Winter Internship Project

CARRIED OUT AT
NATIONAL ENGINEERING INDUSTRIES LTD.
JAIPUR [RAJASTHAN]
In
Taper Roller Department
On
Project
Study of Different Parameters of Taper Roller Bearings

Submitted towards the partial fulfilment of

Bachelor of Technology
In
Mechanical engineering

2013-2017

From

School of Mechanical Engineering

Lovely Professional University

Punjab

Submitted By
Manish Kumar
Registration No. 11307508
Section- 1304
 ACKNOWLEDGEMENT
As the technologically advancement will enable us to get the environment
we desire. The basic beatitude, bliss, euphoria & our endeavour to achieve
complete and perfect knowledge in the field we choose that accompany the
successful completion of any task would not be complete without the expression
of appreciation of simple virtues to the people who made
i t possible. So, with reverence honour I acknowledge all those guidance and
encouragement has made successful completion of training.
I a m t h a n k f u l t o Mr. Rajesh Sharma, Taper Roller Department, NEI Ltd.,
Jaipur for his constant cooperation and able guidance & without his support this
work would not have been so understable.
I am also thankful to Mr. Gurkeerat Singh, Department Head, Taper Roller
Department, NEI Ltd., Jaipur for his constant motivation and able support to
guide us throughout the training.
I am also thankful to Mr. Vineet Sharma, Head, HR, NEI Ltd., Jaipur for
providing us an opportunity to train and work with their esteemed organization.
I am also thankful to Mr. Nitin Chauhan, Assistant Professor, School Of
Mechanical Engineering, Mechanical Department, Lovely Professional
University, Punjab who is always mentor to us.
I am also very thankful to all respected persons who have directly or indirectly
helped me in my earnest effort to accomplish this training.
 PREFACE

The Engineering curriculum is designed in such a way that student can grasp
maximum knowledge and can get practical exposure to the corporate world in
minimum possible time. Engineering schools of today realize the importance of
practical knowledge over the theoretical base. The research report is necessary
for the partial fulfilment of engineering curriculum and it provides an opportunity
to the researcher in understanding the industry with special emphasis on the
development of skills in analysing and interpreting practical problems through
the application of engineering theories and techniques. It is a new platform
of learning through practical experience. It gives the learner an opportunity to
relate the theory with the practice, to test the validity and applicability of his
classroom learning against real life engineering situations.

Working under this project I have gained the knowledge about whole bearing
industry. Here I have learnt about the use of bearing in different sectors and I
have also gained knowledge about the application of No. of bearings in a single
vehicle and how a supply chain management plays a vital Role in the success of
the economy and various other industries.
 Table of Contents
S. No. Contents Page No.
Chapter: One
1 Introduction 7
2 Company Profile 8-15
Chapter: Two
3 History & Evolution of Bearings 17-18
4 Classification of Bearings 19-20
5 Failure of Bearings
6 Indian Bearing Industry 21-23
7 Global Bearing Industry 24
Chapter: Three
8 Flow of Material in Bearing Industry 26
9 Bearing Materials 27
10 Bearing designation 27
11 Taper Roller Bearings 28-31
12 Process Flow chart of Cup 31-32
13 Process Flow chart of Cone 32
14 Process of Heat Treatment 33-37
15 Process of Grinding 37
16 Roller Manufacturing 37-38
17 Cage Manufacturing 39
18 Assembly 40-41
Chapter: Four
19 Research Methodology 43
20 Projects Undertaken 43-64
21 Conclusion 65
22 Summary 66
23 Bibliography 67
 Chapter: One
Introduction & Company Profile
 INTRODUCTION
The current size of the global bearings industry stands at whopping `3 trillion, as per data
released by Industry experts. With the Indian economy undergoing rapid industrialization, the
industry has doubled in the last five years and has registered annual gains well above the global
average of ~35%. With increased infrastructure and industrialization, at least, this trend should
continue for next five years. India is among the fastest growing markets for bearings. Close to
40% of the total demand is fulfilled through imports with the balance being met by indigenous
products. As the Indian infrastructure develops and the industry modernizes, we can see
tremendous opportunities opening up for the bearings industry. In the near future, customers
will look for better and cleaner technologies, hence necessitating aftermarket services including
maintenance of equipment, reliability monitoring, remanufacturing so as to keep their
equipment running efficiently and for long. Moreover, the Indian economy which is driven
largely by the domestic demand was not only spared of the worst of the downturn but also very
well placed to make the most of the upturn. As the government increases its thrust on the
infrastructure build, the economic growth will accelerate.
National Engineering Industries Ltd.oneof the largest manufacturer of Ball and Roller Bearin
gs, Steel Balls and Axle Boxes complete with Roller bearing in India, which are being
produced in factories at Jaipur and Newai. Bearings are manufactured for every possible
application and requirement of modern engineering industry and we continue to develop new
sizes, keeping pace with rapid advancement in the Indian engineering industry. NEIs technical
collaborations with the worlds leading conglomerates in the field of bearing technology
viz. M/s NTN Corporation of Japan, M/s BRENCO incorporated of USA have given a whole
new dimension to the product range and a quality par excellence. NEI has already implemented
modern concepts of Total Quality Management and accredited QS9000 and TS16949
certification, NEI has also been awarded Association of American Railroads (AAR) for AAR
certificate M-1003 for Cartridge Tapered Roller Bearing in Feb 04-05. NEI has also been
awarded ISO-14001 certificate for its concern and commitment towards a cleaner environment.
NEI has successfully implemented SAP-ERP to re-engineer and integrate business processes
to conform to world class standards.
 COMPANY PROFILE

National Engineering Industries Limited (NEI), the flagship company of US$ 1.6 Billion CK
Birla Group, was founded in the year 1946 under the name of National Bearings Company
Limited. Over its seven decade long history, it has gone from strength to strength on the back
of sound business practises, manufacturing capabilities and technology collaborations with
Brenco (now Amsted Rail), NTN and Izumi.
NEI is recognized today as a pioneer brand in the Indian bearings industry. NEI boasts of four
world class manufacturing facilities located at Jaipur, Newai (both in Rajasthan), Manesar
(Haryana) and Savli (Vadodara). The company currently manufactures nearly 150 million
bearings per annum. Its product range currently comprises of bearings across categories such
as Ball, Taper Roller, Double Row Angular Contact (DRAC), Cylindrical Roller & Spherical
Roller Bearings. The company has specially equipped facilities to manufacture axle boxes for
railway applications, Cartridge Taper Roller Bearings and Large Dia. Bearings for industrial
applications. NEI is capable of developing bearings from 6mm bore to 2000mm outer diameter,
over a 1000 sizes.
NBC Bearings are widely used by manufactures of 2 &3 wheelers, cars, trucks, tractors, electric
motors, railway wagon, coach and locomotives. NEI product range are also used in steel mills,
heavy engineering plants, bulldozers, shovels, tillers and thermal power plants all across the
country.
NBC Bearings are exported to various countries like USA, Germany, Italy, Japan, South
Africa, Saudi Arabia, Brazil, Peru, Guyana, Sri Lanka, Bangladesh, Pakistan, Nepal, Bhutan,
Indonesia, Singapore, Turkey, Australia, China, Canada, Guatemala, Mexico, Malaysia,
Nigeria, Argentina and Columbia.

VISION
NEI will be the best market driven Antifriction Bearing Company providing innovative
products& service to achieve satisfaction of customers and other stake holders by using world
class technology and management practices and through employee commitment. NEI will
diversify in allied precision engineering products and special purpose machine.

MISSION
NEI Ltd. is in the business of precision rolling bearings, providing technical services and
seeking opportunities for new business consistent with its vision to
Provide product and services of world class quality.
Meet customer requirements.
Increase Shareholder value.
Develop mutually beneficial supplier relationships.
 Create opportunity for the employees to achieve their reasonable Aspirations. To serve
the society by providing products and services of excellent quality, meeting consumer
requirement, providing adequate return to shareholders and creating opportunity for the
employees to achieve their aspirations.

TECHNICAL COLLABORATIONS
a. Amsted Rail (Brenco Incorporated), USA:
1982 Onwards: For Cartridge Taper Roller Bearings used in Railway Wagons
b. NTN Corporate, Japan:
1985 onwards: For Ball Bearings, Cylindrical and Spherical Bearings
1997 Onwards: For Taper Roller Bearings
c. Isumi Kinzoku Kogya Co. Ltd., Japan
1996 Onwards: For re-manufacturing, retrofitting, and overhauling of grinding &
super-finishing machines used on the races/tracks of bearings.
Milestones:

MANUFACTURING FACILITIES
1. JAIPUR PLANT

i. Ball Bearings
Precision Ball Bearings from 6mm bore to 75mm bore diameter are manufactured
using state-of-the-art manufacturing facilities with in process and post process
gauging in grinding and centrally air-conditioned assembly lines with auto gauging
and testing equipments. The latest advanced techniques for manufacturing and
quality assurance are implemented to meet the rapid increase in demand for quality,
 diversity of specifications and new types of bearings. This division is spread over
a covered area of 14,694 sqm.

ii. Steel Ball

Precision steel balls (upto 25mm diameter) are manufactured on precision grinding
and lapping machines to achieve a super finished surface, accuracy and roundness
as per ISO standards. This division is spread over a covered area of 4,700 sqm.

iii. Taper Roller Bearings

Precision Taper Roller Bearings are manufactured in inch and metric series from a
bore size of 15.875mm to 95.25mm with technology obtained from our earlier
collaborator, Federal Mogul Corporation USA and now with NTN Corporation,
Japan. These Bearings are used by all major automobiles manufacturers in the
country as Original Equipment. This division is spread over an area of 11,652 sqm.

iv. Railway Bearings

a. 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 in locomotives manufactured by Diesel
Locomotive Works, General Motors locomotives, Chittaranjan Locomotive
Works, the ICF Broad and Meter Gauge Coaches, as well as various Wagon
Builders. Over a million NBC bearings and boxes are in service with Indian
 railways. The development of completely Indigenous axle boxes and bearings
for the high speed Rajdhani Locomotives, the Yugoslavian and the Egyptian
Railway Wagons are the highlights of the design capabilities at NEI. Today
more than 100 types of axle boxes and bearings are being manufactured.
b. 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.

c. Cartridge Taper Roller Bearings

For fitment to the new BOX-IN Updated Wagons designed by the RDSO. NEI
is the only manufacturer in the country to indigenise these bearings to a high
percentage in 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.
d. Large Diameter Bearings
Self-sufficiency in steel is the call of the day and bearings are a crucial
component of steel mills. NEI has the distinction of being one of the only ten
manufacturers of these bearings in the world, who can manufacture large
diameter bearings upto 200mm diameter. The largest bearing manufactured by
NEI for fitment to the plant mill of Rourkela Steel Plant was released by Mr.
G.P. Birla in September 1985. This 4 Row Taper Roller Bearing measured
1300mm dia and weighed 4.39 tons. The large diameter bearings are mainly
manufactured out of case carburising steel and 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 2000mm diameter with electronic sizing and numerical
display. Production of these bearings started in 1975, and till date over 100
different types of special large diameter bearings have been manufactured and
successfully used in various industries. The Large dia. Bearings division is
spread over an area of 2508 sqm.
 2. Newai Plant
The plant was 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 and
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 sqm.

