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CHAPTER-1 
1 
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 
Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers 
and Thermal Power Plants all across the country.
2 
1.2. Milestones 
Fig.1.1 Milestones of NEI 
i. 1946 -Company established as National Bearing Company (NBC) under 
technical collaboration with Hoffman, U.K. 
ii. 1950 Ball Bearing Production started. 
iii. 1958 Company is renamed National Engineering Industries Limited (NEI); 
NBC Trademark retained. 
iv. 1967 Tapered Roller Bearing production started 
v. 1975 Spherical Roller Bearings production begins 
vi. 1981 Second Plant inaugurated in Newai. 
vii. 1982 Cartridge Tapered Roller Bearing in Technical Collaboration with 
Brenco Incorporated of U.S.A. 
viii. 1985 Technical Collaboration with NTN Corporation of Japan for Ball, 
Cylindrical & Spherical Roller Bearing. 
ix. 1995 ISO - 9001 Quality Management System Certification 
x. 1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for 
Machine Retrofitting 
xi. 2007 Third Plant inaugurated in Manesar. 
xii. 2008 NBC receives TPM Excellence Award 
xiii. 2010 NBC receives Deming Award
xiv. 2012 NBC receives the ACMA awards for Manufacturing and Technology 
3 
Excellence 
1.3. Technical collaboration 
(i) BRENCO Incorporated of U.S.A. Since 1982 - For Cartridge Tapered Roller 
Bearings for Railroad applications. 
(ii) NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical & 
Spherical Roller Bearings, JPU Bearings, Double Row Angular Contact Bearings, 
Hub Bearings Since 1997 - for Tapered Roller bearings. 
(iii) Izumi Kinzoku of JAPAN Since 1996 for remanufacturing, retrofitting and 
overhauling of Grinding and Super-finishing machines for bearing races. 
1.4. Main Customers 
Rolling Stock: - 
 DLW (Diesel Locomotive Work) 
 CLW (Chittaranjan Locomotive Works) 
 ICF (Integral Coach Factory, Chennai) 
 RCF (Rail Coach Factor, Kapurthala) 
 CIMMCO 
 BEML (Bharat Earth Movers, Bangalore) 
 TEXMACO 
 Hindustan Motors Ltd. 
 Maruti Udyog Ltd. 
 Mahindra & Mahindra 
Automobiles-LCV: - 
 Ashok Leyland 
 Force Motors 
 Eicher Motors 
 Tata Motors 
Automobiles-Two/ Three Wheelers:- 
 Bajaj Auto Ltd. 
 Hero Honda Motors Ltd.
 Honda Motorcycle & Scooters India Ltd. 
 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 
 NGEF 
 MICO 
Fans: - 
 Bajaj Electricals 
 Crompton Greaves 
4 
1.5. Manufacturing Facilities 
NBC has manufacturing facilities at Jaipur (established in 1946), Newai(established 
in 1980) and Manesar (established in 2006). A fourth plant, a green field project, 
atSavli 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
5 
 Newai (Gunsi) Plant 
 Manesar Plant 
1.5.1. Newai (Gunsi) Plant 
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. 
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. 
Fig1.2: Manesar Plant
CHAPTER-2 
6 
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. 
Fig. 2.1: Jaipur Plant 
Fig.2.2: Nbc Design and Development 
The plant at Jaipur includes-i. 
Ball Bearing 
ii. Precision Ball Making
7 
iii. Tapered Roller Bearing 
iv. Railway Bearing 
v. Research & Development 
vi. Large diameter bearings 
vii. SAP-ERP 
2.2. Ball Bearing 
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. 
Type of Ball Bearing:- 
a. Radial Ball Bearing 
b. Angular Contact Bearing 
c. Self-Aligning Two-Row Ball Bearing 
Radial ball bearing Angular Contact Bearing Self-Aligning Two-Row Ball 
Bearing 
(a) (b) (c) 
Fig. 2.3: Ball Bearings 
The initial technology was from Hoffman Manufacturing Company Ltd., U.K. a 
collaboration, which continued for 20 years. They offer a wide range of both metric 
and inch series deep groove ball bearings, angular contact ball bearings, self-aligning 
ball bearings etc. With their tie up with the world's leading bearing manufacturing 
company NTN Corporation, JAPAN, They have gained access to the most advanced
ball bearing technology i.e. thermo mechanical bearings (TMB) and tensioner 
bearings available today and their wide range of ball bearings is increasing under this 
collaboration. Precision ball bearing from 6mm bore to 160mm OD is 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. 
8 
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. 
Fig. 2.4: Steel Ball 
2.4. Tapered roller bearing 
Type of Tapered Roller Bearing 
a. Single Row Tapered Roller Bearing 
b. Double Row Tapered Roller Bearing
Single Row Tape re d Roller Bearing Double Row Tape r ed Roller Bearin g 
(a) (b) 
Fig. 2.5: 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 
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 modernization 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. 
9 
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 
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. 
Fig 2.6: Axle Boxes 
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. 
10 
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 
Fig 2.7: Railway Bearings
2.5.3. Cartridge tapered roller bearing 
For fitment to the new BOX-N Uprated Wagons designed by the RDSO, NEI is the 
only manufacturer in the country who is the first to indigenize these bearings to a high 
percentage under collaboration with the largest manufacturer of these bearings in the 
world. Production of these bearings is grease packed and requires no field lubrication 
for a period of 7 year. The Railway Bearing Division is spread over a covered area of 
1.2 acres. 
11 
2.6. 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 up to 2000 mm diameter. The largest bearing produced by NEI for 
fitment to plate will of Rourkela Steel Plant was released by Mr. G.P. Birla in 
September 1985. This 4-row tapered roller bearing measures 1300 mm diameter and 
weighs 4.39 tones. The large diameter bearings are mainly produced out of case 
carburizing steels, heat treated on special equipment and furnaces developed by NEI. 
The 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. 
2.7. Research and development 
2.7.1. Design and development 
Complete in-house facility for design & development of all types of bearings and 
tooling is available. The design is done on CAD. The large diameter bearings and 
tooling have been entirely designed and developed by NEI’s R&D at its Computer 
center. Complete engineering and research facility is available to solve problem of 
design development, manufacturing, installation and maintenance of bearings. With 
the signing of the technical collaboration agreement with NTN CORPORATION 
JAPAN & BRENCO IN CORPORATED OF USA, the capability to offer the finest 
engineering services in the bearing industry has enhanced.
