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JSC EPK Volzhsky

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JSC EPK Volzhsky

Production of over 500 types of bearings for car industry and agricultural machinery

JSC EPK Saratov

Design and production of over 1000 types of bearings for agricultural machinery, metallurgy, defense, railway and automobile industry

Stepnogorsky Bearing Plant

Production of 12 types of bearings for rolling stock

Moscow

Volzhsky

Stepnogorsk

KAZAHSTAN

SamaraSaratov

Russian Federation

St. Petersburg

Omsk

Irkutsk

Nizhniy Novgorod

Central warehouse

Domodedovo

Aviation Bearing Plant (Samara)

Design and production of over 5,000 types of special purpose bearings for aircraft engines and for machine-building industry

ManufacturingplantLogistic center

Moscow plant

Design and production of over 800 types of industrial and rail bearings

JV EPK-Brenco

Design and production of TBU bearings

Geography of Corporation’s enterprises

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March 25, 1961Start-up of first turn on the plantFirst bearings were delivered to the Stalingrad tractor

factory

1971-1975 Development of bearings and providing of serial production for JSC AVTOVAZ

1974-1975Development of bearings and providing of serial

production for JSC KAMAZ.Development of new bearings for automobile models:

Moskvich, Zaparozhec and others.

1978-1980Development of double-row bearings of closed type for

wheel hubs and delivery to JSC AVTOVAZ

1996 Development of high precision bearing production for machine tool industry

1999Lloyd’s Register Quality Assurance certificate of

conformity to quality requirements (Great Britain) ISO 9001:1994

History of the plant

JSC EPK Volzhsky

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2001 Plant joined to holding company JSC EPK

1980 – 2003

•Development of own machine tool building manufacture(creating a department and a workshop of the production motorization and automation)• Bearing development

- for foreign cars on the secondary market- for railway transport (axle boxes)

• Creating the sector of bearing modular production

2005Delivery of bearings and automobile parts to the

companies Daimler AG, GKN, BPW, SAF, ZF, Schmitz Cargobull and others

2008 Production of the double-raw ball bearing of enclosed type for JSC AVTOVAZ

2011

•Certificates of conformity to quality requirements ISO/TS 16949:2002 and ISO 9001:2008 from company TÜV Rheinland •Delivering bearings for the fuel pumps to Czech company Motorpal

2008 – 2014 Development of capacities for forging production

History of the plant

JSC EPK Volzhsky

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Development strategy

• Expansion of bearing market share for automobileconveyor enterprises with development of newproducts and delivery to the foreign automobile plantsin Russia

• Expansion of European sales markets

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Development strategy

Development of the existing production of taper and cylindrical bearings with diameter Ø30 – Ø200 mm

Increasing of capacities for production of hub double-row ball bearings of type Hub Unit First generation for passenger cars

Сreating the production of units for soil processing machines (UPA 3, UPA 4)

Creating the production of type Hub Unit II generation for the passenger cars

Creating the production of double-row taper bearings of type Hub Unit I and II generation for freight motor transport

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JSC EPK Volzhsky bearings

roller bearings Ball bearings

taper bearings cylindrical bearingsdouble-row

single-row double-row single-row

JSC EPK VolzhskyОАО "ЕПК Волжский"

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JSC EPK Volzhsky Test center makes all types of bearing tests in accordance to GOST 520-2011 requirements

JSC EPK Volzhsky Test Centeris accredited in Russian Federal Accreditation Service. Accreditation certificate ROSS RU. 0001.22 SHP06 for

making the metrological, vibroacoustic, bench, metallographic, and other tests, according to accreditation sphere

Test center

JSC EPK VolzhskyОАО "ЕПК Волжский"

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• antitorque moment measuring

• service life testing

• leakage testing in difficult environment

• testing to determine the optimal axle clearance of the bearing in unit

• geometric test

Bearing testing

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Service life testing

Test conditions :

Fr = 600 kgf (point of load application is displaced from bearing middleon 1,4 mm in direction of the support bearings)

Fа = 170 kgf

К = 285 mm (shoulder of applying the axle load)

Tightening torque for fastening nut of the bearing 280 Nм

Rotation frequency of the inner ring n=350/700 rpm

Test time is 5 mln cycles

Продолжительность испытаний – 20 млн. циклов

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The bearing production technology

Manufacture of preparation ( rings, rollers)

