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8/6/2019 Industrial Bearings Market in India
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Industrial Bearings Market inIndustrial Bearings Market inIndia :Issues and problemsIndia :Issues and problems
Ajay K Gupta
Managing Director
Kamtech Associates Pvt Ltd.
www.bearingsindustry.com
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Bearings of various types and sizesBearings of various types and sizes
are used for different sectorsare used for different sectorsThe major sectors are as follows:
Automobiles
Railways
Electrical Motors Electric Fans
Diesel Engines
Pumps
Machine Tools
Textile machinery and
Other heavy industries (Steel Plants , Sugar Plants, Process Plants, HeavyEngineering, Industries , Heavy Earth Moving Equipment , Cement Plants , Power
Generation Units
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Replacement MarketReplacement Market Replacement Demand is the after demand where as a part
of the maintenance of the machines or rotating machine ,the bearings are replaced by new bearings after it is failed
as natural life deterioration / wear or tear or due topremature failures and need replacement The replacementmarket represents the demand arising on account ofreplacing the used and worn-out bearings. The size ofreplacement market is dependent on equipment population
and frequency of maintenance. Replacement marketaccounts for 40% of total demand for bearing industry. Themargins in this market are relatively higher placed ascompared to OEM market.
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ContCont The replacement market is highly price sensitive and has
higher share of unorganized players and cheaper importedbearings. Exhibit4 represent the bearing demand per sector.
From the inception of the industry, bearing manufacturingin the country is dependent on foreign technology. Theorganised sector of the industry has imported know-how
from various internationally leading manufacturers ofbearings. The import of technology is generally restrictedto small and standard bearings. Technology borrowingspecifically for special bearings has not taken place so far.
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ImportsImports 30% of total demand for bearing industry is met by
imports. While a part of the imports come through officialchannels, there is also a huge volume of illegal imports.
Legal Imports generally represent the specialized bearingsnot manufactured in India. There are a large variants ofimported bearings, each holding a small market share inIndia.
Though, the quality of bearings manufactured by large players in India is comparable to world standards,domestic manufacture is not viable due to the small size ofthe market segment. It becomes uneconomical tomanufacture such type of bearings as it includes hugecapital expenditure.
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ContCont Illegal imports generally represent the entry of spurious
imports of bearings. In the past, the Indian bearingsindustry was highly protected on account of very high
import duties ranging from 150% to 240% ad- valorem. Asa result , illegal imports via smuggling and under invoicingof imports was the order of the day, accounting for a high45-50% of total imports. While duty rates have come downover the last few years, a few countries like China,Russia,
Eastern Europe dump their excess production at a very lowrate. This leads to a huge price differential betweendomestic and imported bearings (almost 40-50%),encouraging imports.
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Technological InterventionsTechnological Interventions The heavy dependence on borrowed technology indicates
that continuous efforts towards development have notyielded the desired results. Moreover, in spite of
collaborations the Indian industry generally has notachieved standards of quality close to international levels.Research and Development appears conspicuous more byits absence, in this industry.
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ContCont The industry undertakes routine development programmes
from time to time, in terms of additional bearing sizes orincreased production.
The various reasons that have been put forward forselection of a foreign collaborator are as follows :
The advantages associated with an internationally
renowned name.
Favourable terms and conditions of collaboration.
Quality of product. Assured access to latest developments at the
international level.
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COMPARISONOFTECHNICALCOMPARISONOFTECHNICAL
SPECIFICATIONSSPECIFICATIONS Since the product is standardized internationally, the
designs followed by the industry are more or less, thesame. Technical specifications are restricted to basic
parameters. Quality specifications adopted from thecollaborator's specifications, vary usually.
The bearing manufacturers have been adopting theequipment technology suitable for low volume production.
This was essentially due to the demand pattern of rolling bearings in the country being made up of a largediversified range of bearings in small quantities. In view ofthe very high cost of bearing equipment, most of the
bearing manufacturers did not venture to change theirequipment technology in favour of large batch production
or line production.
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THRUST AREASFORTHRUST AREASFOR
TECHNOLOGYTECHNOLOGYThe thrust areas for indigenous technology would include :
Development of indigenous machine tools and equipment fortesting, equivalent to international standards of precision.
The suitability of these machines in the Indian workingenvironment would be the critical factor.
Materials are available indigenously. However, the quality oftubes in particular, is not to the satisfaction of the industry.Moreover, consistency in supplies is also not experienced.
Cleanliness of material needs to be improved to a great extentto enable the industry to take basic advantage of quality rawmaterial. As regards forged rings, suppliers meeting sufficientquality standards need to be encouraged.
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ContCont Operational expertise of a very high calibre has to beachieved.
Maximum precision in the process, minimum handling
damages, and maximum cleanliness should be observed to
get the desired quality of bearings.