12 
2.7.2. Machine building 
The NEI has the capability of Machine Building to design, develop and manufacture 
special purpose CNC grinding lines, HT lines, material handling equipment’s 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 M/c Building division. Machine 
Building has the capability and supports the Manufacturing divisions by overhauling 
and retrofitting of the existing equipment’s so that these are upgraded to help produce 
quality and improve productivity. R& D is spread over a covered area of ½ acres. 
2.8. SAP-ERP 
In order to re-engineer and integrate the Business processes for Sales, Production, 
Materials and Finance, NEI has success- fully implemented SAP ERP.
CHAPTER-3 
13 
BEARING 
3.1. Definition of 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. 
Plain bearings are very widely used, and use surfaces in rubbing contact. Particularly 
with lubrication they often give entirely acceptable life and friction. On the other 
hand, low friction bearings are often important for efficiency, to reduce wear and to 
facilitate extended use at high speeds. Essentially, a bearing can reduce friction by 
virtue of its shape, by its material, or by introducing and containing a fluid between 
surfaces or by separating the surfaces with an electromagnetic field. 
By shape, gains advantage usually by using spheres or rollers, or by forming 
flexure bearings. 
By material exploits the nature of the bearing material used. (An example would be 
using plastics that have low surface friction.) 
By fluid exploits the low viscosity of a layer of fluid, such as a lubricant or as 
a pressurized medium to keep the two solid parts from touching, or by reducing the 
normal force between them. 
By fields exploits electromagnetic fields, such as magnetic fields, to keep solid parts 
from touching. 
Combinations of these can even be employed within the same bearing. An example 
of this is where the cage is made of plastic, and it separates the rollers/balls, which 
reduce friction by their shape and finish 
3.2. Principles of Operation 
There are at least six common principles of operation: 
• Sliding bearings, usually called "bushes", "bushings", "journal bearings", 
"sleeve bearings", "rifle bearings", or "plain bearings”.
• Rolling-element bearings such as ball bearings and roller bearings. 
• Jewel bearings, in which the load is carried by rolling the axle slightly off-center. 
• Fluid bearings, in which the load is carried by a gas or liquid. 
• Magnetic bearings, in which the load is carried by a magnetic field. 
• Flexure bearings, in which the motion is supported by a load element which bends. 
14 
3.3. Motions 
Common motions permitted by bearings are: 
• Axial rotation e.g. shaft rotation 
• Linear motion e.g. drawer 
• Spherical rotation e.g. ball and socket joint 
• Hinge motion e.g. door 
3.4. Loads 
Bearings vary greatly over the size and directions of forces that they can support. 
Forces can be predominately radial, axial (thrust bearings) or moments perpendicular 
to the main axis.
CHAPTER-4 
CLASSIFICATION OF BEARING 
According to nature of relative motion between two contacting surface 
There are numerous different kinds of bearings that are designed to handle radial load, 
thrust load, or some combination of the two. Because different applications require 
bearings that are designed to handle a specific kind of load and different amounts of 
weight, the differences between types of bearings concern load type and ability to 
handle weight. 
15 
4.1. Sliding contact bearing 
4.1.1. Hydrodynamic bearing 
Load supporting high pressure fluid film is created due to the shape and relative 
motion between the two surfaces. 
Fig.4.1: Hydrodynamic bearing
16 
4.1.2. Hydrostatic bearing 
The load supporting fluid film is created by an external source, like pump. 
Fig. 4.2: Hydrostatic bearing 
4.2. Rolling contact bearing 
4.2.1. Ball Bearings 
Ball bearings are extremely common because they can handle both radial and thrust 
loads, but can only handle a small amount of weight. They are found in a wide array 
of applications, such as roller blades and even hard drives, but are prone to deforming 
if they are overloaded. 
4.2.2. Roller Bearings 
Roller bearings are designed to carry heavy loads—the primary roller is a cylinder, 
which means the load is distributed over a larger area, enabling the bearing to handle 
larger amounts of weight. This structure, however, means the bearing can handle 
primarily radial loads, but is not suited to thrust loads. For applications where space is 
an issue, a needle bearing can be used. Needle bearings work with small diameter 
cylinders, so they are easier to fit in smaller applications. 
4.2.2.1. Tapered Roller Bearings 
This style of bearing is designed to handle large radial and thrust loads—as a result of 
their load versatility, they are found in car hubs due to the extreme amount of both 
radial and thrust loads that car wheels are expected to carry.
CHAPTER-5 
MATERIAL USED IN BEARING 
17 
5.1. Bearing material 
Bearing reliability begins with the material from which the product is made. The 
material selection can have a dramatic impact on a bearing’s ability to meet the 
application requirements. Additionally, the heat-treatment process that accompanies 
material selection largely dictates durability by its impact on several bearing 
characteristics, including hardness profile, bearing microstructure, final raceway 
surface finish and residual stress. 
Traditionally, Bearings have been produced from low carbon, carburizing grades of 
steel. The introduction of carbon during manufacture, and the high alloys in the steel, 
assures the proper combination of a hard, fatigue-resistant case and a tough, ductile 
core. Benefits of casehardened bearings include: 
Residual compressive stresses in the surface that retard propagation of fatigue cracks. 
An enhanced ability to endure heavy shock loads as a result of the tough, ductile core. 
Improved debris resistance due to the metallurgical characteristics of the surface 
Tapered roller bearings have a spherical surface ground on the large ends of the 
rollers. The radius of this surface is slightly less than the apex length (distance from 
the roller large end to the apex). The roller large end makes point contact with the 
cone large rib when under light load. Under heavier load, this contact area becomes 
elliptical. The roller rib interface geometry promotes hydrodynamic lubrication in the 
contact area. The seating force of the roller against the rib is normally small and 
therefore contact stresses are relatively low. This is true whether pure radial load or 
pure thrust load is involved.
18 
5.2 Flow of Material in Bearing 
Fig.5.1: Flow of Material in Bearing
CHAPTER-6 
TAPERED ROLLER BEARING 
19 
6.1. Introduction 
Tapered roller bearings are bearings that can take large axial forces (i.e., they are 
good thrust bearings) as well as being able to sustain large radial forces. 
The inner and outer ring raceways are segments of cones and the rollers are also made 
with a taper so that the conical surfaces of the raceways and the roller axes if 
projected, would all meet at a common point on the main axis of the bearing. 