3. Manesar Plant
The Plant has covered area of 5,200 sqm 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.

4. Savli(Vadodara) Plant
The recently commissioned plant is spread over an area of 80,937 sqm. This plant is
designed and constructed to achieve IGBC Platinum Certification which is the highest
Green rating available.

RESEARCH AND DEVELOPMENT

a. Design & Development
Complete in-house facility for design and development of all types of bearings and tools
is available. The design of all types of bearings is done on Pro Engineering 3D
Modelling & Analysis Software. Complete engineering & research facility is available
to solve intricate problems with expert advice on design development, manufacturing,
installation and maintenance of bearings. With the signing of the technical collaboration
agreement with NTN Corporation, Japan and BRENCO Inc. of USA, the capability to
offer the finest engineering services in the bearing industry has been enhanced. Services
of teams of experienced engineers are available for selection of bearing as per
application.

b. Machine Building
NEI has the technology to design, develop and manufacture special purpose CNC
Grinding Lines, HT Lines, Material Handling Equipments and other special purpose
machines which have been made for its captive use to keep pace with the latest
technology.

c. 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.
Quality Management System

ISO / TS 16949:2002
NEI has been awarded TS 16949: 2002 on 17th October, 2003- THE MARK OF
EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by BVQI for design,
development, manufacture & supply of Ball Bearing, Tapered Roller Bearing andCylindrical
Roller Bearings. NEI Ltd. is the first bearing industry in India to have been recommended for
TS 16949: 2002.This certificate is awarded only to suppliers of automobile manufacturers. TS
16949: 2002 quality management system is based on ISO 9001:2000 in which many
supplementary and additional requirements of automobile industries have beenincorporated.S
implicity, effectiveness & efficiency of processes, error proofing and continuousimprovement
in processes thus become the highlight of TS quality management system.

ISO 9001:2000
NEIs large dia. bearing division and railway bearing division which are
manufacturingcylindrical Roller Bearings, Spherical Roller Bearings, Cartridge Tapered Roll
er Bearings, Railway Rolling Stock and Spares has also been awarded to ISO 9001: 2000 on
9th October, 2003 by BVQI.

ISO 14001:1996
NEI was awarded ISO 14001 certificates by BVQI in the month of March 2000 for
Environmental Management System. NEI has done tremendous efforts in resource
conservation, recycling and thick plantation. The efforts at NEI have saved precious natural
resources like water, oil and power etc.
 Chapter: Two
Bearings & Bearings Industry
 History & Evolution of Bearing
An early type of linear bearing uses tree trunks laid down under sleds. This technology may
date as far back as the construction of the Pyramids of Giza, though there is no definitive
evidence. Modern linear bearings use a similar principle, sometimes with ball sin place of
rollers.
Tapered steering head bearings for a motorcycle. The first plain and rolling-element bearings
were wood, but ceramic, sapphire, or glass were also used, and steel, bronze, other metals,
ceramics, and plastic (e.g., nylon, polyoxymethylene, Teflon, and UHMWPE) are all common
today. A pocket watch uses stones to reduce friction, and allow more precise timekeeping. Even
old materials can have good durability. As examples, wood bearings can still be seen today in
old water mills where the water provides cooling and lubrication.

BEARING

Definition- 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 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 v i r t u e o f 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 fluids 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.

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-centre.
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.

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

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.
 CLASSIFICATION OF BEARINGS

Depending upon the direction of load to be supported:-Based on this criteria, the bearings
may be categorized into
a) Radial Bearings:-These are also known as Journal Bearings. In these bearings the main
load is perpendicular to the axis of rotation of the moving elements.
b) Thrust Bearings:-In these bearings the load acts along the axis of rotation.

Depending upon the type of loading:-Based on this criteria, the journal bearings may be
categorized into.

a) Bearing with a steady load, such as bearings of electric generators, and motors,
centrifugal pumps, or various blowers or fans. Such bearings are called POWER
BEARINGS.
b) Bearing with a variable or fluctuating load, such as main crankpin, wrist pin, or
camshaft bearings in diesel engines.

Depending upon the nature of contact between the working:-Based on this criteria they
may be categorized into two general classes, each with two sub-types.

1) Plain (Sliding Contact Bearings):-The primary motion between the bearing and the
moving element is the sliding one :
a) Cylindrical bearing: can be made from a cast, solid bronze material. Cylindrical bearings
can be available as plain bearings, cored bars or solid bars in the market.
b) Thrust bearing: can be made from porous bronze, oil impregnated type of bearing
material. Thrust bearings can be available as plain bearings (also known as sleeve bearings),
flanged bearings, thrust-bearings, cored bars, solid bars and plate stock.

2) Anti-Friction Bearings (Rolling Contact Bearings):- In these bearings, the contact

between the bearing element is rolling instead of sliding as in plain bearings. Since the rolling
friction is very less as compared to the sliding friction, such bearings are also known as
Anti-friction Bearings.

2.1) The rolling element bearings are classified into:

a) Ball bearing: - In these bearings, the rolling element is a spherical ball.
b) Roller bearings: - In these bearings, the rolling element is a roller, which might be
cylindrical, conical, spherical, or concave.

2.2) Depending upon the load to be carried, the rolling contact bearings may be categorized
as:
a) Radial Bearings: - In radial contact bearings, the load is primarily radial with only low
magnitude thrust load.
b) Thrust Bearings:-These bearings handle loads which are primarily thrust.
c) Angular Contact Bearings:-These bearings are used where the loads are combined
radial and high thrust, and where accurate shaft location is required.
 Share

7 6 3

54
30

Ball Bearings Taper Roller Cylindrical Needle Spherical

Failures of Bearing

Causes:
Only 34% of bearings fail due to Fatigue, which is the basis of life calculation.
Poor lubrication is the reason for 36% of premature bearing failure.
Contamination is the reason for 14% of premature bearing failure.
Poor installation is the reason for 16% of premature bearing failure.

Common symptoms of failure:

A. Overheated bearing
B. Noisy bearing
C. Vibration
D. Shaft is jammed
E. Bearing clearance has increased
F. Lubricant has metallic debris
G. Unsatisfactory equipment performance

Failure Mode:
Surface fatigue
a. Subsurface fatigue
b. Surface initiated fatigue
Wear
a. Abrasive wear
b. Adhesive wear
Corrosion
a. Moisture corrosion
b. Frictional corrosion
i. Fretting corrosion
ii. False brinelling
Electrical Corrosion
Plastic deformation
Fracture
 Indian Bearing Industry
The Indian Bearing Industry is estimated at Rs30 Billion approximately. The Industry has
established a highly diversified product range of around 1000 type of Bearing, having High
Volume Demand. As much as 70% of the total Demand for common varieties and size of
bearing is met by the domestic Industry, and the remaining demand of 30% is
imported essentially for Industrial Application and special purpose. The Indian bearing
Industry can be divided in to the organized sector and un-organized sector. The organized
sector primarily caters to the Original Equipment Manufacturer (OEM) Segment, which
predominantly comprises automotive railway and other Industrial users. The replacement
market is dominated by unorganized Sector.

ORGANISED SECTOR
The organized Sector comprises about 12 big Manufacturer, who contribute to more than50%
of total turnover. Most of the big players are having either technical or
financialwith International Manufacturer. International Collaboration gives access to besttech
nology in the world. SKF Bearing is the major player in the Indian market with the largest
market share followed by National Engineering Industry (NBC) and FAG Bearing India the
two other major players.

Sectors

30

55
15

Organized Unorganized Imports

UNORGANISED SECTOR
The Unorganized Sector Include the Small Scale Manufacturer and Manufacturer of Spurious
Bearing. The unorganized Sector Contribute to almost 15% of Total Industry turnover. The
Unorganized Sector players have a strong regional presence and mainly cater to the needs of
the replacement market.
The direct employment provided by the above sectors is more than 12000 people. Indirect
employment for Transportation, Tools, Containers, and Packaging etc. further helps
in providing employment.

Threats & Limitations to Indian Market

Increasing Competition in Domestic market.
Very Low Volume of Direct Export.
Weak Marketing Linkages.
Raw Material Bank is not present.
Low level of technology used by most of manufacturing Units.
Quality of Bearing Manufactured in the Small Scale Industry (SSI) Sector does not meet
the International Quality Standard.
No Recent upgradation in Design, Technology, Process of Manufacturing and
Quality Control.
Non-existence of highly skilled Man Power.
Stiff Competition from China made Bearing.
Increase in Illegal Imports.
No Entry Barrier in the cluster
Increase in Raw Material Prices.
Government Rules & Regulations
According to estimate an entrepreneur need to interact with 14 Govt. departments to
get permission for manufacturing &exporting. Most of their time is spend in filling up forms
and submitting paper as per their requirement. Therefore Govt. rules and regulation have to
be liberalized& the role of Govt. Department should be a facilitator rather than regulator.
 Market Share

