearings are

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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.

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

The following New Bearings are Developed for Railway ApplicationSPHERICAL ROLLER BEARINGS

22312D1 (Bore 60 mm x OD 130 mm x Width 46 mm)

22312KD1 (Bore 60 mm x OD 130 mm x Width 46 mm)

22314D1 (Bore 70 mm x OD 150 mm x Width 51 mm}

22314KD1 (Bore 70 mm x OD 150 mm x Width 51 mm)

22222 (Bore 110 mm x OD 200 mm x Width 53

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mm)

22222KD1 (Bore 110mm x OD 200 mm x Width 53mm)

For Industrial use.

CYLINDRICAL ROLLER BEARINGS

NH318 (Bore 90 mm x OD 190 mm x Width 43 mm) Traction Motor Bearings

NU1964 (Bore 320 mm x OD 440 mm x Width 56 mm)Suspension Bearing developed for Indian Railways for WAG-9 Locomotive

NH1044 (Bore 220 mm x OD 340 mm x Width 56 mm)Suspension Bearing developed for Indian Railways for WAG-9 Locomotive

SUSPENSION TUBE KIT ASSEMBLY

Suspension tube kit assembly developed for Indian Railways for GM Locomotive WDG-4

TAPERED ROLLER BEARING

M244249A/N1060 (Bore 220.662 mm x OD 314.325 mm x Width 61.912 mm) Suspension Bearing developed for Indian Railways for GM Locomotive WDG-4

N1059/M244210 (Bore 221.17 mm x OD 314.325 mm x Width 61.912 mm) Suspension Bearing developed for Indian Railways GM

Locomotive WDG-4

TPM(Total Production Management)

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(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

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

7. Safety Health and Environment Developing perfect machine for perfect quality Eliminating in process defects and customer complaints

8. Development Management Offices oriented for excellent support for manufacturing Improving offices and man-hour efficiency

1S – Seiri – Clean Up2S – Seition – Make Convenient3S – Seiso – Maintain Cleanliness4S – Seiketsu – Healthy Environment5S – Shitsuke – Promote Good Habits

Bearing Designation

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Rolling bearing part numbers indicate bearing type, dimensions, tolerances, internal construction and other related specifications. The first letter (digit) indicates the bearing type. The second digit indicates the width (or height) series and the third indicates the diameter series. The last two digits indicate the bore diameter by multiplying the last two digits by the five for bearing bore diameter original 40 mm and above. This method is applicable for metric series bearing only.

Rolling Bearing Construction And Classification

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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.

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.

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BEARING CLASSIFAICATION

1. Single Row Radial Ball Bearings

The Single row radial ball bearings accommodate pure radial, pure axial or any combination of radial and axial loads within its capacity. These can operate at very high speeds. For these reasons and its economical price, it is the most widely used bearing.

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.

2. Single Row Radial Ball Bearing with Tapered Bore

The Single row radial ball bearings with tapered bore are identical to the 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 the small bore.

3. Single Row Angular Contact Ball Bearing

The single row angular contact bearings have higher axial load capacity than the single row radial ball bearings. The radial load must always be less than the axial load. The bearings can carry axial load in one direction only and should be adjusted against another bearing, if axial load is coming 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 used where accurate alignment can not be guaranteed between bearing 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 contact and prevent alignment.

These bearings can be located endwise in the both the directions.

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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. The 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 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.

7. Thrust Ball Bearing

The thrust bearings are used for high axial loads at low speeds. These can not operate at high speed as it will give rise to centrifugal or radial forces which can 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 bearing of same external dimensions and are particularly suitable for arduous duties. The bearing features a modified line contact between rollers and raceways to eliminate edge stressing. These bearings have a high radial capacity and are suitable for high speeds. Due to detachable design character they have advantage of mounting inner ring and outer ring separately.

The direction of axial load which a bearing can take depends upon the geometry of the bearing.

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

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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 bearings with exceptionally steep cone angle enables the bearings to take heavier axial load.

The bearings are of separable type, enabling separate mounting of cones and cups.

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.

10. Spherical Roller Bearing

Spherical roller bearings are particularly suitable for carrying heavy loads. They are usually of the double row design, both 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.

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Heat Treatment Process

Chugai – Ro Heat Treatment Furnance

Hardening Procedure

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

Process Hardening Quenching TemperingAir

Cooling

Procedure

Heat the Furnace850-870O C

Fast cooling 600 C – Oil Quenching1800C – Salt Bath

Furnace Heating 1650-1800C

Cool at Room Temperature

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Hardness ------ 62 – 66 HRC 60 – 64 HRC ------

Time 35-60 min.According to the job

5-15 min. 150 min. ------

Hardening Procedure

Steel MaterialLC Steel (Low Carbon Steel)

Process Carburizing Hardening Quenching Tempering

Procedure

Carbon Furnace heating at 9400 C - 9500 C

Furnace temperature at 8500 C – 8700 C

Fast cooling 600 C –for oil quenching only

Heat the Furnace at 1650 C-1800 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

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Heat Treatment

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)

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Tempering(160 0C) (4 hrs.)

Shot Blasting

(Wheel Abrator)

Hardness Inspection

(60 HRC)

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 partsa) Markerb) Controllerc) Water-cooled Unitd) Filter Kite) Consolef) Control Panelg) 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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Ball Bearing Division

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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. Cage2. Rubber Seal3. Snarping4. Dust Shield5. Ball

Inspection/Testing

Analysis of Rejections

ECT / EVT EOT

Heading Defects Flashing Damages Pitting Defects Odd Shaped Balls

Dirty Material Rusty Balls Pitting Defects Black Surface Balls

ECT : Eddy Current TestEOT : Electrical Optical TestEVT : Electronic Vibration Test

Some Ball Defects and Problems

Balls stuck in outshoot Slug inserted in finger at an angle different from perpendicular Bulging Defects Slug shearing is incorrect

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Some Special Types of Bearings

Double Row Angular Contact Sealed Bearings

(DRAC) (Wheel Application)DRAC Lubrication

Objective of lubrication is to form a film of oil on rolling or sliding surface to prevent the metals from making direct contact with each other, Lubrication has the following effects:

Reduces friction and wear. Extends Bearing life. Prevents rusting. Prevents penetration of foreign matter.

Fretting wear particularly tends to occur on the raceway of DRAC Bearing during transport of finished automobiles. Therefore the fretting resistance property of the Lubricant should be taken into account while selecting lubricant for DRAC 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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LappingPaste Composition

L1 L23

7/32” – 9/32”

1500 gm(Green Powder)

(Cr2O3)(Chromium Oxide)

+2 liter

(Honilo)+

1 liter(Oleic Acid)

7/32” – 3/4”

600 gm+

1 liter(Honilo)

+1/4 liter

(Oleic Acid)

GRINDING

Centre less Grinding

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Cone Track Grinding

Causes of Step in Cone –

a) Baking plate is not properly aligned in accordanceb) Width of Grinding Wheel is Lessc) Width of Cone Track is mored) Undercut Width is less.

Cartridge Roller Bearings Components

a) Cone Assemblyb) Cupc) Spacerd) Wear Ringe) Grease Sealf) Axel and Cupg) Axel Cup Screwh) Locking Platei) Backing Ring

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