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HANDLINGHANDLING ANDSTORAGEOFANDSTORAGEOF
BEARINGSBEARINGS If possible, determine when a bearing was manufactured and if it was
properly stored before being purchased. Ask the bearing distributorabout his storage and handling procedures. It might be prudent to havea representative from your company personally visit the bearingdistributor to confirm how bearings are being stored. For example, atapered roller bearing should be stored with the taper down and neverstacked, one on top of another.
Store bearings in an attitude angle that will reduce or eliminate the possibility of damage to rolling elements and raceway. It may beweeks or months before the bearing is called into service. Reducing therisk of startup damage begins with proper storage.
Bearings are manufactured with extremely tight tolerances andtherefore require special care when moving or handling. Consider them
fragile at all times and make the effort to treat them as such. Consider the proximity of the storeroom to areas of the plant that are
affected by vibration. Could a railroad main line affect the storeroom?Does the plant have equipment that vibrates nearby buildings?Bearings subjected to even minor daily vibrations can becomedamaged while in storage. Take the necessary steps to insulate stored bearings from any vibrations.
Always store bearings in a clean and sterile environment. Keep themfree of moisture, dust, and chemicals.
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Bearing installation andBearing installation and
handlinghandling Take care when removing old or damaged bearings from their shafts
and housings. Be careful to not damage holders or surfaces where thenew bearings will be installed.
Clean all housings, shafts, holders, keyways, etc., before attemptingto install a new bearing. Inspect the shafts and equipment for damage.Install new bearings in as clean and dry an environment as possible. Ifpossible, use sterile gloves to prevent contamination. Contamination atthis stage will ensure a shorter bearing life cycle.
Carefully inspect the new bearing for any obvious damage that mayhave occurred during shipping, storage, or manufacture. Inspectbearings to determine if all parts are present. Bearings have beenknown to ship from the factory missing roller elements and other parts.Also, check for factory lubricant. Lack of lubricant from the factory
can cause rust.
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Storage of BearingsStorage of Bearings a. Avoid storing bearings in
places with high humidity.
b. Store bearings in a coolplace.
c. If bearings come packed
in a wooden box, take themout of the wooden boximmediately, and store themon a shelf.
d. Do not take bearings outof the cardboard boxes or
protective wrappings. e. Do not stack bearings
because the protective anti-rust compound may besqueezed out of bottom
bearings.
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Temperatures Effects onTemperatures Effects on
Mounted BearingsMounted Bearings I cant lay my hand on the bearing because it's operating too hot!" While this is a commonly heard
complaint, most sleeve and rolling element bearings can operate successfully at temperatures well
above the pain threshold of a human hand. The stabilized operating temperature of a bearing is the
result of many factors. The key influences on operational temperature are bearing style, lubrication
type, operational factors, environmental conditions and level of maintenance
The particular bearing style (ball, roller, sleeve, etc.), the shaft mounting style (slip fit, adapter
mounted, press fit, etc.) and auxiliary items (housings, seals, shields, flingers, etc.) all contribute to a
final operating temperature. For a given set of application conditions, a particular bearing type will
generate friction given off as heat. A typical bearing temperature rise range would be 40 to 80F (4
to 27C) for most industrial applications. However, a bearing temperature rise over ambient of up to
a 120F (49C) can be observed at extreme conditions
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MOISTUREMOISTURE
Moisture is generally referred to as a chemical contaminantwhen suspended in lubricating oils. Its destructive effectsin bearing applications can reach or exceed that of particle
contamination, depending on various conditions. Likeparticles, vigilant control must be exercised over entry ofwater to minimize its accumulation in the lubricants and itsdamage to bearing surfaces
Once water enters the casing of a machine where bearingsare used, such as an engine, turbine, or gear box, it maymove through several chemical and physical states. Thesechanges are complex, but important to understanding howto control and analyze its movements. To begin with, waterwill enter an oil in generally one of the five following ways
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PRE LOADPRE LOAD Preload is the force that is applied to a
bearing assembly during installation to
remove the axial play and to furthercompress the bearing to provide both axialand radial stiffness. It is an important designparameter, affecting rotational performance
and lifetime of a bearing assembly. Afterpreload, the resulting ball contact angle must be considered
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Minimum LoadsMinimum Loads
Rolling element bearings require minimum loads to function
satisfactorily. This is because the balls or rollers must rotate
when carrying the load.
Skidding will occur if the load is not sufficient to overcome cage
friction and the resistance from the lubricant, especially during
periods of low temperature operation.
The consequent is damage to both raceways and rolling
elements. Usually the load from the shaft assembly is sufficient
to prevent this from happening. In cases where the load is not
sufficient, the bearings can be pre-loaded by the use of springs.