Fig.6.1: Tapered roller bearings 
Fig.6.2: Tapered roller bearing components 
This conical geometry is used as it gives a larger contact patch, which permits greater 
loads to be carried than with spherical (ball) bearings, while the geometry means that
the tangential speeds of the surfaces of each of the rollers are the same as their 
raceways along the whole length of the contact patch and no differential scrubbing 
occurs. When a roller slides rather than rolls, it can generate wear at the roller-to-race 
interface, i.e. the differences in surface speeds creates a scrubbing action. Wear will 
degenerate the close tolerances normally held in the bearing and can lead to other 
problems. Much closer to pure rolling can be achieved in a tapered roller bearing and 
this avoids rapid wear. 
The rollers are guided by a flange on the inner ring. This stops the rollers from sliding 
out at high speed due to their momentum. 
The larger the half angles of these cones the larger the axial force that the bearing can 
sustain. 
Tapered roller bearings are separable and have the following components: outer ring, 
inner ring, and roller assembly (containing the rollers and a cage). The non-separable 
inner ring and roller assembly is called the cone, and the outer ring is called the cup. 
Internal clearance is established during mounting by the axial position of the cone 
relative to the cup. 
20 
6.2. Product Subtypes 
6.2.1. Single Row (TRB) 
Fig.6.3: Single Row (TRB)
21 
6.2.2. Double Row (TRB) 
Fig.6.4: Double Row (TRB) 
6.2.3. Four Row (TRB) 
Fig.6.5: Four Row (TRB) 
6.2.4. Tapered Roller Thrust 
Fig.6.6: Tapered Roller Thrust
CHAPTER-7 
PROCESS OF MANUFACTURING 
7.1. Manufacturing Processes of Tapered Roller Bearing Bearing 
NBC gets forged and roller bearings from their vendors, as there are no separate dept. 
for forging or rolling. Than they do carburizing or other heat treatment to strengthen 
the bearing or finally grinding or other finishing operation is performed 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- 
Fig.7.1: Manufacturing Processes of Tapered Roller Bearing Bearing 
22
7.2. Heat treatment and laboratory 
Heat treatment of bearing steel components necessitates heating and cooling under 
controlled atmospheric conditions to impact the desired material characteristics and 
properties such as hardness, a diffused high carbon surface layer, high fracture 
toughness or ductility, high tensile strength, improved machinability, proper grain 
size, or reduced stress state. The specific thermal cycles that produce these material 
characteristics are: 
23 
(i) Annealing 
(ii) Normalizing 
(iii) Hardening 
(iv) Carburizing 
(v) Tampering 
(vi) Stress Reliving. 
Fig.7.2: Heat treatment sequence
Let’s discusses each process with respect to these parts for simplicity of 
understanding 
Fig: 7.3: Flow diagram of heating sequence of spherical bearings 
24 
7.3. Carburizing 
Carburizing is a is a heat treatment process in which iron or steel absorbs carbon 
liberated when the metal is heated in the presence of a carbon bearing material, such 
as charcoal or carbon monoxide, with the intent of making the metal harder. 
Depending on the amount of time and temperature, the affected area can vary in 
carbon content. Longer carburizing times and higher temperatures lead to greater 
carbon diffusion into the part as well as increased depth of carbon diffusion. When the 
iron or steel is cooled rapidly by quenching, the higher carbon content on the outer 
surface becomes hard via the transformation from austenite to martensite, while the 
core remains soft and tough as a ferritic and/or pearlite microstructure.
The carburizing is performed 940º to 980ºc in rotary hearth furnace with time of 
10hrs. But carburizing is done for only cup and cone with Air: LPG =10:1 (Endo 
Gas). 
Fig.7.4: Rotary hearth furnace 
25 
7.4. Hardening Furnace 
To control the mechanical properties, it is essential to start a structure with a structure 
of austenite since it is state where the carbon atoms are distributed into the iron matrix 
uniformly. The austenitic structure in steel is achieved by heating it and soaking at a 
temperature above 7230C, depending on the carbon percentage. 
In hardening furnace “case hardening” of the job is carried out in the presence of R-Gas. 
R-Gas is a mixture of CO+H2+N2+CO2+H2O. R-Gas is formed by the reaction of 
LPG with air. This reaction is taken place in retort at a temperature of 950 0C in the 
presence of catalyst. 
Hardening furnace has four chambers. First chamber is at 840 0C and rest three 
chambers are at 850 0C. After the hardening furnace bearing material (steel) is 
converted into austenite form. 
7.5. Quenching 
Quenching 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. 
26 
7.6. Tampering 
Martensite 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. 
Fig.7.5: Tempering furnace
27 
7.7. Rockwell hardness test 
To see the effect of tampering on bearing races Rockwell hardness test is being used 
to check the hardness of races before and after the tampering. Before the tampering 
hardness range lies between is 62 to 64 HRC and after tampering hardness range is 
60-62HRC. The overall effect of tampering also affects the hardness and this reduced 
by 2HRC. 
Principal of the Rockwell Test 
 The indenter moves down into position on the part surface 
 A minor load is applied and a zero reference position is established 
 The major load is applied for a specified time period (dwell time) beyond zero 
 The major load is released leaving the minor load applied 
The resulting Rockwell number represents the difference in depth from the zero 
reference position as a result of the application of the major load. If HRC doesn’t 
meet our requirements then we reject the tampered lot. Behind this there may be 
following causes-a) 
Manufacturing Fault 
b) Furnace temperature fault 
c) Tampering fault
Fig.7.6: Rockwell hardness test setup 
28 
7.8. Grinding Section 
Grinding is a finishing process used to improve surface finish, abrade hard materials, 
and tighten the tolerance on flat and cylindrical surfaces by removing a 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.
29 
7.9. Assembly section 
The assembly part in NEI is done manually. The parts after going through various in 
line inspection or a separate inspection for all bearing components sent to assembly 
line. In assembly line each parts width, bore, track is checked again through various 
gauges. 
Assembly of Spherical Roller Bearings Components: -It includes 
a) Inner race. 
b) Outer race. 
c) Roller section (Retainer Section). 
d) Roller Cage. 
Fig.7.7: Elements after assembly of spherical bearings 
7.10. Maintenance and inspection section 
7.10.1 For machines 
Maintenance and inspection is that section where various types of machines, tools and 
machine parts are inspected for life requirement and better working features. Various 
types of pressure gauges, vibration inspection machines and the noise inspection 
machines are the special features of this section.
Maintenance and inspection is that section where various types of machines, tools and 
machine parts are inspected for life requirement and better working features. Various 
types of pressure gauges, vibration inspection machines and the noise inspection 
machines are the special features of this section. 
