Industrial Training Report

Industrial Training Report
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INDUSTRIAL TRAINING REPORT

Prepared by
Shashank Pathak
Kautilya Institute of Technology and Engineering, Jaipur
Roll no.-10EKTME058

Submitted to:-
Mr. B.K. Garg
Dean Mechanical Department
Kautilya Institute of Technology & Engineering, Jaipur


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Certificate


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PREFACE

As per the syllabus of B.Tech Engineering prescribed by Rajasthan Technical
University in Mechanical Engineering an industrial training for the duration of
one month is must to be conducted by the students.
The practical knowledge and classroom discussion are not sufficient for an
engineering student. It is also important to have the practical knowledge in
order to know various facts of engineering.
Such has been the presentations and projects which enhanced our learning by
adding on to our world of knowledge. And summer training is one of the ways
to enhance our practical knowledge and skills. It was a life time experience for
which I thank to all the staff members of National Engineering Industries
Limited (N.B.C), my parents, faculty members, administration of the kautilya
institute of technology & engineering which is affiliated to Rajasthan Technical
University.
In our case we underwent training at NATIONAL ENGINEERING
INDUSTRIES LIMITED (N.B.C).
The following information is a comprehensive analysis of the work-done by us
made possible due to the joint efforts of co-operative staff of National
Engineering Industries Limited (N.B.C), and respected our professor.


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ACKNOWLDGEMENT

The accomplishment of such vast experience and knowledge through this
industrial training would not have been possible without the sheer brilliant guidance
of experienced personals of the industry who with their support and vast experienced
who in one way or another contributed and extended their valuable assistance in the
preparation and completion of this project specially the head of department Mr. V.K.
Sharma.

Firstly I would like to thanks our director Er. C.K. Bafna for providing
students a campus to learn and apply their practical knowledge into the field of
technology with such distinction facility with all the and faculties who prepare the
students for real world and to make them eligible for industry oriented programs.

I would also like to show my gratitude toward Mr. Onkar Bunkar (head of the
mechanical department) for his positive and enthusiastic attitude towards the welfare
of the students and encouraging me by answering my questions and giving prompt
replies for my uncertainties in all the fields including education, social and
engineering work.

I would also like to acknowledge our dean of the department Mr. B.K. Garg
sir who provided us with the opportunity so that we could apply our knowledge of
what we have theoretically and practically learned in to the industry through the
industrial training program.

Most Importantly, I would like to thank the company N.I.E.L, Jaipur, for
providing me such a wonderful opportunity to work on such an interesting summer
training project. This training really helped me in increasing my knowledge as well as
my potential in technical field.

Last but not the least I would like to thank my family and my dear friends for
being a constant support in my life and encouraging me whenever I hit the lows in my
life that helped me improve my work.


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INDEX

CONTENT PAGE NO.
Introduction 6-10
Background on N.E.I.L 6-7
Bearings 8-11
Jaipur Plant 12-13
Bearing Designation 15

Research and Development 16

Project at N.I.E.L 17
Railway Bearing Heat Treatment
Spherical Bearing 18
Cylindrical Bearing 20
C.T.R.B (Cartridge tapered roller bearing) 21
Heat Treatment 24
Machines 27
Production of different bearing parts 30
Assembly Line 33

Conclusion 36


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INTRODUCTION

1. BACKGROUND ON N.E.I.L

Jaipur is the capital city of the state of Rajasthan, and is also known by the name of
pink city. It is the fastest growing city of the India which is not only witnessing the
social, educational development but also emerging out to be the industrial hub for the
rising market in Asia community.

National engineering industries limited was established in 1946 by the industrialist
Mr. B.M. Birla in Jaipur. The company was formerly known by the name of National
Bearing Company Ltd. which was later changed into the present name in the year
1958, retaining its original trade mark NBC due to increasing activities and grant of
industrial licenses for other vital industries and manufacturing. The company
commenced manufacturing in 1950 with an annual production of 30,000 bearings in
19 sizes.

Over the past 60 years, NBC has grown to be the leading and fastest growing
bearings brand in India and currently produces over 100 million bearings in more
than a 1000 sizes every year. It has the capacity to develop bearings from 10 mm
bore to 2000 mm outer diameter. The product range includes ball bearings, tapered
roller bearings, and double row angular contact (DRAC) bearings, cylindrical and
spherical roller bearings. The company has specially equipped facilities to
manufacture axle boxes for railway applications; cartridge tapered roller bearings,
large-diameter bearings for industrial applications and allied engineering products.

