A PROJECT REPORT

ON

A PRATICAL TRAINING SEMINAR REPORT

NATIONAL BEARING COMPANY

Submitted for the partial fulfilament

Bachelior of technology

In

Mechanical engineering

3RD YEAR TRAINING REPORT

DATED FROM 30TH MAY TO 29TH JUNE

SUBMITTED SUBMITTED

BY TO

RAJ PAREEK MR. VINIT2012BTME024 DEPARTMENT OF MECHANICAL ENGINEERING DR K.N. MODI UNIVERSITY(NEWAI)

  Project report on training in National engineering industry  TABLE OF CONTENT

Executive Summary

Acknowledgement

Preface

Introduction to Bearings

Bearing industry

Global Scenario

Indian Bearing Industry

Threats and limitation to Indian Market

Organizational Profile

Introduction

Mile Stones

Company Profile

Research & Development

Quality Management System

Bearing Manufacturing

Flow of Material in Bearing Industry

Classification of Bearing

 Types & Features of Rolling Bearing

Bearing Designation in NBC

Ball Bearing Manufacturing

Inner & Outer Ring Manufacturing

Cage Manufacturing

Ball Bearing Assembly Line

Roller Bearing Manufacturing

Roller Manufacturing

Cage Manufacturing

Roller Bearing Assembly

Heat Treatment

Heat Treatment Process

Hardening Procedure for High Carbon Steel

Hardening Procedure for Low Carbon Steel

Salt Bath Furnace

Heat Treatment flow Chart

Conclusion

EXECUTIVE SUMMARY  NBC Bearings Limited, a member company of C.K. BIRLA group of Companies - is aleading player in the Indian Bearing industry.The company manufactures a very wide range of bearings conforming to the stringent international quality standards. NBC manufacturing plants, located at Gunsi (Newai) Rajasthan, Manesa

r Haryana &Jaipur - was incorporated in the year 1946. Its feature the most advanced manufacturingtechnology. The company i s ce r t i f ied to ISO/TS 16949, ISO 9001, and ISO 14001standards. NBC India is a leading OEM supplier to the automotive industry, mechanical andelectrical engineering industry, besides the Railways.Bearings produced at the EOU plant have gained ready acceptance and recognition of customers located in India & Indian Sub Continent, Europe & Africa. NBC’s main competitors in bearing are SKF, TIMKEN, NRB, FAG and other local brands.OBJECTIVE:The main objective of this training is to learn different engineering processes and to develop ski l ls and with that at t i tude. I had done my engineering training with NBCBearings Ltd. In this one month training period I had seen different work and key responsibility of various bearings department.Training was started with brief introduction program of NBC Bearing Ltd. and plant visitof different department. I t was such a great experience to learn various engineering  production methods used now a days & to better correlate the theoretical knowledge with practical observations and understandings.

ACKNOWLEDGEMENT Project report on training in National Bearing CompanyAs the technologically advancement will enable us to get the environmentwe desire. The basic beatitude, bliss, euphoria & our endeavor to achievecomplete and perfect knowledge in the field we choose that accompany thes u c c e s s f u l c o m p l e t i o n o f a n y t a s k w o u l d n o t b e c o m p l e t e w i t h o u t t h e expression of appreciat ion of simple vir tues to the people who made i t  possible. So, with reverence honor I acknowledge all those guidance andencouragement has made successful completion of training.I am thankful to Mr . Ankit purohitfor her constant cooperation and able guidance & without his support this work would not have been so understandable.

I am also very thankful to all respected persons who have directly or indirectly helped me in my earnest effort to accomplish this training.