The machines used in this section are as follows - 
30 
i. LATHE m/c, 
ii. SHAPER m/c, 
iii. BORING m/c, 
iv. PLANNER m/c, 
v. DRILLING m/c, 
vi. MILLING m/c, 
vii. Universal type, 
viii. Vertical and Common type, Plain Milling m/c 
7.10.2. For bearing components 
All these inspections are done manually 
Inline Inspection- after every specific operation there is checking of bearing 
components (1 out of 20) through gauging processes like width, track or bore gauge 
after width, bore or track grinding Resp. 
Final Inspection- when the complete grinding of a particular product is completed like 
for cone all processes width, bore or track grinding is completed than it sent to final 
inspection. 
In Final Inspection we detect crack check by two methods: 
a. Crack check Machine - kerosene or magnetic flux is used 
b. Demagnetize Washing
CHAPTER-8 
MANUFACTURING & ASSEMBLY 
8.1. Inner & Outer Ring Manufacturing 
Fig.8.1: Flow Chart of Inner & Outer Ring Manufacturing 
The contact surfaces of the bearing rings and rolling elements are subjected to 
repeated heavy stresses, so they must maintain high precision and rotational accuracy. 
To accomplish this, the rings and rolling elements must be made of a material that has 
high hardness, resistant to rolling fatigue, wear resistant and has good dimensional 
stability. 
31
High carbon chromium bearing steel (SUJ 2) deep hardened by the hardening method 
&case hardening steel (SC/SCM/SNCM) with a hardened carburized outer layer are 
used for the rings and rolling elements of standard bearings. 
The most widely used and most suitable materials for rolling bearings are high carbon 
steels. The most commonly used of these steels is SUJ2. For bearings with large cross 
section dimensions SUJ3 or SUJ5 having good hardening properties are used. NBC 
uses high carbon steel for almost all of spherical roller & cylindrical roller bearings. 
For case hardening steel; Chrome Steel (SCr), Chrome Molybdenum Steel (SCM) 
and Nickel Chrome Molybdenum Steel (SNCM) are used because of its combination 
of a hard surface layer which has been carburized and hardened to an appropriate 
depth, and a relatively pliable inner core, case hardening steel has excellent efficiency 
against shock load. NBC uses case hardening steel for almost all of tapered roller 
bearings. 
Since the life of the bearing steel is determined by the purity of cleanliness of steel the 
above grade steels are low in non-metallic impurities & low in oxygen content 
because they are refined by a vacuum degassing process & outside hearth smelting 
process. 
The Turning operations are divided into various lathe Operations viz. O.D., face, track 
&Bore. All these operations are done on production lathe machines. The Hardening of 
steel is achieved by heat treatment process in which the steel microstructure is 
manipulated by cycles of heating & quick cooling to obtain the optimum hardness 
range for steel – usually on the order of 60 to 64 on Rockwell C Hardness Scale. 
When slowly quenched it would form Austenite & Pearlite which is a partly hard and 
partly soft structure respectively. Hardening of steel requires a change in structure 
from Body Centered Cubic Structure found at room temperature to Face Centered 
Cubic Structure found in Austenite Region. When Steel is suddenly Quenched Marten 
site is formed which is extremely strong and if steel is Quenched slowly then Pearlite 
is formed which is extremely Soft. 
32
33 
8.2. Roller Manufacturing 
Fig.8.2: Manufacturing of Roller 
The Raw Material used (SUJ 2 Steel) for manufacturing of rollers is a specially 
formulated grade of Steel. The Material is Supplies by rod. It is then cut to length 
&width on Production Lathe. 
For Spherical Rollers or Tapered Rollers, The rod is then fed through a header. This 
cold forged process produce “slugs” at an incredibly high speed. Rod is fed from
decoilers into cold heading machines where it is cut into blanks and then pressed 
between hemispherical dies or conical dies. For Cylindrical Rollers the above 
procedure is not done. 
The flash around the rollers produced during pressing is removed by filing plates in 
deburring machines. These rough shaped spherical rollers have a ring around the 
middle. The next process is to remove this ring by machining in rill-filing machine, 
equipped with one fixed and one rotating cast iron rill-plate. Concentric grooves in the 
plate ensure that the whole roller surface is machined to same extent and thus a 
spherical form is achieved 
The next process for Rollers is grinding in which rollers are grind in the order: Face, 
O.D. and I.D. The grinding process is done in two phases; one prior to Heat 
Treatment (Rough Grinding) & one after the heat treatment process (Finish 
Grinding).Final inspection for size, form and surface finish is carried out on a sample 
basis by means of high resolution microscopes and other precision equipment because 
a tiniest deviation even of the order of 1 Å (10-10m) in the roundness of bearing 
element can have an impact on bearing quality. The rollers are then cleaned and 
dispatched for bearing assembly operation. 
34 
8.3. Cage Manufacturing 
Fig.8.3: Cage Manufacturing
The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & Cold 
Annealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in 
Press Machine in Successive Operations: Blanking, Punching, Forming (Pocketing) 
rivet holes and visual inspection is carried for any deformity. 
8.4. Roller Bearing Assembly Line 
The assembly part in NEI is done manually. The parts after going through various in 
line inspection or a separate inspection for all bearing components sent to assembly 
line. In assembly line each parts width, bore, track is checked again through various 
gauges. 
Flow Chart 
Fig.8.4: Roller Bearing Assembly Line 
35
CHAPTER-9 
36 
APPLICATIONS 
While Engineered Surfaces have been successfully applied to a variety of 
components, our first and most extensive experience is using these processes with 
anti-friction bearings. Timken research revealed that modifying the topography of a 
bearing’s contact surfaces resulted in significant improvement in overall performance. 
Inadequate lubrication, poor maintenance, extreme operating environments and 
vibration can be detrimental to bearing performance. Engineered Surfaces enable 
bearings to better resist these potentially damaging environmental factors. 
Real-world benefits have been demonstrated in rugged applications that include 
bearings used in aircraft landing gear, heavy equipment drive trains and industrial 
rolling mills. 
In many applications tapered roller bearings are used in back-to-back pairs so that 
axial forces can be supported equally in either direction. 
Pairs of tapered roller bearings are used in car and vehicle wheel bearings where they 
must cope simultaneously with large vertical (radial) and horizontal (axial) forces. 