The production plant at Jaipur boasts of the world class manufacturing and process
technology. NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks,
Tractors, Electric Motors, Railway wagons, coaches & locomotives, Steel Mills, Heavy
Engineering Plants, Bulldozers, Shovels, Tillers and Thermal Power Plants. The
automotive and railway industries form the two largest client segments.
NBC has emerged as a leading exporter of bearings from India and its current export
foot-print comprises of over 21 countries across 5 continents. Leading customers
from US, Germany, Brazil, Japan, and Australia etc. have entrusted NBC with their

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critical product requirements. NBC serves the Indian aftermarket through a
countrywide network of 500 authorized partners.

It is the second-largest Original Equipment Manufacturer (OEM) bearings to all the
leading companies of India and abroad. In addition, the company exports bearings to
more than 21 countries including OEMs in Europe and USA. Being one of the largest
exporters of bearings from India, around 50 percent of its exports are for railways.

N.E.I.L has been awarded the coveted 20120 Deming Application Prize by the Union
of Japanese Scientist and Engineers (JUSE), Japan, for achieving distinctive
performance improvement through the application of Total Quality Management
(TQM). The Deming medal confirms that the quality management system is one of
the best, globally. For the customers this means enjoying consistently superior
products and assurance of highest quality for every NBC bearing they use.

Manufacturing facility
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, at Savli in
Gujarat will ship out its first bearing in November 2013, ramping up production capacity to
150 million bearings per year once it is fully operational.
All NBC manufacturing facilities boast of world-class manufacturing and process
technology. International technical collaborations on critical machines & equipment and
complete automation by flex-link conveyor systems contribute to an advanced, precise and
highly productive manufacturing environment. Efficient and optimum use of space and best
practices in every function and process sharpen the professional setting.
There is a stringent focus on accuracy, high productivity and reduced cycle
time. Employing poka-yoke the Japanese approach to mistake proofing entire processes
ensures error free operations. NBC practices are based on Kaizen and continuous
improvement and the outcome is visible across the organization from the shop floor to the
boardroom. All NBC plants are automated and systematic, sorted and kept clean, with
standardized processes and sustained service. There is a place for everything and everything
has its place.
The Jaipur Facility has a brand-new state of the art R & D Centre that lies at the heart of the
Excellence that NBC delivers. The Centre and its lab, considered among the best in Asia,
fulfils a critical function in the innovative and superior quality of products that NBC produces
and is aligned to the companys core values and vision.


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BEARING

A bearing is a machine element that constrains relative motion between moving parts to only
the desired motion. The design of the bearing may, for example, provide for
free linear movement of the moving part or for free rotation around a fixed axis; or, it
may prevent a motion by controlling the vectors of normal forces that bear on the moving
parts. Many bearings also facilitate the desired motion as much as possible, such as by
minimizing friction. Bearings are classified broadly according to the type of operation, the
motions allowed, or to the directions of the loads (forces) applied to the parts.
a. The bearing ensures free rotation of the shaft or the axle with minimum friction.
b. The bearing supports the shaft or the axle and holds it in the correct position.
c. The bearing takes up the forces that act on the shaft or the axle and transmits them to
the frame or the foundation.

Bearings are generally of two types
1. Rolling contact bearing
2. Sliding contact bearing
These further can be sub catagerosied into different types.
1. Roller contact bearing

Roller contact bearing are also called antifriction bearings or simply ball bearings.
Rolling elements such as balls or rollers are introduced between the surfaces that are
in relative motion. In this type of bearing sliding friction is replaced by the rolling
friction. For starting condition and at moderate speeds, the frictional losses in rolling
contact bearing are lower than that most of equivalent hydrodynamic journal bearing.
This is because the sliding contact is replaced by rolling contact resulting in low
coefficient of friction. Therefore rolling contact bearing is called, antifriction
bearing. However this is a misnomer. There is always a friction at the contacting
surfaces between the rolling element and inner and outer cages.