Project report on training in National engineering industry

Technical Collaboration with NTN Corporation of Japan for Ball,Cylindrical & Spherical Roller BearingModernization in Three PhasesISO – 9001 CertificateTechnical Collaboration with M/S Izumi Kogyo Co. Ltd., Japan for Machine Retrofitting/Remanufacturing & OverhaulingTechnical Collaboration with NTN Corporation, Japan for TaperedRoller Bearing & Hub BearingIV-Phase Modernization StartedImplemented st

Phase of SAP-ERP SolutionsQS-9000 & ISO-14001 CertificationTs-16949 CertificationAAR Certification M-1003 for Cartridge Tapered Roller Bearing17

Project report on training in National engineering industry

Company Profile

National Engineering Industries Ltd., Jaipur was founded in the year 1946 as a pioneer industry in the field of bearing manufacture by the renowned industrialist, late Shri B.M.Birla, under the name of "National Bearing Company Limited." The first bearing wasmanufactured in 1950 with a modest start of 30,000 bearings in 19 sizes. The company isnow manufacturing nearly 3.8 million bearings per month in over 500 different sizesranging from 6 mm bore to 1300 mm outer diameter and has the capacity to manufacture bearings upto 2000 mm outer diameter. At NEI, the development of

bearings is a never ending job. With ever increasing activities and grant of industrial licenses for other vitalindustries and manufacturing of Roller Bearing Axle Boxes for Railway Rolling Stock,Steel Balls, Tapered Roller Bearings, Spindle Inserts etc., the name of the company waschanged in 1958 to "National Engineering Industries Ltd." retaining its original trademark NBC.The industry is spread over 118 acres of land in Jaipur and 56 acres in Gunsi (Newai).This is the only unit in the country manufacturing wide variety and range of bearingssuch as Ball Bearings, Steel Balls, Tapered Roller Bearings, and Cylindrical Roller Bearings & Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings,Cartridge Tapered Roller Bearings and Large Diameter special Bearings in separate fullyequipped factories. The development of National Engineering Industries Ltd., was pioneered with a theme "Indigenisation and Self-reliance".NBC Bearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors, ElectricMotors, Railway wagon, Coach and Locomotive manufacturers as Original Equipmentand Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and ThermalPower Plants all across the country.

Mission of Company

“Keeping Nation on the Move”

PLANT AT JAIPUR

i)Ball Bearing

Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are manufactured within-process and post-process manufacturing facilities and centrally air conditionedassembly lines with auto gauging in grinding and testing equipments. The latest advancedtechniques of manufacturing and Quality Assurance are implemented to meet the rapidincrease in demand for Quality, diversity of specifications and new types of bearings.This Division is spread over a covered area of 14,694 Sq. Meters.

ii)Steel Ball

Precision Steel Balls up to 25 mm diameters for NBC Bearings are manufactured on precision grinding and lapping machines to achieve super finished surface, accuracy androundness as per ISO standards.This Division is spread over a covered area of 4,700 Sq. Meters.

PLANT AT GUNSI (NEWAI)

Established in the year 1980-81, as an expansion project of NEI Ltd., The factory isequipped with fully automated grinding lines with electronic in-process & post- processgauging and centrally air-conditioned assembly lines with auto gauging and testequipments for quality and reliability

Project report on training in National engineering industry

Collaboration

BRENCO Incorporated , U.S.A.

Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and locomotives.

NTN Corporation , Japan

Since 1985-For Ball Bearings, Cylindrical & Spherical Roller Bearings. Since 1997-For Tapered Roller Bearings.

Izumi Kinzoku Kogyo Co. Ltd., Japan

Since 1996 - For re-manufacturing, retrofitting and overhauling of grinding and super finishing machines for bearing races.24

Network of NBC the nei network in all india is

Flow of Material in Bering IndustryChennai

Gurgaon

Jaipur

Kolkata

Mumbai

Newdelhi

Newai (gunsi)

Pune

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

Material is sendback to vendor

Material is send to specific departments for further Operations

The following Operations are done:

Customer of Company Domestic customer

. Ashok Leyland

. Bharat benz

. Bajaj auto

. Escort tractors

. Hero motocop

. Honda motorcycls

. Indian railway

Maruti suzuki

Tata motors

International customers

Amsted rail (usa)

Agrale brazil

Bonfiglio oil (itly)

Con met (usa)

Nissan (japan)

Rio tinto( australia)

1.Hardening Or Heat Treatment

2.Rough Grinding (Face, O.D., Inner & Track)

3.Finish Grinding (Face, O.D., Inner & Track)

4.Inspection

5.Assembly

Grinding process

Outer grinding

Grinding process Izumi (kN2130)