Applications for tapered roller bearings are commonly used for moderate speed, 
heavy duty applications where durability is required. Common real world applications 
are in agriculture, construction and mining equipment, axle systems, gear box, engine 
motors and reducers
CHAPTER-10 
37 
CONCLUSION 
My training period of 45 days turned out to be a wonderful experience both 
industrially and learning wise; experiencing the functionalities of Heavy Fabrication 
Block, flow of knowledge as well as decision making processes within the block. 
Working with the employees and learning from them was such a life changing 
experience. 
This report describes the NBC bearing industry and its technology. My Through this 
report, I have tried to present a comprehensive study of the various functionalities and 
responsibilities of NBC Bearings. Starting from the overview of the company till the 
explanation of various type of process i.e. heat treatment, grinding, facing and the 
different type of machines used in that processes like for grinder, machines for honing 
& super finishing machines are available, for heat treatment rotary hearth furnace and 
tampering furnace and CNC machines. This report tries to throw light on each and 
every aspect of the NBC Bearings. 
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 bearing manufacturing companies.

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Training report nbc bearing

  • 1. CHAPTER-1 1 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 Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and Thermal Power Plants all across the country.
  • 2. 2 1.2. Milestones Fig.1.1 Milestones of NEI i. 1946 -Company established as National Bearing Company (NBC) under technical collaboration with Hoffman, U.K. ii. 1950 Ball Bearing Production started. iii. 1958 Company is renamed National Engineering Industries Limited (NEI); NBC Trademark retained. iv. 1967 Tapered Roller Bearing production started v. 1975 Spherical Roller Bearings production begins vi. 1981 Second Plant inaugurated in Newai. vii. 1982 Cartridge Tapered Roller Bearing in Technical Collaboration with Brenco Incorporated of U.S.A. viii. 1985 Technical Collaboration with NTN Corporation of Japan for Ball, Cylindrical & Spherical Roller Bearing. ix. 1995 ISO - 9001 Quality Management System Certification x. 1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine Retrofitting xi. 2007 Third Plant inaugurated in Manesar. xii. 2008 NBC receives TPM Excellence Award xiii. 2010 NBC receives Deming Award
  • 3. xiv. 2012 NBC receives the ACMA awards for Manufacturing and Technology 3 Excellence 1.3. Technical collaboration (i) BRENCO Incorporated of U.S.A. Since 1982 - For Cartridge Tapered Roller Bearings for Railroad applications. (ii) NTN Corporation of JAPAN Since 1985 - For Ball Bearings, Cylindrical & Spherical Roller Bearings, JPU Bearings, Double Row Angular Contact Bearings, Hub Bearings Since 1997 - for Tapered Roller bearings. (iii) Izumi Kinzoku of JAPAN Since 1996 for remanufacturing, retrofitting and overhauling of Grinding and Super-finishing machines for bearing races. 1.4. Main Customers Rolling Stock: -  DLW (Diesel Locomotive Work)  CLW (Chittaranjan Locomotive Works)  ICF (Integral Coach Factory, Chennai)  RCF (Rail Coach Factor, Kapurthala)  CIMMCO  BEML (Bharat Earth Movers, Bangalore)  TEXMACO  Hindustan Motors Ltd.  Maruti Udyog Ltd.  Mahindra & Mahindra Automobiles-LCV: -  Ashok Leyland  Force Motors  Eicher Motors  Tata Motors Automobiles-Two/ Three Wheelers:-  Bajaj Auto Ltd.  Hero Honda Motors Ltd.
  • 4.  Honda Motorcycle & Scooters India Ltd.  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  NGEF  MICO Fans: -  Bajaj Electricals  Crompton Greaves 4 1.5. Manufacturing Facilities NBC has manufacturing facilities at Jaipur (established in 1946), Newai(established in 1980) and Manesar (established in 2006). A fourth plant, a green field project, atSavli 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
  • 5. 5  Newai (Gunsi) Plant  Manesar Plant 1.5.1. Newai (Gunsi) Plant 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. 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. Fig1.2: Manesar Plant
  • 6. CHAPTER-2 6 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. Fig. 2.1: Jaipur Plant Fig.2.2: Nbc Design and Development The plant at Jaipur includes-i. Ball Bearing ii. Precision Ball Making
  • 7. 7 iii. Tapered Roller Bearing iv. Railway Bearing v. Research & Development vi. Large diameter bearings vii. SAP-ERP 2.2. Ball Bearing 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. Type of Ball Bearing:- a. Radial Ball Bearing b. Angular Contact Bearing c. Self-Aligning Two-Row Ball Bearing Radial ball bearing Angular Contact Bearing Self-Aligning Two-Row Ball Bearing (a) (b) (c) Fig. 2.3: Ball Bearings The initial technology was from Hoffman Manufacturing Company Ltd., U.K. a collaboration, which continued for 20 years. They offer a wide range of both metric and inch series deep groove ball bearings, angular contact ball bearings, self-aligning ball bearings etc. With their tie up with the world's leading bearing manufacturing company NTN Corporation, JAPAN, They have gained access to the most advanced
  • 8. ball bearing technology i.e. thermo mechanical bearings (TMB) and tensioner bearings available today and their wide range of ball bearings is increasing under this collaboration. Precision ball bearing from 6mm bore to 160mm OD is 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. 8 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. Fig. 2.4: Steel Ball 2.4. Tapered roller bearing Type of Tapered Roller Bearing a. Single Row Tapered Roller Bearing b. Double Row Tapered Roller Bearing
  • 9. Single Row Tape re d Roller Bearing Double Row Tape r ed Roller Bearin g (a) (b) Fig. 2.5: 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 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 modernization 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. 9 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 With the production of Roller Bearings and Axle Boxes, since 1952 the company has
  • 10. 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. Fig 2.6: Axle Boxes 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. 10 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 Fig 2.7: Railway Bearings
  • 11. 2.5.3. Cartridge tapered roller bearing For fitment to the new BOX-N Uprated Wagons designed by the RDSO, NEI is the only manufacturer in the country who is the first to indigenize these bearings to a high percentage under collaboration with the largest manufacturer of these bearings in the world. Production of these bearings is grease packed and requires no field lubrication for a period of 7 year. The Railway Bearing Division is spread over a covered area of 1.2 acres. 11 2.6. 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 up to 2000 mm diameter. The largest bearing produced by NEI for fitment to plate will of Rourkela Steel Plant was released by Mr. G.P. Birla in September 1985. This 4-row tapered roller bearing measures 1300 mm diameter and weighs 4.39 tones. The large diameter bearings are mainly produced out of case carburizing steels, heat treated on special equipment and furnaces developed by NEI. The 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. 2.7. Research and development 2.7.1. Design and development Complete in-house facility for design & development of all types of bearings and tooling is available. The design is done on CAD. The large diameter bearings and tooling have been entirely designed and developed by NEI’s R&D at its Computer center. Complete engineering and research facility is available to solve problem of design development, manufacturing, installation and maintenance of bearings. With the signing of the technical collaboration agreement with NTN CORPORATION JAPAN & BRENCO IN CORPORATED OF USA, the capability to offer the finest engineering services in the bearing industry has enhanced.