Types of roller contact bearing

Deep groove
Cylindrical roller
Angular contact
Self-aligning
Spherical roller
Taper roller
Thrust ball bearing

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Applications
Machine tool spindles
Automobile front and rear axles
Gear boxes
Small size electric motors
Rope sheaves, crane hooks and hoisting drums

2. Sliding contact bearing
Sliding contact bearings are also called plain bearings, journal bearings or sleeve
bearings. In this case the surface of the shaft slides over the surface of the bush
resulting in friction and wear.in order to reduce the friction, these two surfaces are
separated by a film of lubricating oil. The bush is made of special material like white
metal or bronze.
Sliding contact bearings are classified in three ways.
1. Based on type of load carried
2. Based on type of lubrication
3. Based on lubrication mechanism

Bearing classification based on type of load carried
Radial bearings
Thrust bearings or axial bearings
Radial thrust bearings

Bearing classification based on type of lubrication
The type of lubrication means the extent to which the contacting surfaces are
separated in a shaft bearing combination. This classification includes
Thick film lubrication
Thin film lubrication
Boundary lubrication

Bearing classification based on lubrication mechanism
Hydrodynamic lubricated bearings
Hydrostatic lubricated bearings
Elastohydrodynamic lubricated bearings
Boundary lubricated bearings
Solid film lubricated bearings


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Application
Crankshaft bearings in diesel and petrol engine
Centrifugal pumps
Large size electric motor
Steam and gas turbines
Concrete mixers, rope conveyors and marine installations


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BRIEF TABLE OF DIFFERENT TYPE OF BEARINGS

Name Application
Single Row
Radial Ball
Bearing
1. In addition to Radial Loads, Axial Loads can be
imposed in either direction.
2. Highly Suitable for applications where High Speed &
Low Power loss are required.
Single Row
Angular Contact
Ball Bearing
1. They are capable of taking Radial Load & also the
Axial Load in one direction.
2. 4 contact angles 15, 25, 30 & 40 are available.
Higher the contact angle higher is the Axial
Load carrying capacity.
3. For Higher Speed lower contact angles are preferred.

Double Row
Angular Contact
Ball Bearing
1. They are 2 single Row Angular Contact Ball Bearing
mounted back to back.
2. They have only one inner and one outer ring.
3. They can take axial load in either direction
Self-Aligning Ball
Bearing
1. The Inner Ring has 2 Raceways & Outer Ring has a
single Spherical Raceway with its centre of curvature
coincident with bearing axis.
2. This has an advantage of correcting minor angular
misalignment of Shaft and Housing caused
by Machining or Mounting Error
Cylindrical
Roller Bearing
1. They have High Radial Load capacity and are suitable
for High Speed.
2. Double Row bearing have high Radial Rigidity and
are used primarily for high Precision Instruments.
Tapered Roller
Bearing
1. They are capable of taking high Radial Loads &
also Axial Load in one Direction.
2. Depending upon the contact angle they are divided
into 3 types,
Normal, Medium & Steep Angle

Spherical
Roller Bearing
1. Due to coincide of the centre of curvature of the outer
ring raceway surface with the bearing axis, they
are also called as Self Aligning Bearing.
2. They can take Heavy Radial Load & some Axial
Load in either direction.
3. They are suitable for the use where there is Heavy or
Impact Load.
Thrust Bearing 1. They are capable of taking High Axial Load and some
amount of Radial Load.
2. Outer & Inner Rings are called as Washer because
they seem to be as Washer in Structure.


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JAIPUR PLANT
There are generally four main types of bearing manufactured at the Jaipur plant which are
mentioned as following:-

1. Ball bearing
2. Steel ball
3. Tapered roller bearing
4. Railway bearing
5. Very large diameter bearing

1. 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 equipment. 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.

2. 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

3. 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.


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4. Railway bearing

Roller Bearing in Axle Box:

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 indigenized 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.

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.

Cartridge Tapered Roller Bearing:

For fitment to the new BOX-IN Up rated Wagons designed by the RDSO, NEI is
the only manufacturer in the country to indigenize 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 year1984. These
bearings are grease packed and require no field lubrication for a period of 7 years.

Very 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 1985. This 4-Row
Tapered Roller Bearing measures 1300 mm diameter 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

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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.


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BEARING DESIGNATION

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


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RESEARCH & DEVELOPMENT

Design & Development
The design of all types of bearings is done on Pro-Engineer 3D Modelling &
AnalysisSoftware.Complete engineering and research with in-house facility for design
development of all types of bearings and tooling with expert advice on design, development,
manufacturing, installation and maintenance of bearings facility is available. 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.

Machine Building
NEI has the capability of machine building to design, develop and manufacture special purpo
se 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 byov
erhauling 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.