6 4
8 29

20
15

SKF NBC FAG TATA NRB TIMKEN ABC HMT

 Global Bearing Industry

The global bearings market is generally seen as the worldwide sales of rolling bearings,
comprising ball and roller bearing assemblies of various designs, including mounted bearing
units. SKF estimates that the global rolling bearing markets size in 2016 reached a value of
between SEK 340 and 360 billion.
The industrial original equipment bearing markets accounted for almost 40% of world demand
and included manufacturers of light and heavy industrial machines and equipment, as well as
aerospace, off-highway and railway vehicles. Sales through distributors (industrial distribution
and the independent vehicle aftermarket) maintained around 30% of world bearing demand, of
which around 25% is related to the vehicle service market and around 75% to the industrial
market.
The automotive original equipment bearing markets, including two and four wheelers,
accounted for more than 30%. Europe accounts for 25% of the total world market with
Germany alone accounting for almost 10%.The Americas now represent slightly more than
20% of global demand, of which the USA, Canada and Mexico together account for about
80%. In South America, Brazil is the major market and makes up more than 50% of regional
demand. Asias share of the world bearing market grew the most year-on-year and accounted
for more than 50% compared with less than 30% fifteen years ago. Chinas share of the total
world bearing market grew heavily to about 30%. Japans share of the world bearing market
accounts for slightly more than 10%. Other Asian markets with sizeable bearing sales account
for about 10%, including India, Thailand, Indonesia, Taiwan and South Korea. The Chinese
bearing market, which remains the largest of the emerging markets, is very fragmented, with
the main international bearing companies accounting for about one third of the market, while
the other two thirds of the market consists of a host of local manufacturers. Some of the largest
include: Wafangdian (ZWZ), Luoyang (LYC), Harbin (HRB), Zhejiang Tianma (TMB),
Wanxiang Qianchao, and C&U. The Indian bearing market accounts for less than 5% of the
world bearing market. The players in that market include international manufacturers and
several local manufacturers such as NEI, NRB, ABC and TATA.
Radial deep groove ball bearings are the most common rolling bearing type, accounting for
almost 30% of world bearing demand. Other major ball bearing types include angular contact
ball bearings, self-aligning ball bearings, thrust ball bearings and automotive wheel hub ball
bearing units. Roller bearings account for less than half of worldwide rolling bearing sales.
Roller bearings are named after the roller shape, such as cylindrical roller bearings, needle
roller bearings, tapered roller bearings and spherical roller bearings. All of these are available
for loads acting across the shaft (radial bearings) and for loads that are parallel with the shaft
(thrust bearings). The largest roller bearing family is the tapered roller bearing, with almost
20% of the world bearing market.
 Chapter: Three
Manufacturing of Taper Roller Bearings
 Flow of Material in Bearing Industry

Material from outside Vendor

Such as Races (Inner & Outer), Cages, retainers etc.

Store House for Size Inspection

Laboratory
For Metallurgical inspection based on the norms set by R & D Department

Yes/No Material is sent back to Vendor

Material is send to specific departments for further Operations

The following Operations are done:

1. Hardening or Heat Treatment
2. Rough Grinding (Face, O.D., Inner & Outer Track)
3. Finish Grinding (Face, O.D., Inner & Outer Track)
4. Inspection
5. Assembly
 Bearing Materials

MATERIAL OF BEARING COMPONENTS:

Balls, rollers and rings of rolling bearings are manufactured from bearing steel that has
capability of being hardened to a high degree, at least at the surface.
Commonly used bearing steel SAE 52100/SUJ2 is rich in Chromium (through hardened) or
SAE3310/ SAE4320 (case hardened steel). In both the cases the surface hardness achieved is
59~65 HRC.
In certain applications, stainless steel is also used where environment is corrosive e.g. chemical
plants.

Chemical Composition of SAE 52100:

Carbon- 0.95-1.1%
Silicon- 0.15-0.35%
Manganese- 0.5% (max)
Molybdenum- 0.08% (max)
Phosphorus- 0.012% (max)
Silicon- 0.25% (max)
Chromium- 1.3-1.6% (max)
Nickel- 0.25% (max)

Bearing Designation in NBC

Rolling bearing part numbers indicate Bearing type, Dimensions, Tolerance, Internal
Construction & other related specifications.
The Digits & Indications are:-
1st Digit Bearing Type
2nd Digit Width or Height Series
3rdDigit Diameter Series
Last 2 Digits Bore Diameter
 Taper Roller Bearings
Tapered roller bearings consist of 2 basic components: the cup and the cone assembly. The cup
is the outer ring and is a separate component. The cone assembly is made up of the inner ring,
rollers, and the cage.

The inner and outer ring raceways are segments of cones and the rollers are tapered 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. This geometry makes the motion of the cones remain
coaxial, with no sliding motion between the raceways and the OD of the rollers.
This conical geometry creates a linear contact patch which permits greater loads to be carried
than with spherical (ball) bearings, which have point contact. 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.
The rollers are stabilized and restrained by a flange on the inner ring, against which their large
end slides, which stops the rollers from popping out due to the "pumpkin seed effect" of their
conical shape.
The larger the half angles of these cones the larger the axial force that the bearing can sustain.
Tapered roller bearings are separable into a cone assembly and a cup. The non-separable cone
assembly consists of the inner ring, the rollers, and a cage that retains & evenly spaces the
rollers. The cup is simply the outer ring. Internal clearance is established during mounting by
the axial position of the cone relative to the cup, although preloaded installations without
clearance are common.

Tapered roller bearings are based on the observation that cones that meet at a point can
roll over each other without slipping. In practice, sections of cones are used.
Taper roller bearing types and characteristics
Single Row TRB
Taper roller bearings can take both axial and radial loads. The axial load carrying capacity of
the bearings is largely determined by the contact angle as shown in the figure below. If the
contact angle is larger, then the axial load carrying capacity is higher and vice versa.
Taper roller bearings 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 taper roller
bearings support radial loads and axial loads from one direction only. The line contact between
rollers and raceways provide the bearings with a high load carrying capacity.
Steep angle taper roller bearing with exceptionally steep cone angle enables the bearings to
take heavier axial load. The bearings are of separable type, enabling separate mounting of cups
and cones.
Since the taper roller bearings can absorb thrust loads in one direction only, these bearings
should generally be installed as opposed mountings. The correct amount of radial and axial
clearance is obtained by adjusting the two bearings against each other.
Besides, double row and four row taper roller bearings are also widely used for heavy loads
such as rolling mills. A single row taper roller bearing can be located endwise in one direction
only.

Double Row TRB

In Double Row Taper Roller bearings, NBC provides both back-to-back arrangement (using
double row outer rings) and face-to-face arrangement (using double row inner rings). These
are adjusted to fix the clearance values of each type. Only parts with identical manufacturing
numbers can be used and they must be assembled according to their code numbers.
Four row TRB
Four Row Taper roller bearings are made up of two double row inner rings and two double row
outer rings. These bearings are used for heavy load capacity as in the roller necks of rolling
mills. The life of large bearings is extended by using case hardened steel, hollow rollers and
pin-type cages.

Taper Roller Thrust

NBC Taper Roller Thrust bearings include rollers that have conical sections. These bearings
are designed primarily to support axial loads at contact angles between 30 and 90. These
bearing are suited for applications where extremely high thrust loads like in crane hooks, coal
pulveriser etc. These bearings can be supplied with a full complement of rollers.
 Applications
Common uses for this tapered roller bearings include:
Automotive wheel bearings; as well as in gearboxes, axle systems, and engines
Agricultural machinery shafts and line shafts
As steady rest rollers, strip levellers, or in combination with a rail element
Helicopter transmissions
Aircraft fuel pumps

Process Flow Chart for Cup

Turning

Heat Treatment

Face Grinding

OD Grinding

Track Grinding
 Honing

Assembly

Process Flow Chart for Cone

Turning

Face Grinding

Track Grinding

Flange Grinding

Bore Grinding

Honing

Assembly
 Process of Heat Treatment
Heat treatment of cups and cones of taper roller bearings are done on Chugai-Ro furnace and
Weins troth furnace. The contact surfaces of the bearing rings and rolling elements
are subjected to repeated high stresses, so they must maintain high precision and rotational
accuracy. T o 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.
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 ahard
surface layer which has been carburized and hardened to an appropriate depth, and are
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 Hardening of steel is achieved by heat treatment process in which the steelmicrostructure
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 Centred Cubic
Structure found at room temperature to Face Centred Cubic Structure found in Austenite
Region. When Steel is suddenly Quenched Martensite is formed which is extremely strong and
If steel is Quenched slowly then Pearlite is formed which is extremely Soft.
 Working of Chugai-Ro Furnace
1. Input: Raw materials after turning is fed into the hopper of the Chugai-Ro furnace.

Chugai-Ro Furnace
1. Automatic Prewashing: It consists of no man. 3 preheaters at 60C +10/-20C are used to
heat the materials. Cerfa clean (L2S) is used to remove the oil because the oil can stick to the
job and then due to heating marks can be left on the surface of the materials.
Simple H2O cleaning is used to remove the excess of cerfa clean at 4-5 KPa Pressure for almost
1 hour.
Then the jobs are sent forward where the blower dries the job and removes excess water from
them.
2. Alignment: Then comes the rabbit conveyer which moves the jobs in batch wise for proper
alignment because if jobs are not aligned properly then there can be production delay and if
more number of jobs go in then they might get stuck and whole process has to be stopped and
started all over again.
3. Heating: Heating is done in the main furnace. Its capacity is 450 kg/hour. The furnace is
thermally insulated using glass wool. The furnace consists of 4 zones. These zones control the
amount of CO^2. If the CO2 is more it will lead to scaling and if less, then the hardness can
get affected. Thus its control is very important. An inert atmosphere is maintained inside to
prevent the air flow in and out to prevent oxidation. And thus for this we have an LPG
connection which reacts with the H2 inside and thus a continuous flame curtain is produced
which prevents the air to pass in or go out. And in the bottom side there is a water curtain which
does the same process.
Zone 1: Its function is to provide ambient temperature of approx. 840 C.
Zone 2: In this the temperature varies from 830-850C according to hardness to be achieved.
Soaking of temperature takes place here.
 Zone 3 & 4: Its function is to maintain a constant temperature of around 830-850 C
according to requirement. This is the most important zone.

4. Quenching: After the heating process we have the quenching process. Jobs are quenched up
to 105 C in Nippon 303 oil tank. Vapours made after the quenching process are not allowed
to go back into the inert atmosphere by the oil curtain. A shell type heat exchanger is used to
cool the hot quenching oil.
5. Post-washing: The quenched jobs are sent to the cooler fan to cool them and then to the
post washing tank at temperature 22.5 7.5 C to remove the quenched oil.
6. Tempering: It is the last process. Tempering is done at 170 C 5C temperature for about
90 minutes to relieve the internal stresses. It reduces the hardness to about 3 HRC but increases
the toughness.