  • 12. 12 2.7.2. Machine building The NEI has the capability of Machine Building to design, develop and manufacture special purpose CNC grinding lines, HT lines, material handling equipment’s 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 M/c Building division. Machine Building has the capability and supports the Manufacturing divisions by overhauling and retrofitting of the existing equipment’s so that these are upgraded to help produce quality and improve productivity. R& D is spread over a covered area of ½ acres. 2.8. SAP-ERP In order to re-engineer and integrate the Business processes for Sales, Production, Materials and Finance, NEI has success- fully implemented SAP ERP.
  • 13. CHAPTER-3 13 BEARING 3.1. Definition of 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. Plain bearings are very widely used, and use surfaces in rubbing contact. Particularly with lubrication they often give entirely acceptable life and friction. On the other hand, low friction bearings are often important for efficiency, to reduce wear and to facilitate extended use at high speeds. Essentially, a bearing can reduce friction by virtue of its shape, by its material, or by introducing and containing a fluid between surfaces or by separating the surfaces with an electromagnetic field. By shape, gains advantage usually by using spheres or rollers, or by forming flexure bearings. By material exploits the nature of the bearing material used. (An example would be using plastics that have low surface friction.) By fluid exploits the low viscosity of a layer of fluid, such as a lubricant or as a pressurized medium to keep the two solid parts from touching, or by reducing the normal force between them. By fields exploits electromagnetic fields, such as magnetic fields, to keep solid parts from touching. Combinations of these can even be employed within the same bearing. An example of this is where the cage is made of plastic, and it separates the rollers/balls, which reduce friction by their shape and finish 3.2. Principles of Operation There are at least six common principles of operation: • Sliding bearings, usually called "bushes", "bushings", "journal bearings", "sleeve bearings", "rifle bearings", or "plain bearings”.
  • 14. • Rolling-element bearings such as ball bearings and roller bearings. • Jewel bearings, in which the load is carried by rolling the axle slightly off-center. • Fluid bearings, in which the load is carried by a gas or liquid. • Magnetic bearings, in which the load is carried by a magnetic field. • Flexure bearings, in which the motion is supported by a load element which bends. 14 3.3. Motions Common motions permitted by bearings are: • Axial rotation e.g. shaft rotation • Linear motion e.g. drawer • Spherical rotation e.g. ball and socket joint • Hinge motion e.g. door 3.4. Loads Bearings vary greatly over the size and directions of forces that they can support. Forces can be predominately radial, axial (thrust bearings) or moments perpendicular to the main axis.
  • 15. CHAPTER-4 CLASSIFICATION OF BEARING According to nature of relative motion between two contacting surface There are numerous different kinds of bearings that are designed to handle radial load, thrust load, or some combination of the two. Because different applications require bearings that are designed to handle a specific kind of load and different amounts of weight, the differences between types of bearings concern load type and ability to handle weight. 15 4.1. Sliding contact bearing 4.1.1. Hydrodynamic bearing Load supporting high pressure fluid film is created due to the shape and relative motion between the two surfaces. Fig.4.1: Hydrodynamic bearing
  • 16. 16 4.1.2. Hydrostatic bearing The load supporting fluid film is created by an external source, like pump. Fig. 4.2: Hydrostatic bearing 4.2. Rolling contact bearing 4.2.1. Ball Bearings Ball bearings are extremely common because they can handle both radial and thrust loads, but can only handle a small amount of weight. They are found in a wide array of applications, such as roller blades and even hard drives, but are prone to deforming if they are overloaded. 4.2.2. Roller Bearings Roller bearings are designed to carry heavy loads—the primary roller is a cylinder, which means the load is distributed over a larger area, enabling the bearing to handle larger amounts of weight. This structure, however, means the bearing can handle primarily radial loads, but is not suited to thrust loads. For applications where space is an issue, a needle bearing can be used. Needle bearings work with small diameter cylinders, so they are easier to fit in smaller applications. 4.2.2.1. Tapered Roller Bearings This style of bearing is designed to handle large radial and thrust loads—as a result of their load versatility, they are found in car hubs due to the extreme amount of both radial and thrust loads that car wheels are expected to carry.
  • 17. CHAPTER-5 MATERIAL USED IN BEARING 17 5.1. Bearing material Bearing reliability begins with the material from which the product is made. The material selection can have a dramatic impact on a bearing’s ability to meet the application requirements. Additionally, the heat-treatment process that accompanies material selection largely dictates durability by its impact on several bearing characteristics, including hardness profile, bearing microstructure, final raceway surface finish and residual stress. Traditionally, Bearings have been produced from low carbon, carburizing grades of steel. The introduction of carbon during manufacture, and the high alloys in the steel, assures the proper combination of a hard, fatigue-resistant case and a tough, ductile core. Benefits of casehardened bearings include: Residual compressive stresses in the surface that retard propagation of fatigue cracks. An enhanced ability to endure heavy shock loads as a result of the tough, ductile core. Improved debris resistance due to the metallurgical characteristics of the surface Tapered roller bearings have a spherical surface ground on the large ends of the rollers. The radius of this surface is slightly less than the apex length (distance from the roller large end to the apex). The roller large end makes point contact with the cone large rib when under light load. Under heavier load, this contact area becomes elliptical. The roller rib interface geometry promotes hydrodynamic lubrication in the contact area. The seating force of the roller against the rib is normally small and therefore contact stresses are relatively low. This is true whether pure radial load or pure thrust load is involved.