SAP ERP
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, their
processes now conform to international standard


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PROJECT AT NEIL
RAILWAY BEARING AND HEAT TREATMENT DEPARTMENT
The project assigned to mechanical students was in the department of railway bearing and
heat treatment, where the bearing for the railways were manufactured through heat treatment
process. As mentioned above there are four types of bearing manufactured and processed in
this department.
Spherical
Cylindrical
CTRB (cartridge tapered roller bearing)
The department dealt with bearings required for the railway and the heat treatment of the
bearings and their rings. This Division is spread over a covered area of 4,855 Sq. Meters.
ROLLER BEARING IN AXLE BOX
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.
SPHERICAL ROLLER BEARINGS
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.
CARTRIDGE TAPERED ROLLER BEARINGS
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.


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LARGE DIAMETER BEARINGS
The Large Diameter Bearings Division is spread over a covered area of 2,508 Sq. Meters.
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 in September 1985. This 4-Row Tapered Roller Bearing measures 1300mm dia and
weigh 4.39 tons.
The large diameter bearings are mainly manufactured out of case carburising steel, heat
treated on special equipment and furnaces developed by NEI. Precision grinding is done to
close tolerances on CNC Twin Spindle Programmable Berthiez Machine for bearings ranging
from 500 to 2000 mm diameter with electronic sizing and numerical display.


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1. SPHERICAL BEARINGS

A spherical bearing is a bearing that permits angular rotation about a central point in
two orthogonal directions (usually within a specified angular limit based on the
bearing geometry). Typically these bearings support a rotating shaft in the [bore] of
the inner ring that must move not only rotationally, but also at an angle.

Meanings of suffix/prefix
C = Type C Roller (Symmetrical)
C3 = Radial internal clearance C3
B = Type B Roller (Asymmetrical)
L1= High Strength machined brass cage
Outer ring
Outer ring for NBC spherical roller bearings are manufactured from forged and rolled
rings from bearing quality steel. It is through hardened and precision ground all over. The
track or roller surface of bearing outer ring is spherical in shape for self-aligning.
Inner Ring
Inner ring for NBC spherical roller bearing are also made from bearing quality steel
which is forged and rolled. Inner rings are also precision machined heat-treated and
precision ground. Inner ring have two rolling surface which are ground together with high
accuracy.

Nbc spherical roller
bearing
Application in Indian
railways
Axle load
22320 C/C3 M.G. Passenger
Coach
10.25t
22326 C/C3 B.G. Pasaanager
Coach
16.25t
22328 BL1C3 B.G, E.M.U 20.0t

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Roller
Roller are either forged or machined from bearing quality steel bars & then through
hardened and ground to high degree of accuracies. In bearing 22320 and 22326,
symmetrical design rollers are used and for bearing 22328, asymmetrical design rollers
are used.

Cage
NBC spherical roller bearings are fitted with machined brass cages. These cages are made
from brass centrifugal castings and then precision machined. Brass cages have advantage
of assuring positive lubrication and cooler running of the bearing therefore are best
recommended for railway applications.


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CYLINDRICAL BEARING

The cylindrical roller bearings have greater radial load capacity than ball bearings 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 load 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 depending upon the geometry of the
bearing. Many variations available are shown below :


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CTRB (CARTRIDGE TAPERED ROLLER BEARING)

Tapered roller bearing are designed in such a way that vertices of the cone for each roller and
those for the inner and outer 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 bearing supports radial loads and axial loads from one direction only. The
line contact between rollers and raceway provide the bearings with a high load carrying
capacity. Steep angle tapered roller bearing with exceptionally steep cone angle enables the
bearings to take heavier load.
The bearings are of separable type, enabling separate mounting of cups and cones. Since the
tapered roller bearings can absorb thrusts 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.
The inner and outer 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 a
common point on the main axis of the bearing.
This conical geometry is used as it gives a larger contact patch, which permits greater loads
to be carried than with the spherical 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 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.