Heating
(850 C)
Quenc
(Austentization) hing Tempering
Air
(115C) Cooling Chilling (170C)
10

Martensite Tempered
Martensite
Features:
A charge throat is provided between the charge & the preheating zone to recover the heat
of the return belt.
A water seal tank device for the return for the belt is provided at the charge & of the furnace
to prevent the air from entering the furnace & reduce the consumption of the atmosphere
gas.
Energy saving due to in-built INDO GAS generator.
A cascade seal is adopted on the quench chute to prevent the fume from entering the
hardening furnace & reduce the consumption of the furnace atmosphere gas.

Working of Wiens troth furnace:

The working of Wiens troth furnace is same as Chugai-Ro but quenching is done in a salt bath.
Hardenability is more in case of Weins troth as compared to Chugai-Ro.

Features:
Fully automated plant with multiple faults diagnostics programs through various POKA-
YOKE systems.
Batch to batch variation in hardness is controlled.
Precise temperature control within set temperature.
Excellent microstructure, hardness profile.
Controlled Retained Austenite (Within the given limit)
Elevated type quenching resulted better quality
Better distortion (Ovality) controlled thus improve quality of the jobs.
Traceability of Batch history (Recipes. Alarms, etc.)
Online data monitoring system through SCADA.
The capacity is 1500 kg/hour.
 Note: The jobs after heating in Wiens troth furnace are bluish-grey or black in texture but
in Chugai-Ro the texture is Brownish in colour.

Process of Grinding
The Next stage is grinding, in order to give the rings the right form and dimension. The
operations occur in following Order:
Face Grinding It is the first operation for both inner & outer rings. Both faces are ground
simultaneously to give the final width.
Outside / Centre less Grinding Outside diameter of inner ring is ground to final dimension in
centre less grinding machine.
The final machining operations are carried out on parallel lines of grinding and finishing
machines. Inner Rings have the bores & raceways ground while Outer Rings have the only the
raceway ground. These operations are carried away by form dressed grinding wheels.
After grinding Operation, Honing is done.
After honing the rings are thoroughly washed with water based cleaning medium so Rings get
perfectly cleaned before Assembly is done.
Theory of Roller Manufacturing:
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
decoilersinto cold heading machines where it is cut into blanks and then pressed betweenhem
ispherical 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 (10
-10 m) in the roundness of bearing element can have an impact on bearing quality. The rollers
are then cleaned and dispatched for bearing assembly operation.
 Cage Manufacturing

Theory of 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.
Theory of Roller Bearing Assembly Line:

Finally the rings, Rollers & Cage which have been manufactured in different locations come
together for semi Automatic or Automatic Assembly. Raceways & Rings are Optically
Inspected separately prior to assembly. By selecting suitable combinations of ring & Rollers
sizes the required internal clearance is obtained. Rollers are fed into the cage which are together
fed in between the Outer & Inner Raceway & are fitted together through pressing. After
washing, the final inspection sequence starts which consist of number of checks such as running
accuracy, vibration level, outside and bore diameters and radial clearance of bearings. The
bearings are then automatically washed, coated with preservative, greased and fitted with seals
or shields before being packed.
 Chapter: Four
Projects Undertaken
 RESEARCH METHODOLOGY
Research can be defined as a scientific and systematic search for pertinent information in any
branch of knowledge. It is the pursuit of truth with the help of study, observation, comparison
and experiment. Research is, thus, an original contribution to the existing stock of knowledge
making for its advancement.

TITLE OF THE STUDY

Title of the study is Study of different Parameters of Taper Roller Bearings

DURATION OF THE PROJECT

The duration of the project is 4 months in N. E.I .Limited Jaipur from 5th Jan17 to 29
April17.

OBJECTIVES OF STUDY
The purpose of attending this training is to understand the different processes involved in the
manufacturing of bearings and its applications in different areas. The study also includes the
understanding of the industrial production processes and work culture present there.

Project 1: Study of width and flange width expansion and contraction

Description: The project includes study of width expansion and contraction in
cups and width and flange width expansion or contraction in cones after heat
treatment on two furnaces namely Chugai-Ro and Wiens troth.
Data: The project related data taken during the study are as follows:-
MATERIAL INSPECTION DATA CP

Job : 32208 Process Turning Date 09.01.17

WIDTH

S.NO W1 W2 Avg Width Var

1 20 40 30 20
2 30 40 35 10
3 40 60 50 20
4 20 50 35 30
5 10 40 25 30
6 30 50 40 20
 7 30 50 40 20
8 30 40 35 10
9 30 40 35 10
10 20 40 30 20
11 20 30 25 10
12 0 30 15 30
13 30 50 40 20
14 20 40 30 20
15 20 40 30 20
16 10 40 25 30
17 30 40 35 10
18 10 30 20 20
19 30 50 40 20
20 10 40 25 30
USL -50 50
LSL 50 0
X 32.00 20.0
8.2 7.3
Pp -2.04 1.38
Ppk -3.34
Max 40 60 50 30
Min 0 30 15 10

MATERIAL INSPECTION DATA CP

Date 10.01.17
AFTER
Job : 32208 Process HT CHUGAI RO

WIDTH

S.NO W1 W2 Avg Width Var

1 40 70 55 30
2 50 70 60 20
3 60 80 70 20
4 50 80 65 30
5 40 90 65 50
6 50 80 65 30
7 50 90 70 40
 8 50 70 60 20
9 60 80 70 20
10 40 70 55 30
11 50 70 60 20
12 30 60 45 30
13 50 80 65 30
14 60 100 80 40
15 50 90 70 40
16 50 80 65 30
17 50 80 65 30
18 40 70 55 30
19 60 100 80 40
20 30 80 55 50
USL -50 50
LSL 50 0
X 63.75 31.5
8.6 9.3
Pp -1.95 0.66
Ppk -4.43
Max 60 100 80 50
Min 30 60 45 20

MATERIAL INSPECTION DATA CN

Job : 31594 Process Turning Date 11.01.17

Flange WIDTH WIDTH

S.NO F1 F2 Avg Var W1 W2 Avg Width Var

1 -10 10 0 20 -30 -20 -25 10

2 -20 0 -10 20 -10 0 -5 10
3 0 10 5 10 -20 -10 -15 10
4 10 20 15 10 -10 0 -5 10
5 0 10 5 10 -10 0 -5 10
6 0 10 5 10 -20 -10 -15 10
7 -10 0 -5 10 -20 -10 -15 10
8 -10 10 0 20 -20 -10 -15 10
9 10 20 15 10 -20 -10 -15 10
 10 0 10 5 10 -30 -10 -20 20
11 0 20 10 20 -10 0 -5 10
12 -10 0 -5 10 -30 -20 -25 10
13 10 20 15 10 -20 -10 -15 10
14 -10 10 0 20 -40 -30 -35 10
15 -10 0 -5 10 -20 -10 -15 10
16 -10 10 0 20 -30 -20 -25 10
17 10 30 20 20 -20 -10 -15 10
18 -20 0 -10 20 -30 -20 -25 10
19 -20 0 -10 20 -20 -10 -15 10
20 -10 10 0 20 -10 0 -5 10
USL -50 50 -50 50
LSL 50 0 50 0
X 2.50 15.0 -15.75 10.5
9.0 5.1 8.3 2.2
Pp -1.86 2.27 -2.00 5.89
Ppk -1.95 -2.64
Max 10 30 20 20 -10 0 -5 20
Min -20 0 -10 10 -40 -30 -35 10

MATERIAL INSPECTION DATA CN

Job : 31594 Process After HT (Chugai-Ro) Date:12.01.17

Flange WIDTH WIDTH

S.NO F1 F2 Avg Var W1 W2 Avg Width Var

1 -10 10 0 20 10 20 15 10
2 0 -20 -10 20 30 50 40 20
3 -10 10 0 20 30 40 35 10
4 0 20 10 20 30 50 40 20
5 0 20 10 20 50 60 55 10
6 0 -20 -10 20 30 50 40 20
7 0 20 10 20 30 40 35 10
8 -10 10 0 20 30 40 35 10
9 0 20 10 20 40 50 45 10
10 0 20 10 20 30 40 35 10
11 -10 10 0 20 50 60 55 10
 12 0 -20 -10 20 30 40 35 10
13 -10 10 0 20 30 40 35 10
14 -10 20 5 30 20 30 25 10
15 -20 10 -5 30 40 50 45 10
16 0 20 10 20 20 40 30 20
17 10 30 20 20 40 50 45 10
18 -10 20 5 30 20 30 25 10
19 0 -20 -10 20 30 40 35 10
20 -10 20 5 30 30 60 45 30
USL -50 50 -50 50
LSL 50 0 50 0
X 2.50 22.0 37.50 13.0
8.5 4.1 9.7 5.7
Pp -1.96 2.27 -1.72 2.16
Ppk -2.06 -3.02
Max 10 30 20 30 50 60 55 30
Min -20 -20 -10 20 10 20 15 10

MATERIAL INSPECTION DATA CP

Date 17.01.17
Job : 32004X Process Turning Chugai-Ro

WIDTH
Width Size Avg
Variation
S.NO W1 W2 Size
1 -20 0 -10 20
2 -40 -30 -35 10
3 -30 -10 -20 20
4 -60 -20 -40 40
5 -20 10 -5 30
6 -20 0 -10 20
7 -40 -20 -30 20
8 -20 0 -10 20
9 -40 -10 -25 30
10 0 20 10 20
11 -30 0 -15 30
12 -20 0 -10 20
13 -30 0 -15 30
14 -20 0 -10 20
 15 0 10 5 10
16 -20 0 -10 20
17 -30 -10 -20 20
18 -10 20 5 30
19 -40 -10 -25 30
20 0 20 10 20
USL 50 50
LSL -50 0
X -13.0 23.0
14.0 7.3
Pp 1.19 1.23
Ppk 0.88
Max 0 20 10 40
Min -60 -30 -40 10

MATERIAL INSPECTION DATA CP

Date 18.01.17
Job : 32004X Process AFTER HT Chugai-Ro

WIDTH
Width Size Avg
Variation
S.NO W1 W2 Size
1 10 30 20 20
2 -20 -10 -15 10
3 -10 20 5 30
4 -40 10 -15 50
5 -10 30 10 40
6 0 20 10 20
7 -20 0 -10 20
8 10 30 20 20
9 -10 20 5 30
10 20 40 30 20
11 -10 20 5 30
12 0 20 10 20
13 0 30 15 30
14 10 20 15 10
15 20 30 25 10
16 0 20 10 20
17 -10 10 0 20
18 10 40 25 30
19 -20 20 0 40
20 20 40 30 20
 USL 50 50
LSL -50 0
X 9.8 24.5
13.4 10.5
Pp 1.24 0.81
Ppk 1.00
Max 20 40 30 50
Min -40 -10 -15 10