  • 18. 18 5.2 Flow of Material in Bearing Fig.5.1: Flow of Material in Bearing
  • 19. CHAPTER-6 TAPERED ROLLER BEARING 19 6.1. Introduction Tapered roller bearings are bearings that can take large axial forces (i.e., they are good thrust bearings) as well as being able to sustain large radial forces. The inner and outer ring raceways are segments of cones and the rollers are also made with a taper so that the conical surfaces of the raceways and the roller axes if projected, would all meet at a common point on the main axis of the bearing. Fig.6.1: Tapered roller bearings Fig.6.2: Tapered roller bearing components This conical geometry is used as it gives a larger contact patch, which permits greater loads to be carried than with spherical (ball) bearings, while the geometry means that
  • 20. the tangential speeds of the surfaces of each of the rollers are the same as their raceways along the whole length of the contact patch and no differential scrubbing occurs. When a roller slides rather than rolls, it can generate wear at the roller-to-race interface, i.e. the differences in surface speeds creates a scrubbing action. Wear will degenerate the close tolerances normally held in the bearing and can lead to other problems. Much closer to pure rolling can be achieved in a tapered roller bearing and this avoids rapid wear. The rollers are guided by a flange on the inner ring. This stops the rollers from sliding out at high speed due to their momentum. The larger the half angles of these cones the larger the axial force that the bearing can sustain. Tapered roller bearings are separable and have the following components: outer ring, inner ring, and roller assembly (containing the rollers and a cage). The non-separable inner ring and roller assembly is called the cone, and the outer ring is called the cup. Internal clearance is established during mounting by the axial position of the cone relative to the cup. 20 6.2. Product Subtypes 6.2.1. Single Row (TRB) Fig.6.3: Single Row (TRB)
  • 21. 21 6.2.2. Double Row (TRB) Fig.6.4: Double Row (TRB) 6.2.3. Four Row (TRB) Fig.6.5: Four Row (TRB) 6.2.4. Tapered Roller Thrust Fig.6.6: Tapered Roller Thrust
  • 22. CHAPTER-7 PROCESS OF MANUFACTURING 7.1. Manufacturing Processes of Tapered Roller Bearing Bearing NBC gets forged and roller bearings from their vendors, as there are no separate dept. for forging or rolling. Than they do carburizing or other heat treatment to strengthen the bearing or finally grinding or other finishing operation is performed 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- Fig.7.1: Manufacturing Processes of Tapered Roller Bearing Bearing 22
  • 23. 7.2. Heat treatment and laboratory Heat treatment of bearing steel components necessitates heating and cooling under controlled atmospheric conditions to impact the desired material characteristics and properties such as hardness, a diffused high carbon surface layer, high fracture toughness or ductility, high tensile strength, improved machinability, proper grain size, or reduced stress state. The specific thermal cycles that produce these material characteristics are: 23 (i) Annealing (ii) Normalizing (iii) Hardening (iv) Carburizing (v) Tampering (vi) Stress Reliving. Fig.7.2: Heat treatment sequence
  • 24. Let’s discusses each process with respect to these parts for simplicity of understanding Fig: 7.3: Flow diagram of heating sequence of spherical bearings 24 7.3. Carburizing Carburizing is a is a heat treatment process in which iron or steel absorbs carbon liberated when the metal is heated in the presence of a carbon bearing material, such as charcoal or carbon monoxide, with the intent of making the metal harder. Depending on the amount of time and temperature, the affected area can vary in carbon content. Longer carburizing times and higher temperatures lead to greater carbon diffusion into the part as well as increased depth of carbon diffusion. When the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard via the transformation from austenite to martensite, while the core remains soft and tough as a ferritic and/or pearlite microstructure.
  • 25. The carburizing is performed 940º to 980ºc in rotary hearth furnace with time of 10hrs. But carburizing is done for only cup and cone with Air: LPG =10:1 (Endo Gas). Fig.7.4: Rotary hearth furnace 25 7.4. Hardening Furnace To control the mechanical properties, it is essential to start a structure with a structure of austenite since it is state where the carbon atoms are distributed into the iron matrix uniformly. The austenitic structure in steel is achieved by heating it and soaking at a temperature above 7230C, depending on the carbon percentage. In hardening furnace “case hardening” of the job is carried out in the presence of R-Gas. R-Gas is a mixture of CO+H2+N2+CO2+H2O. R-Gas is formed by the reaction of LPG with air. This reaction is taken place in retort at a temperature of 950 0C in the presence of catalyst. Hardening furnace has four chambers. First chamber is at 840 0C and rest three chambers are at 850 0C. After the hardening furnace bearing material (steel) is converted into austenite form. 7.5. Quenching Quenching 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
  • 26. 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. 26 7.6. Tampering Martensite 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. Fig.7.5: Tempering furnace
  • 27. 27 7.7. Rockwell hardness test To see the effect of tampering on bearing races Rockwell hardness test is being used to check the hardness of races before and after the tampering. Before the tampering hardness range lies between is 62 to 64 HRC and after tampering hardness range is 60-62HRC. The overall effect of tampering also affects the hardness and this reduced by 2HRC. Principal of the Rockwell Test  The indenter moves down into position on the part surface  A minor load is applied and a zero reference position is established  The major load is applied for a specified time period (dwell time) beyond zero  The major load is released leaving the minor load applied The resulting Rockwell number represents the difference in depth from the zero reference position as a result of the application of the major load. If HRC doesn’t meet our requirements then we reject the tampered lot. Behind this there may be following causes-a) Manufacturing Fault b) Furnace temperature fault c) Tampering fault
  • 28. Fig.7.6: Rockwell hardness test setup 28 7.8. Grinding Section Grinding is a finishing process used to improve surface finish, abrade hard materials, and tighten the tolerance on flat and cylindrical surfaces by removing a 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.
  • 29. 29 7.9. Assembly section The assembly part in NEI is done manually. The parts after going through various in line inspection or a separate inspection for all bearing components sent to assembly line. In assembly line each parts width, bore, track is checked again through various gauges. Assembly of Spherical Roller Bearings Components: -It includes a) Inner race. b) Outer race. c) Roller section (Retainer Section). d) Roller Cage. Fig.7.7: Elements after assembly of spherical bearings 7.10. Maintenance and inspection section 7.10.1 For machines Maintenance and inspection is that section where various types of machines, tools and machine parts are inspected for life requirement and better working features. Various types of pressure gauges, vibration inspection machines and the noise inspection machines are the special features of this section.