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The rollers are guided by a flange on the inner ring. This stops the rollers from sliding out at
the high speed due to their momentum.
The larger the half angles of those 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.
RAW MATERIAL:
The Races & Rolling elements of Bearing are subjected to stress on a very small contact
surface must be of such material also as to with stand wear and have high elastic Limit &
fatigue Limit. The raw material being used by the Industry for Manufacturing of various
Bearing components are as under:
CUP AND CONE:
The raw material used in the Manufacturing of bearing Races is SAE 52100 high Carbon
Chrome bearing steel, which has composition similar to EN-31 (100 CR 6 Asper BIS
specification). The raw material for Bearing Races is in the form of Rods &Seamless Hollow
Tubes. This is a Spheroids Annealed Steel. Approx. 80% of the Seamless Hollow tubes are
purchased by the Industry from M/s. Indian Seamless Metal tube PUNE, while the rest of the
tube used in the cluster is imported material. The Steel bar are purchased from M/s. Indian
Seamless Steel & Alloy Pune & M/s.Mahindra Ugine Steel Company KHAPOLI
(Maharashtra).Some of the units are buying the steel scrap rod for manufacturing bearing
races. Bearing Races material and their heat treatment are required to be selected carefully,
taking account the mechanical strength and required life of the Bearing, Approximate
required composition for bearing races are Constitute %
CompositionCarbon 0.95 to 1.1Chromium 1.4 to 1.6Manganese 0.50 max.Silicon 0.15 to 0.3
5Sulphur 0.025 (Max.)Phosphorous 0.05
CAGE'S:
Cage is used to return balls at proper distance to prevent them from containing each other and
to prevent a temperature rise and resultant damage due to friction.
The Material for manufacturing cages is CRCA Strips of C2015 Bearing grade steel having
carbon percentage at0.08% max. And Magnesium ranging from 0.25% to 0.45%


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HEAT TREATMENT

The heat treatment process for all the four bearings is almost same. With only few differences
here and there. The general process of heat treatment is shown in the following diagram. Heat
treatment process is the process of hardening the soft material. The row materials soft
material and it has to be hardened before grinding, and hardening increase the life of bearing.
Hardening is done in a special furnace named CHUGAIRO furnace. The soft machined
material is feed in the furnace and washed at 600C, then send to a chamber where the
material heated in four chambers the first chamber has the temperature 840c and further
chamber contains the 850c temperature.
Then it is dipped into an oil tank at temperature 25c where the material get quenched then it
is washed and then it is tempered in water for about 90 min. at temperature 105c after that
dried and cooled in air, the hardened material is obtained.

Salt Bath Furnace
Pre-heat at 500C
Superheat at 850C
Quenching Salt 170-
180c
Cooled in air
Washed In Hot Water
Washed In Cold Water
Tempered At 180c
Rockwell Hardness
Testing (58 to 62 HRC)

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Some salient features of heat treatment in R.B.H.T
There are three different manually operated heat treatment process units are available
for the three bearing i.e. spherical, cylindrical and cartridge. And one specially
automated robotic hate treatment unit is installed in the Railway Bearing Heat
Treatment department for the Cartridge Tapered Railway Bearing.
A plant for the production of heating agent which is gas there is also installed in the
facility. the gas used is the endo gas and L.P.G gas.
Other than heat treatment of various bearings, C.T.R.B cups and wear rings are also
made to go through the heat treatment process and the plant.
The oil used in the quenching process of CTRB rings and cups is generally
Betaquinine U3. The general purpose of using oil is for the protection and heating
maintenance of the material.
The salt is used in the heating process of the spherical and cylindrical bearings, the
general purpose of the salt is to prevent scaling and a bit of carbonising.
V-belt is used in the tempering process machine in the heat treatment process of
CTRB cups in chugairo furnace.

A simple diagram showing the heat treatment plant.

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Expected tangible benefits- heat treatment

Production/hour Rejection-%

Hardness-HRC

0
100
200
300
Before After
0%
2%
4%
6%
Before After
Series 1
46
48
50
52
54
56
Min. Allowed Avg. Achieved
Series 1

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MACHINES
The various machines used in the heat treatment of these bearings and wear rings and cups
are mentioned as follows:-
1. R.H.F
2. U.B.H
3. Salt bath furnace
4. Automatic cup machine

1. R.H.F (Rotary Hearth Furnace)

This robust furnace type is extremely versatile in its use. It is designed for both carburizing
shallow case depths and for reheating pre-treated work pieces. Its high throughput makes it
particularly suitable for heat treating large quantities of the same parts.
The rotary hearth furnace can be operated as a stand-alone unit with either manual or
automatic loading/unloading, and also be interlinked with other plant components.
The benefits of this furnace type include:
High throughput with even temperature distribution
Robotic loading for automated press quenching systems
Hardening applications for a wide range of products
Special tray and door design for maximum performance


Page | 28

2. U.B.H (Universal Batch Hardening)

Intensive quenching is a very rapid and uniform cooling of steel parts that causes the
simultaneous formation of martensite throughout the whole part surface, creating a firm shell.
The strong martensite case or shell minimizes part distortion.
Metallurgical processes include neutral hardening, carburizing, carbonitriding, normalizing,
and annealing. The UBIQ furnace is suitable for drive and axle components, transmission
components, shafts, fasteners, bearing components, and precision machined
components. Capacity ranges from 1100 to 6000 lb., in sizes up to 6 ft. Normal operating
temperature is 1450 to 1750F, with a maximum of 2000F, and excellent temperature
uniformity.