MATERIAL INSPECTION DATA CN

CHUGAIRO
Job :
32004X Process Turning Date 18.01.17

Flange Size WIDTH

Flange Size Avg Width Size Avg
Variation Variation
S.NO F1 F2 Size W1 W2 Size
1 -10 40 15 50 0 20 10 20
2 -60 -20 -40 40 -10 20 5 30
3 -30 0 -15 30 0 20 10 20
4 -40 -20 -30 20 -10 10 0 20
5 -30 0 -15 30 10 30 20 20
6 -50 -30 -40 20 0 10 5 10
7 -20 0 -10 20 0 10 5 10
8 -10 10 0 20 -10 10 0 20
9 0 10 5 10 -10 0 -5 10
10 -40 -20 -30 20 0 10 5 10
11 -50 -20 -35 30 10 30 20 20
12 -40 -20 -30 20 0 10 5 10
13 -30 -10 -20 20 0 20 10 20
14 10 30 20 20 -10 0 -5 10
15 -10 10 0 20 -10 0 -5 10
16 -30 10 -10 40 -10 10 0 20
17 -40 0 -20 40 -10 30 10 40
18 -60 -40 -50 20 -10 10 0 20
19 -40 -20 -30 20 10 30 20 20
20 -50 0 -25 50 -20 20 0 40
USL 50 50 50 50
LSL -50 0 -50 0
X -18.0 27.0 5.5 19.0
18.9 11.3 7.9 9.1
Pp 0.88 0.68 2.10 1.13
Ppk 0.57 1.87
 Max 10 40 20 50 10 30 20 40
Min -60 -40 -50 10 -20 0 -5 10

MATERIAL INSPECTION DATA CN

CHUGAI-RO
Job :
32004x Process: After HT Date: 19.01.17

Flange Size WIDTH

Flange Size Avg Width Size Avg
Variation Variation
S.NO F1 F2 Size W1 W2 Size
1 -10 30 10 40 20 40 30 20
2 -60 -30 -45 30 10 50 30 40
3 -30 -10 -20 20 20 40 30 20
4 -60 -30 -45 30 10 30 20 20
5 -30 0 -15 30 30 60 45 30
6 -40 -20 -30 20 20 30 25 10
7 0 20 10 20 10 30 20 20
8 0 20 10 20 10 30 20 20
9 -20 0 -10 20 10 20 15 10
10 -50 -30 -40 20 10 30 20 20
11 -50 -10 -30 40 20 50 35 30
12 -50 -30 -40 20 20 30 25 10
13 -60 -30 -45 30 20 40 30 20
14 -10 10 0 20 10 20 15 10
15 -10 10 0 20 0 20 10 20
16 -60 -30 -45 30 10 40 25 30
17 -50 10 -20 60 10 50 30 40
18 -70 -50 -60 20 20 40 30 20
19 -30 -10 -20 20 30 50 40 20
20 -10 -20 -15 10 0 40 20 40
USL 50 50 50 50
LSL -50 0 -50 0
X -22.5 26.0 25.8 22.5
21.3 11.0 8.6 9.7
Pp 0.78 0.73 1.93 0.95
Ppk 0.43 0.94
Max 0 30 10 60 30 60 45 40
Min -70 -50 -60 10 0 20 10 10

MATERIAL INSPECTION DATA CP

Date 23.01.17
Job : 32213 Process Turning Wiens troth
WIDTH
Width Size Avg
S.NO Variation
W1 W2 Size
1 -20 0 -10 20
2 10 20 15 10
3 -20 50 15 70
4 50 60 55 10
5 -10 10 0 20
6 -10 0 -5 10
7 -20 0 -10 20
8 0 10 5 10
9 -20 10 -5 30
10 10 40 25 30
11 0 20 10 20
12 -10 40 15 50
13 -10 0 -5 10
14 -10 0 -5 10
15 -10 0 -5 10
16 -90 -50 -70 40
17 -100 -50 -75 50
18 -70 -50 -60 20
19 -20 -10 -15 10
20 -10 10 0 20
USL 50 50
LSL -50 0
X -6.3 23.5
31.1 16.9
Pp 0.54 0.52
Ppk 0.47
Max 50 60 55 70
Min -100 -50 -75 10

Date 30.01.17
Job : 32213 Process After HT Wiens troth
WIDTH
Width Size Avg
Variation
S.NO W1 W2 Size
1 40 90 65 50
2 60 100 80 40
3 40 90 65 50
4 90 110 100 20
5 30 50 40 20
 6 40 70 55 30
7 30 50 40 20
8 50 80 65 30
9 30 60 45 30
10 40 90 65 50
11 50 80 65 30
12 40 90 65 50
13 30 90 60 60
14 40 90 65 50
15 30 60 45 30
16 -30 20 -5 50
17 -50 0 -25 50
18 -40 20 -10 60
19 20 40 30 20
20 40 70 55 30
USL 50 50
LSL -50 0
X 48.3 38.5
30.7 13.9
Pp 0.54 0.28
Ppk 0.02
Max 90 110 100 60
Min -50 0 -25 20

Material Inspection Data-CN

Job 31594 Process Turning Date: 06.02.17 Wiens Troth

Flange Size WIDTH

Flange Size Avg Width Size Avg
Variation Variation
S.NO F1 F2 Size W1 W2 Size
1 -50 0 -25 50 -50 -10 -30 40
2 -30 -10 -20 20 -10 10 0 20
3 -10 20 5 30 -20 0 -10 20
4 0 10 5 10 -10 10 0 20
5 -10 0 -5 10 -10 10 0 20
6 -10 20 5 30 0 10 5 10
7 10 20 15 10 10 20 15 10
8 -10 10 0 20 0 10 5 10
9 0 10 5 10 0 10 5 10
10 0 10 5 10 0 10 5 10
11 20 30 25 10 0 10 5 10
12 -20 0 -10 20 -10 10 0 20
13 0 20 10 20 -10 10 0 20
 14 -10 0 -5 10 0 10 5 10
15 -10 0 -5 10 -10 10 0 20
16 10 20 15 10 0 10 5 10
17 -20 -10 -15 10 -20 -10 -15 10
18 -30 -10 -20 20 -30 -20 -25 10
19 0 20 10 20 0 10 5 10
20 -20 0 -10 20 -10 10 0 20
USL 50 50 50 50
LSL -50 0 -50 0
X -0.8 17.5 -1.3 15.5
13.2 10.2 10.9 7.6
Pp 1.26 1.06 1.53 1.51
Ppk 1.24 1.50
Max 20 30 25 50 10 20 15 40
Min -50 -10 -25 10 -50 -20 -30 10

Material Inspection Data-CN

Process
Job 31594 After HT Date 13.02.17
Wienstroth
Flange Size WIDTH
Flange Size Avg Width Size Avg
Variation Variation
S.NO F1 F2 Size W1 W2 Size
1 -70 -10 -40 60 10 50 30 40
2 -30 0 -15 30 20 40 30 20
3 -20 0 -10 20 40 50 45 10
4 -20 0 -10 20 40 60 50 20
5 -20 0 -10 20 50 60 55 10
6 -20 10 -5 30 50 60 55 10
7 -10 20 5 30 60 70 65 10
8 -10 0 -5 10 50 70 60 20
9 0 10 5 10 40 50 45 10
10 -20 0 -10 20 50 60 55 10
11 0 20 10 20 60 80 70 20
12 -20 10 -5 30 40 60 50 20
13 -10 20 5 30 50 70 60 20
14 -20 10 -5 30 50 70 60 20
15 -10 10 0 20 50 60 55 10
16 0 20 10 20 50 60 55 10
17 -30 -20 -25 10 20 40 30 20
18 -40 -20 -30 20 20 30 25 10
19 10 20 15 10 40 50 45 10
20 -30 -10 -20 20 40 60 50 20
USL 50 50 50 50
LSL -50 0 -50 0
X -7.0 23.0 49.5 16.0
14.1 11.3 12.4 7.5
Pp 1.18 0.80 1.34 1.50
Ppk 1.02 0.01
Max 10 20 15 60 60 80 70 40
Min -70 -20 -40 10 10 30 25 10

Summary
of Cups

Standard Observed Parameter

Job Part Hard on Parameter Before HT After HT Remarks
Min Max Min Max Min Max
Expansion
Chugai-Ro
32208 Cup Width Found up
#1
-50 50 0 60 30 100 to 40 m
Expansion
Chugai-Ro
32004x Cup Width Found up
#1
-41 59 -60 20 -40 40 to 20 m
Expansion
Wiens
32213 Cup Width Found up
troth
-50 50 -100 60 -50 110 to 50 m

Summary
of Cones

Standard Observed Parameter

Job Part Hard on Parameter Before HT After HT Remarks
Min Max Min Max Min Max
Expansion
Found up
Width Chugai-Ro -50 50 -40 0 10 60 to 60 m
31594 Cone
#1 Expansion
Flange Found up
Width -50 50 -10 20 -20 30 to 10 m
Expansion
Found up
Width Chugai-Ro -40 60 -20 30 0 60 to 30 m
32004x Cone
#1 Contraction
Flange Found up
Width -50 50 -60 40 -70 30 to 10 m
 Expansion
Found up
Width Wiens -50 50 -50 20 10 80 to 60 m
31594 Cone
troth Contraction
Flange Found up
Width -50 50 -50 30 -70 20 to 20 m

Result: The result of this project shows that contraction and expansion of width
of cups and cones are in the defined standard limits of up to 50 m.