- pressing of blanks, turning- cutting, boring, semi-hot calibration

Heat treatment- Annealing of a blank- Quenching of the bearing rings, rollers

Finishing operations- Grinding- Finishing operations- Super-finishing

Bearing assembly- assembly- washing- packing

OAO “EPK Volzhsky”ОАО "ЕПК Волжский"

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Making a blank from a bar for bearing rings

Through-type aggregate for annealing the blanksof bearing rings A/SP-1200 “Elterma”

Blanking operations

Producing the blanks for the bearing rings on the hot forming line L-324,

JSC EPK Volzhsky

Annealing the ring blanks provide:• hardness reducing for machining

• preparation of microstructure for following heat treatment in order to

achieve more metal homogeneity

• internal stresses relieving

ОАО "ЕПК Волжский"

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Production capacity

Turning processing of rings of bearings on machine tools with CNC

OAO “EPK Volzhsky”

Turning process

ОАО "ЕПК Волжский"

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Production capacityGrinding of the bearing rings

Processing of bearing rings by the

grinding-assembly module allows to exclude other types of bearing rings

Finishing operations are made on the modern grinding equipment

OAO “EPK Volzhsky”"

ОАО "ЕПК Волжский"

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turning

Grinding-Assembling module

Machining the rings

JSC EPK Volzhsky

on the multi-spindle semi-automatic lathes

ОАО "ЕПК Волжский"

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Manufacture of bearing cages Manufacture of the cages

of bearing on presses AIDA, Weingarten, Erfurt

на прессах с применением манипуляторов

Production capacity

Manufacture of cages of bearings on presses with using of manipulators

OAO “EPK Volzhsky”ОАО "ЕПК Волжский"

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Making the roller

JSC EPK Volzhsky

Cold forming from a bar

Grinding

Grinding of end face sphere

Superfinishing

ОАО "ЕПК Волжский"

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Providing of traceability and identification

According to requirements ISO/TS 16949 the plant has:

• Documentary procedure 7.5.3-01 “Marking and back traceability” defines the order of providing the identification and traceability of the assembled bearings and its parts

• separation of the work flows and obligatory cleaning the work flow to prevent the mixing the close by size parts

• through accompanying documentation for process flow from metal obtaining to packing and delivering the finished products:

- route sheets- quality performance charts

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For testing there are laboratories equipped by facilities for precision measurements

Measuring instruments

- linear and angular values(length gages, sine bars, optical calipers,

interferometers)

- micro geometric values:roughness, linearity, circular deviation,

waviness deviation (profile meter, profile testing instrument,circular geometry gauge)

JSC EPK VolzhskyОАО "ЕПК Волжский"

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Manual control devices for measuring the linear and angular values

Measuring instruments

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JSC EPK VolzhskyОАО "ЕПК Волжский"

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Bearing testing

Material testing

metallographic research of the ringsand rollers for the compliance to

normative-technical documentationrequirement

• steel chemical composition• grain direction (microstructure)

• heat treatment quality (microstructure)

• hardness and other

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Development and productionthe taper and cylindrical, roller and ball bearings is certified by company TÜV Rheinland in accordance torequirements ISO/TS 16949:2009 and ISO 9001:2008

JSC EPK Volzhsky has declaration of product conformity

to requirements of Technical rulesabout wheeled vehicle safety

Product validation on the market

JSC EPK VolzhskyОАО "ЕПК Волжский"

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ВПЗ

Double-row taper roller bearings

Single-row cylindrical roller bearings

- Front wheel hubsand rear wheel hubs

- Axle- Engine

- Transfer case- Gearbox- Engine

Single-row taper roller bearings

- Steering- Gearbox differential- Axle- Wheel reduction gear

Double-row ball bearings

Partners-consumers

JSC EPK Volzhsky"

- Front wheel hubsand rear wheel hubs

- Front wheel hubsand rear wheel hubs

- Engine- Gearbox

http://upload.wikimedia.org/wikipedia/ru/7/7e/Daimler_AG.svghttp://upload.wikimedia.org/wikipedia/ru/7/7e/Daimler_AG.svg

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Thank you for your attention!

Слайд номер 1Слайд номер 2Слайд номер 3Слайд номер 4Development strategyDevelopment strategyJSC EPK Volzhsky bearingsTest centerBearing testingService life testingThe bearing production technologyBlanking operationsProduction capacityProduction capacityMachining the ringsProduction capacityMaking the rollerProviding of traceability and identificationMeasuring instrumentsMeasuring instrumentsBearing testingProduct validation on the marketСлайд номер 23Слайд номер 24