Page | 29

3. Salt Bath Furnace

In metal quenching, a part is cooled from the austenitizing temperature fast enough to avoid
the pearlite nose of the materials time-temperature-transformation (TTT) diagram and to
transform the austenite into martensite to the maximum extent possible. When the quenching
medium is water, brine, a polymer solution, or fast oil, it is generally referred to as
conventional quenching. Steels with low hardenability can be quenched this way. However,
this method can cause distortion and in some cases, nonuniform hardness or even
cracking. The tendency to distort increases with increasing steel hardenability.
Causes of distortion usually can be traced to uneven or nonuniform quenching, thermal
stresses, and transformational stresses. These factors often can be mitigated by adopting an
interrupted quenching technique.
In interrupted quenching, parts are cooled rapidly from the austeitizing temperature to a point
above the martensite start temperature (M
s
), where they are held for a specified time and then
cooled to room temperature. Thermal stresses and the potential for distortion are
considerably reduced during the hold above M
s
. Processes that make use of an interrupted
quench include martempering, austempering and variations of them.
For most steel and alloys, the temperature at which the quench is interrupted is usually in the
175 to 370C (350 to 700F) range. Water, brine, polymer solutions and most quench oils
cannot be used at these temperatures. Attempts at using molten lead and fluidized beds do
not appear to have met with much success. Some oils can be used at temperatures up to
230C (450F), but for higher temperatures, molten salt is the natural, practical choice.


Page | 30

PRODUCTION OF BEARING PARTS

1. Production of inner/outer race

Inner and outer tracks are produced in the same way except for the contours being different
and the surfaces being ground. Raw material taken as forged rings of the starting material are
turned and sent for heat treatment. After heat treatment tooling cannot be done because of the
hardness attained by the material. Further machining done is in the form of grinding. Rough
grinding is done on the races. Rough grinding consists of face grinding and Outside Diameter
Grinding for the races. Finish grinding is done on the production line where the raceways are
ground. These are the grooves in which the balls move, therefore require greater accuracy.
After finish grinding honing and super finishing is done using honing stones to obtain a
mirror smooth finish on the tracks.

Page | 31

2. Production of balls

Production of balls is much difficult as compared to the races. This is due to the fact that the
balls can be out of round only to an allowable value of 25 microns even for the most
inexpensive bearings. Balls are made out of wire rods. Required length of wire is sheared off
and pressed between the dies of the ball header which gives us balls with a ring of flash
around them, similar in appearance to the planet Saturn. This flash is removed by making the
balls rotate in concentric channels of two roughing wheels. After this process the balls are
sent for hardening and ground to a size little larger than the required size. Rest of the process
of lapping is done in a similar way as roughing and grinding except for the fact that the wheel
used is of cast iron and abrasive slurry is also used.


Page | 32

3. Cage production

Cages are made out of thin strips of cold rolled steel. Annular rings are blanked out of the
steel strip and formed in between dies to form the pockets for accommodating the balls. Rivet
holes are pierced which hold the rivets which are used to fasten the two halves of the cages
together in case of metallic cages. Finally the surfaces are smoothened out for reduction in
friction and cleaning is done before the cages are sent for assembly. In case of plastic cages,
the material used varies according to the requirements of the bearings. These cages are made
by injection moulding processes and do not require riveting to hold the cages together. The
cages need not be made in two halves. Only one moulding of the cage can be snapped onto
the balls to help faster assembly.


Page | 33

ASSEMBLY OF BEARINGS
1. BALL BEARING ASSMBLE LINE


Page | 34

2. Roller bearing assembly line


Page | 35


Page | 36

CONCLUSION

I hereby conclude my report on industrial training where I had the pleasure of acquainting
myself with the knowledge and practical aspects of theory of bearings that I learned in my
engineering. The training provided me with the skills and aspects of how work is done in
industries and helped me with my experience in industrial skills.
I am thankful to the National Engineering Industries Ltd. (N.B.C) management to permit for
the training in their Jaipur based industry and have helped me to enhance my knowledge of
Mechanical Engineering in an industry.

SHASHANK PATHAK
10EKTME058
MECHANICAL

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