  • 30. Maintenance and inspection is that section where various types of machines, tools and machine parts are inspected for life requirement and better working features. Various types of pressure gauges, vibration inspection machines and the noise inspection machines are the special features of this section. The machines used in this section are as follows - 30 i. LATHE m/c, ii. SHAPER m/c, iii. BORING m/c, iv. PLANNER m/c, v. DRILLING m/c, vi. MILLING m/c, vii. Universal type, viii. Vertical and Common type, Plain Milling m/c 7.10.2. For bearing components All these inspections are done manually Inline Inspection- after every specific operation there is checking of bearing components (1 out of 20) through gauging processes like width, track or bore gauge after width, bore or track grinding Resp. Final Inspection- when the complete grinding of a particular product is completed like for cone all processes width, bore or track grinding is completed than it sent to final inspection. In Final Inspection we detect crack check by two methods: a. Crack check Machine - kerosene or magnetic flux is used b. Demagnetize Washing
  • 31. CHAPTER-8 MANUFACTURING & ASSEMBLY 8.1. Inner & Outer Ring Manufacturing Fig.8.1: Flow Chart of Inner & Outer Ring Manufacturing The contact surfaces of the bearing rings and rolling elements are subjected to repeated heavy stresses, so they must maintain high precision and rotational accuracy. To accomplish this, the rings and rolling elements must be made of a material that has high hardness, resistant to rolling fatigue, wear resistant and has good dimensional stability. 31
  • 32. High carbon chromium bearing steel (SUJ 2) deep hardened by the hardening method &case hardening steel (SC/SCM/SNCM) with a hardened carburized outer layer are used for the rings and rolling elements of standard bearings. The most widely used and most suitable materials for rolling bearings are high carbon steels. The most commonly used of these steels is SUJ2. For bearings with large cross section dimensions SUJ3 or SUJ5 having good hardening properties are used. NBC uses high carbon steel for almost all of spherical roller & cylindrical roller bearings. For case hardening steel; Chrome Steel (SCr), Chrome Molybdenum Steel (SCM) and Nickel Chrome Molybdenum Steel (SNCM) are used because of its combination of a hard surface layer which has been carburized and hardened to an appropriate depth, and a relatively pliable inner core, case hardening steel has excellent efficiency against shock load. NBC uses case hardening steel for almost all of tapered roller bearings. Since the life of the bearing steel is determined by the purity of cleanliness of steel the above grade steels are low in non-metallic impurities & low in oxygen content because they are refined by a vacuum degassing process & outside hearth smelting process. The Turning operations are divided into various lathe Operations viz. O.D., face, track &Bore. All these operations are done on production lathe machines. The Hardening of steel is achieved by heat treatment process in which the steel microstructure is manipulated by cycles of heating & quick cooling to obtain the optimum hardness range for steel – usually on the order of 60 to 64 on Rockwell C Hardness Scale. When slowly quenched it would form Austenite & Pearlite which is a partly hard and partly soft structure respectively. Hardening of steel requires a change in structure from Body Centered Cubic Structure found at room temperature to Face Centered Cubic Structure found in Austenite Region. When Steel is suddenly Quenched Marten site is formed which is extremely strong and if steel is Quenched slowly then Pearlite is formed which is extremely Soft. 32
  • 33. 33 8.2. Roller Manufacturing Fig.8.2: Manufacturing of Roller The Raw Material used (SUJ 2 Steel) for manufacturing of rollers is a specially formulated grade of Steel. The Material is Supplies by rod. It is then cut to length &width on Production Lathe. For Spherical Rollers or Tapered Rollers, The rod is then fed through a header. This cold forged process produce “slugs” at an incredibly high speed. Rod is fed from
  • 34. decoilers into cold heading machines where it is cut into blanks and then pressed between hemispherical dies or conical dies. For Cylindrical Rollers the above procedure is not done. The flash around the rollers produced during pressing is removed by filing plates in deburring machines. These rough shaped spherical rollers have a ring around the middle. The next process is to remove this ring by machining in rill-filing machine, equipped with one fixed and one rotating cast iron rill-plate. Concentric grooves in the plate ensure that the whole roller surface is machined to same extent and thus a spherical form is achieved The next process for Rollers is grinding in which rollers are grind in the order: Face, O.D. and I.D. The grinding process is done in two phases; one prior to Heat Treatment (Rough Grinding) & one after the heat treatment process (Finish Grinding).Final inspection for size, form and surface finish is carried out on a sample basis by means of high resolution microscopes and other precision equipment because a tiniest deviation even of the order of 1 Å (10-10m) in the roundness of bearing element can have an impact on bearing quality. The rollers are then cleaned and dispatched for bearing assembly operation. 34 8.3. Cage Manufacturing Fig.8.3: Cage Manufacturing
  • 35. The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & Cold Annealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in Press Machine in Successive Operations: Blanking, Punching, Forming (Pocketing) rivet holes and visual inspection is carried for any deformity. 8.4. Roller Bearing Assembly Line The assembly part in NEI is done manually. The parts after going through various in line inspection or a separate inspection for all bearing components sent to assembly line. In assembly line each parts width, bore, track is checked again through various gauges. Flow Chart Fig.8.4: Roller Bearing Assembly Line 35
  • 36. CHAPTER-9 36 APPLICATIONS While Engineered Surfaces have been successfully applied to a variety of components, our first and most extensive experience is using these processes with anti-friction bearings. Timken research revealed that modifying the topography of a bearing’s contact surfaces resulted in significant improvement in overall performance. Inadequate lubrication, poor maintenance, extreme operating environments and vibration can be detrimental to bearing performance. Engineered Surfaces enable bearings to better resist these potentially damaging environmental factors. Real-world benefits have been demonstrated in rugged applications that include bearings used in aircraft landing gear, heavy equipment drive trains and industrial rolling mills. In many applications tapered roller bearings are used in back-to-back pairs so that axial forces can be supported equally in either direction. Pairs of tapered roller bearings are used in car and vehicle wheel bearings where they must cope simultaneously with large vertical (radial) and horizontal (axial) forces. Applications for tapered roller bearings are commonly used for moderate speed, heavy duty applications where durability is required. Common real world applications are in agriculture, construction and mining equipment, axle systems, gear box, engine motors and reducers
  • 37. CHAPTER-10 37 CONCLUSION My training period of 45 days turned out to be a wonderful experience both industrially and learning wise; experiencing the functionalities of Heavy Fabrication Block, flow of knowledge as well as decision making processes within the block. Working with the employees and learning from them was such a life changing experience. This report describes the NBC bearing industry and its technology. My Through this report, I have tried to present a comprehensive study of the various functionalities and responsibilities of NBC Bearings. Starting from the overview of the company till the explanation of various type of process i.e. heat treatment, grinding, facing and the different type of machines used in that processes like for grinder, machines for honing & super finishing machines are available, for heat treatment rotary hearth furnace and tampering furnace and CNC machines. This report tries to throw light on each and every aspect of the NBC Bearings. 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 bearing manufacturing companies.