In some instances reduced bearing internal clearance may help
but great caution should be taken to avoid a high pre-load
condition, which can result in catastrophic failure
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Minimizing Bearing DamageMinimizing Bearing Damage
Inclusion-A fatigue crack starts just below the
raceway surface at a nonmetallic inclusion (micro
impurity) and propagates to the surface.
Geometric Stress Concentration-Damage occurs in
a localized region of high stress at the raceway
edges due to high rolling loads and misalignment.
Point Surface Origin-Damage originates at a
localized, high-stress point on the raceway surface,
typically caused by insufficient lubricant film
thickness separating the bearing surfaces.
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Degrees of Life enhancementDegrees of Life enhancement
Various degrees of power density can be applied to
enhance bearing life and durability,
Typically an enhanced bearing will provide a minimum of
1.5 times the life of a standard bearing, although in more
severe operating conditions, performance gains of 4-5times are not uncommon.
To clearly identify the design and life enhancement
potential of power dense bearings, the designer should
make a detailed application analysis of the many bearing
design variables as well as operating and environmental
factors. Bearing manufacturers can apply advanced
software to accurately quantify these effects.
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Fully-enhanced bearings increase life by
minimizing the three primary modes of
fatigue damage through the
incorporation of cleaner steel, super-
finished rolling contact areas (rollers and
raceways) and optimized geometry.Super-clean, air melt steel provides an
additional 30 percent increase in life to
fully enhanced bearings.
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Selectively-enhanced bearings offer the flexibility
of selecting or applying only those
enhancements needed to economically optimize
performance in specific applications. Service life
can increase within the range shown in Figure
and depends both on the specific enhancements
chosen as well as the specific operatingconditions.
Such bearings fill the performance gap between
standard and fully enhanced bearings. Selectively
enhanced bearings are especially cost-effectivein large bearings (8 to 84" OD), where fully-
enhanced features may not be readily feasible.
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Bearing selectionBearing selection Procure the correct bearing for the application. Often, the
replacement bearing is not compatible with the equipment where itis to be installed. Depending upon the age of the equipment,advances in bearing technologies may exist that make the OEM
bearing obsolete. Knowing the limits of the equipment and what bearing best suits the application will save time and money.
Determine the maximum load for the bearing. This is importantboth vertically and horizontally.
Determine the minimum and maximum running speeds for thebearing. This will help determine the correct lubricant and bearingfor the application.
Determine all possible environmental conditions to which thebearing will be exposed. Very hot or cold environments oftenrequire varied bearing specifications. This may, in turn, change thetype of lubricant and relubrication requirements as well.
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Materials -- Improved micro-cleanness, alloys and processing
techniques .
Design -- Improved internal geometry, such as roller/race profiles, to
carry higher loads and handle misalignment within a given envelope
Tribology -- Optimized interaction of bearing surface topography withlubricants, lubricant additives and debris .
Manufacturing -- Advances in processing techniques for surface
finish, plus precision tolerances, improved profiles, material
cleanness and heat treatment.
Application Analysis -- Advanced performance-prediction tools that
consider the effects of bearing design features as well as significant
bearing environmental influences such as load zone, misalignment,
lubrication,
temperature,
housing rigidity,
load and speed
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Bearing repair: An alternative toBearing repair: An alternative to
replacementreplacement
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Bearing repair is not a new concept, nor has it changed a
great deal over the years and that's good news.
Repairing damaged bearings is a precise science that
has been fine-tuned over time through careful and
gradual enhancements to provide superior results.
Just as new designs and technologies improve bearings,growing expertise and technology of bearing repair
continues to increase the reliability and performance of
reconditioned bearings, keeping it an economical
alternative to purchasing new bearings
Knowing and understanding the value of bearing repair
means knowing what repair can do, when to use it, and
where to get it done.
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Bearing LifeBearing LifeBearing life refers to the amount of time any bearing will perform in a
specified operation before failure. Bearing life is commonly defined interms ofL-10 life, which is sometimes referred to as B-10. This is the life
which 90% of identical bearings subjected to identical usage applications
and environments will attain (or surpass) before bearing material fails
from fatigue. The bearings calculated L-10 life is primarily a function of
the load supported by (and/or applied to) the bearing and its operating
speed.
Many factors have a profound affect on the actual life of the bearing.
Some of these factors are:
Temperature
Lubrication
Improper care in mounting resulting in: Contamination
Misalignment
Deformation
As a result of these factors, an estimated 95% of all failures are classified
as premature bearing failures.
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The Butterfly EffectThe Butterfly Effect
An event as small asa butterfly flappingits wings in Texascould set off a chainreaction of eventsculminating in asnow storm inTibet.
extraordinary results
can stem from attention to
the smallest details.