Project 2: Study of ovality and taper in case of 32010X cup

Description: The study includes checking of ovality (Out of Roundness/OOR)
and taper in 32010X cup after each process of heat treatment, grinding and
finishing and suggest for preventive measures if needed.
Data: The project related data are as follows:-
Material Inspection Data-CP
Job: 32010X
HT After Face Grinding After Rough OD Grinding
S.No. OOR OOR OOR
Taper Taper Taper
Side A Side B Side A Side B Side A Side B
1 30 20 105 20 10 165 20 20 140
2 40 60 30 20 60 90 60 50 75
3 30 30 30 30 20 85 40 30 75
4 30 40 75 20 30 95 30 30 120
5 50 40 25 40 50 85 60 50 65
6 100 110 85 50 120 175 110 110 110
7 60 80 130 60 60 200 70 70 170
8 100 100 180 100 100 250 90 110 220
9 60 70 85 60 60 130 30 60 145
10 30 30 140 30 20 215 40 40 190
11 50 40 35 50 40 95 50 30 80
12 70 70 80 70 60 135 70 70 120
13 110 120 85 110 110 120 50 110 80
14 70 70 80 80 70 115
15 110 100 75 100 70 135 100 80 120
16 30 30 50 40 20 130 30 30 80
17 80 100 50 80 100 110 100 130 85
18 100 110 115 80 80 150 110 100 145
19 70 60 65 70 60 115 70 60 105
20 20 20 30 30 30 100 30 20 45
21 70 90 40 90 80 65
22 150 120 185 140 100 250 150 120 215
23 20 20 130 20 20 200 30 20 165
24 120 140 90 130 130 130 20 150 55
25 90 20 95 90 70 210 100 80 180
26 40 20 60 40 40 110 50 50 100
27 70 60 125 70 170 120 100 90 155
28 50 40 35 50 40 95 50 40 65
29 70 80 135 80 80 200 100 90 175
30 30 30 100 40 40 160 40 50 145
31 90 80 65 70 70 130 80 80 120
32 20 20 30 10 20 85 20 30 55
33 90 120 85 90 120 145 100 120 120
34 30 30 100 40 60 170 40 40 140
35 80 90 65 70 70 110 90 80 85
36 70 60 165 60 50 215 60 40 200
37 80 100 120 80 120 180 30 100 165
38 40 40 10 40 40 60 40 40 30
39 60 50 55 40 50 105 60 40 80
40 160 170 125 70 70 130 160 160 170
41 40 50 75 60 50 135 60 70 115
42 60 80 100 70 80 155 70 70 130
43 20 50 45 30 40 115 60 50 135
44 40 40 120 50 50 180 50 50 150
45 30 20 155 20 20 100 50 40 185
46 50 30 90 40 50 155 60 50 145
47 90 100 95 100 90 155 90 90 130
48 80 100 70 80 110 135 100 110 105
49 90 80 115 70 70 150 100 90 135
50 30 30 80 40 40 130 30 30 10
51 30 40 115 60 60 180 60 50 155
52 50 50 50 50 60 115 40 50 105
53 100 200 50 100 130 155 120 120 140
54 130 130 100 140 150 155 140 140 130
55 30 30 140 50 50 180 50 60 165
56 60 70 35 50 60 95 70 80 55
57 80 110 115 110 110 160 110 120 145
58 10 10 70 40 30 115 20 30 95
59 30 30 110 60 40 170 60 40 140
60 50 60 65 50 80 115
61 150 150 100 150 160 145 150 160 125
62 60 100 50 80 80 100 90 100 65
63 60 50 75 60 60 130 70 70 110
64 170 200 85 190 210 140 200 210 115
65 60 50 125 90 80 175
66 30 30 60 30 30 100 30 40 95
67 90 80 55 90 90 120 100 70 105
68 100 80 40 130 120 95 140 120 70
69 100 100 100 110 110 160 110 110 120
70 120 140 90 120 150 145 130 150 110
71 70 100 95 100 100 160 100 100 140
72 30 60 95 20 80 160 40 70 135
73 100 90 135 100 110 185 90 30 120
74 90 60 55 60 60 120 70 80 95
75 70 70 120 100 90 175 110 100 145
76 60 50 115 70 50 160 90 60 145
 77 140 70 135
78 70 70 80 60 50 95 60 90 105
79 60 100 180 100 100 200 100 100 180
80 60 50 125 40 50 175 50 40 155
81 80 150 65 80 80 130
82 100 100 130 130 120 165 130 120 135
83 50 60 75 50 60 115 70 60 105
84 150 100 125 160 170 135 70 160 65
85 30 20 65
86 40 30 85 50 40 155 70 30 100
87 40 30 95 20 30 155 30 30 120
88 100 70 85 70 80 125 60 90 105
89 20 40 130 30 30 170 40 20 170
90 50 100 75 90 110 110 80 50 125
91 30 30 70 30 30 120 40 40 80
92 20 40 130 30 40 175 40 40 160
93 50 50 100 30 70 140 50 70 130
94 50 20 115 40 30 165 50 40 135
95 50 50 70 50 60 95 60 50 85
96 30 50 120 50 40 165
97 70 80 175 60 60 210 60 70 185
98 60 60 100 80 90 145 80 90 125
99 30 20 65 20 20 130 30 30 100
100 80 110 155 110 120 205 100 110 185
Min 10 10 10 10 10 60 20 20 10
Max 170 200 185 190 210 250 200 210 220

Out of Round Workpieces

Problem Possible Cause Correction
Workpieces out-of-round Insufficient stock to allow Leave more stock for
rounding up after clean-up. grinding, or improve
concentricity of stock.
Excessive clamping pressure Reduce clamping force to
causes distortion in minimum.
workpiece.
Wheel too hard or too fine Use proper grade of wheel.
causes excess grinding
pressure.
Interrupted cuts over Decrease feed and traverse
keyways, oil grooves, valve rates. Use largest wheel
parts, etc. possible.
Hard areas in workpiece. Decrease feed and traverse
speeds, change work speed.
Out of balance workpieces. If possible, counterbalance
the workpiece.
Lack of rigidity in machine Check all hold down screws
elements or fixtures. for rigidity.
Worn Tyco/way bearings Check Bearing surfaces.
 Worn or broken headstock Check headstock spindle
spindle bearings. bearings. Replace as needed.
Check jaws worn, unstable Replace worn parts or
chuck. change chucks.

Workpieces not ground straight

Problem
Workpieces not ground
straight, Taper, concavity, or
convexity apparent in
workpieces.
Possible Cause Correction
Shape being dressed into the Check for worn diamond or
grinding wheel. dresser out of alignment.
Work heating and expanding Increase cutting fluid flow.
during grinding. Decrease feed and traverse
rates.
Wheel pressure springing Decrease feed and traverse
thin workpieces. rates. Decrease amount of
feed per cut. Use steady rest.
Grinding wheel passes off Shorten table traverse to
workpiece at end of traverse. prevent wheel from leaving
workpiece. Balance over
travel wheel on both ends.
Incorrect dwell at end of Change the amount of dwell.
traverse.
Machine not level. Check level of machine
base. Relevel if necessary.

Result: The result of this experiment shows that out of roundness of the job is
in the defined standard limit of less than 200 m.
Project 3: Study of effect of change in tempering temperature
Description: The study includes the effect of change in tempering temperature
in the heat treatment process on the different parameters of cups and cones.
Data: The project related data taken during the study are as follows:
Tempering Temperature=170 C

Processing Condition
Zone 1 840.3C
Hardening
Zone 2 845.2C
Furnace
Zone 3 844.8C
Temp.
Zone 4 845.3C
Tempering Zone 1 170.2C
Furnace Zone 2 169.8C
Temp. Zone 3 170.1C
Prewasher Temp.
Quenching Tank Temp. 122.7C
Agitator Position 10+
 MATERIAL INSPECTION DATA - CP

Job : 30211 Process: Turning DATE:- 03.04.17

WIDTH BORE OD
W1 W2 Var LARGE FACE Avg OOR SMALL FACE Avg OOR Taper LARGE FACE Avg OOR SMALL FACE Avg OOR Taper
S.NO Avg Width B1 B2 Side A Side A B3 B4 Side B Side B O1 O2 Side A Side A O3 O4 Side B Side B
1 0 10 5 10 -10 10 0 20 -50 -10 -30 40 30 10 30 20 20 10 30 20 20 0
2 20 40 30 20 10 30 20 20 -10 10 0 20 20 30 40 35 10 20 30 25 10 10
3 0 10 5 10 -20 10 -5 30 -40 0 -20 40 15 10 40 25 30 0 40 20 40 5
4 30 40 35 10 0 20 10 20 -20 0 -10 20 20 0 20 10 20 0 20 10 20 0
5 20 30 25 10 0 30 15 30 -10 20 5 30 10 10 40 25 30 -10 40 15 50 10
6 20 30 25 10 -30 20 -5 50 -50 0 -25 50 20 10 40 25 30 10 30 20 20 5
7 30 40 35 10 -10 30 10 40 -30 10 -10 40 20 0 40 20 40 0 50 25 50 5
8 10 30 20 20 -20 50 15 70 -50 30 -10 80 25 0 60 30 60 -20 80 30 100 0
9 30 40 35 10 30 40 35 10 0 20 10 20 25 0 20 10 20 -20 30 5 50 5
10 10 20 15 10 10 30 20 20 -10 10 0 20 20 20 40 30 20 0 30 15 30 15
11 30 40 35 10 10 30 20 20 -10 10 0 20 20 20 40 30 20 10 30 20 20 10
12 20 30 25 10 10 30 20 20 -10 10 0 20 20 10 30 20 20 -10 30 10 40 10
13 10 30 20 20 -10 20 5 30 -30 0 -15 30 20 30 40 35 10 -10 30 10 40 25
14 0 10 5 10 10 30 20 20 -10 10 0 20 20 30 40 35 10 -10 30 10 40 25
15 10 30 20 20 0 40 20 40 -20 20 0 40 20 30 60 45 30 -10 60 25 70 20
16 0 10 5 10 10 30 20 20 -10 10 0 20 20 30 40 35 10 -20 30 5 50 30
17 0 10 5 10 10 30 20 20 0 20 10 20 10 30 40 35 10 0 30 15 30 20
18 10 20 15 10 10 30 20 20 -20 0 -10 20 30 20 30 25 10 -20 30 5 50 20
19 10 20 15 10 10 20 15 10 -10 10 0 20 15 30 40 35 10 0 30 15 30 20
20 10 30 20 20 -30 20 -5 50 -50 10 -20 60 15 10 60 35 50 -10 60 25 70 10
21 0 10 5 10 10 30 20 20 -10 10 0 20 20 30 40 35 10 -10 30 10 40 25
22 10 30 20 20 0 20 10 20 -20 0 -10 20 20 20 40 30 20 -20 20 0 40 30
23 0 10 5 10 0 20 10 20 -10 10 0 20 10 20 40 30 20 0 40 20 40 10
24 0 20 10 20 0 30 15 30 -20 10 -5 30 20 30 50 40 20 -10 40 15 50 25
25 0 10 5 10 0 20 10 20 -30 10 -10 40 20 30 40 35 10 0 20 10 20 25
26 10 20 15 10 10 30 20 20 -10 10 0 20 20 30 40 35 10 0 30 15 30 20
27 20 30 25 10 10 30 20 20 -10 10 0 20 20 30 40 35 10 -20 40 10 60 25
28 20 30 25 10 -10 10 0 20 -40 10 -15 50 15 10 30 20 20 -20 40 10 60 10
29 10 20 15 10 0 50 25 50 -30 40 5 70 20 10 60 35 50 10 70 40 60 5
30 -20 10 -5 30 0 30 15 30 -30 0 -15 30 30 20 50 35 30 0 40 20 40 15
USL 50 50 50 50 50 50 50 50 50 50 50 50
LSL -50 0 -50 0 -50 0 0 -50 0 -50 0 0
X 17.17 13.0 13.8 27.0 -5.83 31.67 19.67 29.67 22.00 15.83 42.33 14.50
11.0 5.3 9.5 13.4 9.92 16.42 5.07 8.19 13.49 8.52 18.88 9.32
Pp 1.51 2.31 1.75 0.57 1.68 0.37 1.99 2.03 0.69 1.96 0.14 1.27
Ppk 0.99 1.26 1.48 0.83 1.34
Max 30 40 35 30 30 50 35 70 0 40 10 80 30 30 60 45 60 20 80 40 100 30
Min -20 10 -5 10 -30 10 -5 10 -50 -10 -30 20 10 0 20 10 10 -20 20 0 10 0
 MATERIAL INSPECTION DATA - CP

Job : 30211 Process: After Heat Treatment (Chugai-Ro) DATE:- 04.04.17

WIDTH BORE OD
W1 W2 Avg Var LARGE FACE Avg OOR SMALL FACE Avg OOR Taper LARGE FACE Avg OOR SMALL FACE Avg OOR Taper
S.NO Width B1 B2 Side A Side A B3 B4 Side B Side B O1 O2 Side A Side A O3 O4 Side B Side B
1 40 60 50 20 10 60 35 50 -90 -60 -75 30 110 60 140 100 80 -10 50 20 60 80
2 40 60 50 20 30 90 60 60 -80 -10 -45 70 105 80 140 110 60 0 60 30 60 80
3 20 40 30 20 0 30 15 30 -90 -70 -80 20 95 60 80 70 20 10 30 20 20 50
4 50 70 60 20 -10 60 25 70 -100 -50 -75 50 100 30 100 65 70 -40 30 -5 70 70
5 40 60 50 20 40 80 60 40 -40 0 -20 40 80 100 130 115 30 30 70 50 40 65
6 60 120 90 60 10 40 25 30 -110 -60 -85 50 110 70 90 80 20 -20 0 -10 20 90
7 50 70 60 20 0 90 45 90 -110 0 -55 110 100 40 140 90 100 -20 70 25 90 65
8 50 70 60 20 -30 120 45 150 -140 -10 -75 130 120 0 170 85 170 -80 100 10 180 75
9 60 80 70 20 50 90 70 40 -80 -40 -60 40 130 40 90 65 50 -20 20 0 40 65
10 30 50 40 20 60 90 75 30 -50 -20 -35 30 110 100 130 115 30 10 40 25 30 90
11 50 70 60 20 50 80 65 30 -80 -40 -60 40 125 90 120 105 30 0 40 20 40 85
12 60 80 70 20 20 80 50 60 -80 0 -40 80 90 80 110 95 30 10 50 30 40 65
13 40 60 50 20 20 50 35 30 -90 -70 -80 20 115 70 110 90 40 -30 20 -5 50 95
14 40 80 60 40 20 120 70 100 -50 50 0 100 70 70 140 105 70 10 90 50 80 55
15 20 40 30 20 60 100 80 40 0 60 30 60 50 100 150 125 50 60 130 95 70 30
16 40 140 90 100 40 150 95 110 -40 110 35 150 60 90 170 130 80 30 120 75 90 55
17 30 50 40 20 10 80 45 70 -80 0 -40 80 85 40 130 85 90 -30 50 10 80 75
18 50 100 75 50 40 140 90 100 -50 100 25 150 65 90 180 135 90 20 130 75 110 60
19 70 90 80 20 0 70 35 70 -90 -20 -55 70 90 50 100 75 50 -30 30 0 60 75
20 40 70 55 30 -40 40 0 80 -100 -20 -60 80 60 50 120 85 70 -10 60 25 70 60
21 40 60 50 20 10 50 30 40 -50 10 -20 60 50 60 90 75 30 20 50 35 30 40
22 50 80 65 30 20 90 55 70 -80 0 -40 80 95 80 120 100 40 -10 50 20 60 80
23 30 70 50 40 0 80 40 80 -70 30 -20 100 60 60 120 90 60 0 70 35 70 55
24 30 50 40 20 0 100 50 100 -60 -40 -50 20 100 60 140 100 80 10 80 45 70 55
25 40 60 50 20 0 60 30 60 -120 -50 -85 70 115 60 90 75 30 -40 10 -15 50 90
26 40 60 50 20 50 80 65 30 -30 0 -15 30 80 80 110 95 30 30 50 40 20 55
27 30 50 40 20 60 140 100 80 -40 40 0 80 100 100 180 140 80 20 110 65 90 75
28 40 60 50 20 -20 50 15 70 -100 0 -50 100 65 40 100 70 60 -20 60 20 80 50
29 30 50 40 20 10 120 65 110 -50 60 5 110 60 60 170 115 110 10 140 75 130 40
30 30 50 40 20 0 60 30 60 -100 -50 -75 50 105 50 130 90 80 -20 40 10 60 80
USL 80 50 130 100 130 100 50 150 100 150 100 50
LSL -20 0 30 0 30 0 0 50 0 50 0 0
X 54.83 27.0 50.0 66.0 -40.00 70.00 90.00 95.83 61.00 29.00 65.33 66.83
15.5 17.0 24.6 30.2 35.16 36.77 23.30 20.60 32.63 27.74 34.11 16.48
Pp 1.07 0.45 0.68 0.37 0.47 0.27 -0.57 0.81 0.40 0.60 0.34 -0.34
Ppk 0.54 0.27 -0.66 0.74 -0.25
Max 70 140 90 100 60 150 100 150 0 110 35 150 130 100 180 140 170 60 140 95 180 95
Min 20 40 30 20 -40 30 0 30 -140 -70 -85 20 50 0 80 65 20 -80 0 -15 20 30
Tempering Temperature=190C
Processing Condition
Zone 1 840.5C
Hardening
Zone 2 850.1C
Furnace
Zone 3 856.1C
Temp.
Zone 4 850.1C
Tempering Zone 1 190.1C
Furnace Zone 2 189.9C
Temp. Zone 3 190.1C
Prewasher Temp.
Quenching Tank Temp. 115.2C
Agitator Position 2

MATERIAL INSPECTION DATA - CP

Job : 30211 Process: Turning DATE:- 10.04.17

WIDTH BORE OD
W1 W2 Var LARGE FACE Avg OOR SMALL FACE Avg OOR Taper LARGE FACE Avg OOR SMALL FACE Avg OOR Taper
S.NO Avg Width B1 B2 Side A Side A B3 B4 Side B Side B O1 O2 Side A Side A O3 O4 Side B Side B
31 0 20 10 20 0 20 10 20 -20 0 -10 20 20 20 40 30 20 10 30 20 20 10
32 10 20 15 10 10 30 20 20 -20 10 -5 30 25 20 40 30 20 10 30 20 20 10
33 0 20 10 20 -20 20 0 40 -30 10 -10 40 10 30 60 45 30 20 50 35 30 10
34 10 20 15 10 0 20 10 20 -20 0 -10 20 20 20 40 30 20 0 20 10 20 20
35 10 20 15 10 10 30 20 20 -10 10 0 20 20 0 20 10 20 -10 10 0 20 10
36 20 30 25 10 10 30 20 20 0 20 10 20 10 20 40 30 20 10 30 20 20 10
37 20 30 25 10 10 30 20 20 0 20 10 20 10 40 50 45 10 30 40 35 10 10
38 0 20 10 20 10 30 20 20 -10 10 0 20 20 20 40 30 20 10 30 20 20 10
39 0 10 5 10 0 30 15 30 -30 0 -15 30 30 40 60 50 20 20 50 35 30 15
40 20 30 25 10 10 30 20 20 -20 10 -5 30 25 30 50 40 20 30 40 35 10 5
41 10 30 20 20 10 30 20 20 0 20 10 20 10 20 40 30 20 10 30 20 20 10
42 20 30 25 10 0 20 10 20 -20 0 -10 20 20 20 50 35 30 20 40 30 20 5
43 -10 10 0 20 -30 50 10 80 -60 30 -15 90 25 0 70 35 70 -50 40 -5 90 40
44 0 20 10 20 0 20 10 20 -20 0 -10 20 20 30 50 40 20 30 40 35 10 5
45 20 30 25 10 10 30 20 20 -20 0 -10 20 30 30 40 35 10 10 30 20 20 15
46 -10 10 0 20 10 30 20 20 -20 0 -10 20 30 30 40 35 10 10 30 20 20 15
47 10 30 20 20 0 20 10 20 -30 -10 -20 20 30 30 40 35 10 20 40 30 20 5
48 10 20 15 10 -10 10 0 20 -40 -20 -30 20 30 30 50 40 20 30 40 35 10 5
49 10 30 20 20 0 30 15 30 -20 10 -5 30 20 30 50 40 20 10 40 25 30 15
50 20 30 25 10 -10 30 10 40 -40 0 -20 40 30 10 50 30 40 0 50 25 50 5
51 0 10 5 10 0 40 20 40 -20 20 0 40 20 20 40 30 20 10 40 25 30 5
52 20 30 25 10 10 30 20 20 -20 10 -5 30 25 20 40 30 20 10 30 20 20 10
53 20 30 25 10 0 20 10 20 -10 10 0 20 10 20 30 25 10 20 40 30 20 5
54 20 30 25 10 10 30 20 20 -10 10 0 20 20 20 40 30 20 20 40 30 20 0
55 10 20 15 10 -20 10 -5 30 -40 -10 -25 30 20 10 40 25 30 10 40 25 30 0
56 10 30 20 20 10 40 25 30 -10 20 5 30 20 20 50 35 30 10 40 25 30 10
57 10 20 15 10 -20 10 -5 30 -40 -10 -25 30 20 20 40 30 20 30 40 35 10 5
58 20 30 25 10 -10 10 0 20 -20 0 -10 20 10 20 40 30 20 0 30 15 30 15
59 20 30 25 10 -20 20 0 40 -50 10 -20 60 20 0 50 25 50 -10 50 20 60 5
60 20 30 25 10 10 30 20 20 -10 10 0 20 20 20 40 30 20 10 30 20 20 10
USL 50 50 50 50 50 50 50 50 50 50 50 50
LSL -50 0 -50 0 -50 0 0 -50 0 -50 0 0
X 17.33 13.3 12.8 26.3 -7.83 28.33 20.67 32.83 23.00 23.67 25.33 9.83
8.1 4.8 8.7 12.5 10.48 14.87 6.66 7.51 12.36 9.91 16.34 7.37
Pp 2.07 2.55 1.92 0.63 1.59 0.49 1.47 2.22 0.73 1.68 0.50 1.82
Ppk 1.35 0.00 1.43 1.34 0.76 0.89
Max 20 30 25 20 10 50 25 80 0 30 10 90 30 40 70 50 70 30 50 35 90 40
Min -10 10 0 10 -30 10 -5 20 -60 -20 -30 20 10 0 20 10 10 -50 10 -5 10 0
 MATERIAL INSPECTION DATA - CP

Job : 30211 Process: After Heat Treatment (Chugai-Ro) DATE:- 15.04.17

WIDTH BORE OD
W1 W2 Avg Var LARGE FACE Avg OOR SMALL FACE Avg OOR Taper LARGE FACE Avg OOR SMALL FACE Avg OOR Taper
S.NO Width B1 B2 Side A Side A B3 B4 Side B Side B O1 O2 Side A Side A O3 O4 Side B Side B
31 40 60 50 20 10 100 55 90 -110 -20 -65 90 120 60 150 105 90 -10 90 40 100 65
32 30 60 45 30 30 100 65 70 -100 -30 -65 70 130 60 140 100 80 -10 70 30 80 70
33 30 60 45 30 30 90 60 60 -100 -30 -65 70 125 100 150 125 50 30 80 55 50 70
34 40 60 50 20 30 80 55 50 -100 -50 -75 50 130 70 120 95 50 -10 40 15 50 80
35 40 70 55 30 40 100 70 60 -80 -20 -50 60 120 50 110 80 60 -10 60 25 70 55
36 50 100 75 50 20 120 70 100 -90 40 -25 130 95 60 130 95 70 10 100 55 90 40
37 50 80 65 30 30 100 65 70 -80 -10 -45 70 110 60 120 90 60 20 80 50 60 40
38 20 50 35 30 50 90 70 40 -80 -40 -60 40 130 90 140 115 50 20 70 45 50 70
39 30 60 45 30 -10 100 45 110 -170 -40 -105 130 150 70 150 110 80 -40 70 15 110 95
40 60 120 90 60 0 140 70 140 -140 30 -55 170 125 50 150 100 100 -40 100 30 140 70
41 50 100 75 50 -10 230 110 240 -150 140 -5 290 115 10 230 120 220 -60 170 55 230 65
42 40 60 50 20 30 50 40 20 -100 -80 -90 20 130 80 100 90 20 20 40 30 20 60
43 30 60 45 30 50 150 100 100 -90 0 -45 90 145 80 150 115 70 -10 80 35 90 80
44 40 60 50 20 50 100 75 50 -120 -70 -95 50 170 80 150 115 70 0 60 30 60 85
45 50 70 60 20 30 110 70 80 -120 -40 -80 80 150 60 140 100 80 -30 60 15 90 85
46 20 40 30 20 50 100 75 50 -100 -50 -75 50 150 70 140 105 70 -10 60 25 70 80
47 60 80 70 20 10 90 50 80 -110 -40 -75 70 125 60 130 95 70 10 80 45 70 50
48 40 80 60 40 0 70 35 70 -150 -90 -120 60 155 60 140 100 80 -20 50 15 70 85
49 60 80 70 20 60 90 75 30 -90 -70 -80 20 155 100 120 110 20 20 40 30 20 80
50 50 70 60 20 30 50 40 20 -100 0 -50 100 90 60 90 75 30 20 50 35 30 40
51 40 60 50 20 60 120 90 60 -80 -20 -50 60 140 90 160 125 70 0 60 30 60 95
52 50 70 60 20 50 80 65 30 -80 -40 -60 40 125 90 110 100 20 20 50 35 30 65
53 40 60 50 20 50 100 75 50 -100 -40 -70 60 145 60 120 90 60 10 70 40 60 50
54 50 90 70 40 40 120 80 80 -130 -40 -85 90 165 40 150 95 110 -40 60 10 100 85
55 50 70 60 20 30 100 65 70 -110 -40 -75 70 140 80 150 115 70 20 90 55 70 60
56 40 60 50 20 40 100 70 60 -110 -40 -75 70 145 50 150 100 100 -40 50 5 90 95
57 40 80 60 40 -10 100 45 110 -140 -30 -85 110 130 70 120 95 50 10 90 50 80 45
58 40 60 50 20 -20 100 40 120 -100 30 -35 130 75 40 180 110 140 -30 110 40 140 70
59 40 60 50 20 -10 80 35 90 -10 90 40 100 5 50 150 100 100 -20 80 30 100 70
60 40 70 55 30 10 150 80 140 -80 70 -5 150 85 70 180 125 110 -20 100 40 120 85
USL 80 50 130 100 130 100 50 150 100 150 100 50
LSL -20 0 30 0 30 0 0 50 0 50 0 0
X 56.00 28.0 64.7 78.0 -60.83 86.33 125.83 103.17 75.00 33.67 80.00 69.50
12.6 11.0 18.4 44.1 32.03 52.75 32.19 12.70 39.11 14.14 41.85 16.63
Pp 1.33 0.67 0.91 0.17 0.52 0.09 -0.79 1.31 0.21 1.18 0.16 -0.39
Ppk 0.64 0.63 -0.95 1.23 -0.39
Max 60 120 90 60 60 230 110 240 -10 140 40 290 170 100 230 125 220 30 170 55 230 95
Min 20 40 30 20 -20 50 35 20 -170 -90 -120 20 5 10 90 75 20 -60 40 5 20 40
 Summary of Tempering Study

TEMPERING TEMPERATURE TEMPERING TEMPERATURE

Parameters STD
170C 190C Parameters 170C 190C
Min. Max. Min. Max. OOR (0~100) 27 23
Width -20~80 m BORE
20 140 20 120 OOR (100~200) 3 7
CH#2 30211
BORE
L.F.
30~130m
-40 150 -20 230 30211 OOR (100~200) O.D. 3 5
S.F. -140 110 -170 140 TAPER (0~50) 3 1
L.F. 0 180 10 230 TAPER (50~100) BORE 15 3
O.D. 50~150m
S.F. -80 140 -60 170 TAPER (Above100) 12 26
HARDNESS 60/64 HRc 61~63 60~61 TAPER (0~100) O.D. ALL ALL
 Conclusion

This report describes the NBC bearing industry and its technology. 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. 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 .It has been long pursued policy
and commitment of National Engineering Industries Limited (NEI) to adhere to highest
standards of integrity professional and financial and business ethics in the operation of its
business. We believe that this organization has been handed to us by the various stakeholders
in "trust and we as professional managers are the "trustees" of those stakeholders. It is
therefore our responsibility to ensure that the organization is managed in a manner that protects
and furthers the interests of our stakeholders.
 SUMMARY

Bearings are mechanical devices employed to reduce friction between rotating equipment.
Global bearings market is estimated at USD 60 billion, which is dominated by multinational
companies like AB SKF (Sweden), Schaeffler Group (Germany), The Timken Company
(USA) and Japanese companies like NSK, NTN and JTEKT. Indian bearing market is
estimated at Rs 85 billion and it constitutes less than 4% of global bearing demand. In terms of
consumption, about 60% requirement is catered through domestic production while remaining
is met through imports. Industrial segment constitute major share of domestic bearing demand
which is largely driven by general machines/motors, electrical equipments (fans/appliances)
as well as heavy industries. Increasing automation in manufacturing units, thrust by
Governments Make in India program, spending towards railways and metros will support
growth of manufacturing and engineering sector, which augurs well for bearing industry.
Bearing industry is a technology and capital intensive industry, as end products finds
application in critical applications like aviation, automobile engines, railways and others.
Consequently, all major players have technology tie-up with their parent (SKF, FAG, Timken)
or with a foreign collaborator (NEI, NRB, ABC). Bearings are mainly manufactured using high
grade steel or alloy steel, which exposes them to global steel price movement. In general, raw
material accounts for about two third of companys cost structure or around 58% of bearing
manufacturers revenue. While bearing manufacturers have relatively strong pricing flexibility
owing to technology knowhow and strong aftermarket presence; their profitability was also
impacted during FY12-FY14 in the backdrop of increase in steel prices and weak demand. Out
of bearing raw material cost, bearing rings/races constitute major share of raw material
followed by that of rollers, cages and seals. Given that bearings find application in computer
hardware to aerospace industry, the complexity of bearing ring varies with its applications,
weight and size. The entry barrier are relatively lower for smaller bearing rings but
technological knowhow as well as manufacturing capabilities becomes a differentiating factor
as complexity/size of bearing increases. After witnessing flattish performance during FY12-
FY14, Indian bearing industry has witnessed healthy growth of 12.7% YoY during 9mFY15
supported by recovery in domestic automotive sector as well as improved off-take in industrial
activity. Operating profitability of bearing manufacturers has also recovered in FY15,
supported by benign commodity prices and improved operating leverage. With likely
improvement in key end user industries like energy/power (after coal block allocation), cement
(higher infrastructure/road spending), automotive and railways, ICRA expects bearing industry
to grow at healthy 12% CAGR over the medium term. The growth will be also supported by
stable replacement demand, which provides comfort during slowdown in core industries.
 BIBLIOGRAPHY
The following books and websites were referred to during the making of the project report.

1. In house journals and magazines of NEI.

2. The MOVE (magazine of NEI)

3. www.nbcbearings.com

4. www.skf.com

5. www.scribd.com

6. http://www.99business.com/articles/bearing-industry-in-india.html

7. https://en.wikipedia.org/wiki/Tapered_roller_bearing

8. http://www.arb-bearings.com/news_detail.php?id=36

9. http://www.grandviewresearch.com/industry-analysis/bearings-market

10. http://www.engineersedge.com/bearing_types.htm

11. https://chugai.co.jp/en/pro_01_parts_04/