OUTER TRACK GRINDING

ASSAMBLY DEPARTMENT

The Digits & Indications are:-

1stDigit – Bearing Type 6207 6- deep groove ball bearing

2ndDigit – Width or Height Series 2 – diameter series 2

3rdDigit – Diamete Series 07- nominal bore diameter (35mm)

Last 2 Digits – Bore Diameter n

Inner & Outer Ring M

Theory

Ball Bearings are generally made of High Carbon Steels, such as AISI 52100 because thelife of the bearing steel is determined by the purity of cleanliness of steel. The 52100steel are subjected to a rigorous purification process with stringent controls in order tomeet the ever-increasing standard of cleanliness & eliminating non-metallic inclusions &impurities. The impurities are removed through various processes such as

vacuumdegassing 

&

consumable electrode vacuum melting (CEVM)

. The Chemical compositionof the SAE 52100:

ElementCSiMnSPCrMinimum

0.980.150.25--------1.30

Maximum

1.100.350.450.0250.0251.60

Oxygen Content

– Not more than 15 ppmThe Turning operations are divided into various lathe Operations viz. O.D., face, track &Bore. All these operations are done on production lathe machines.The Hardening of steel is achieved by heat treatment process in which the steelmicrostructure is manipulated by cycles of heating & quick cooling to obtain theoptimum hardness range for steel – usually on the order of 60 to 64 on Rockwell CHardness 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 instructure from Body Centered Cubic Structure found at room temperature to FaceCentered Cubic Structure found in Austenite Region. When Steel is suddenly QuenchedMartensite is formed which is extremely strong and If steel is Quenched slowly thenPearlite is formed which is extremely Soft. 31

anufacturing. The Next stage is grinding, in order to give the rings the right form and dimension. Theoperations occur in following Order:

Face Grinding – It is the first operation for both inner & outer rings. Both facesare ground simultaneously to give the final width.

Outside / Center less Grinding –

Outside diameter of inner ring is ground to finaldimension in center less grinding machine.

The final machining operations are carried out on parallel lines of grinding andfinishing machines. Inner Rings have the bores & raceways ground while Outer Rings have the only the raceway ground.

These operations are carried away byform dressed grinding wheels.

After grinding Operation, Honing is done.

After Honing the rings are thoroughly washed with water based cleaning medium soRings get perfectly cleaned before Assembly.

Cage Manufacturing

Flow Chart

Raw Material

(Narrow width Cold Rolled Sheet IS 4397)

Blanking & Punching

Forming (Pocketing)

Inspection & Batch Checking

Shot Blasting/Vibro

Theory

The cages for various bearing sizes are manufacture from Cold Rolled (C.R.) & ColdAnnealed narrow width sheets IS 4397. The C.R. sheet is converted in the cage in PressMachine in Successive Operations:Blanking, Punching, Forming (Pocketing) rivet holes and visual inspection is

Ball Bearing Assembly Line

Flow Chart

Put Inner in Outer

Insert Balls

Put Retainers

Put under Riveting MachineTheory

CageRivetOuterInnerBall

Project report on training in National Bearing CompanyFinally the rings, balls & Cage which have been manufactured in different locations cometogether for semi – Automatic or Automatic Assembly.Raceways & Rings are Optically Inspected separately prior to assembly. By selectingsuitable combinations of ring & ball sizes the required internal clearance is obtained.Balls are fed between the rings and spaced equally before the two cage halves are fittedand riveted together.After washing, the final inspection sequence starts which consist of number of checkssuch as running accuracy, vibration level, outside and bore diameters and radial clearanceof bearings.The bearings are then automatically washed, coated with preservative, greased and fittedwith seals or shields before being packed

Riveting

Washing

De-Magnetizing

Inner & Outer Diameter Inspection Machine

Radial Clearance Testing Machine

Washing

Double side Vibration (Noise) Testing Machine

Laser Aching Machine

Application of Anti Rust

Packaging of Bearing in Pillow Wrapping Machine & Ready to Dispatch

Theory

CageRivetOuterInnerBallcRaceways & Rings are Optically Inspected separately prior to assembly. By selectingsuitable combinations of ring & ball sizes the required internal clearance is obtained.Balls are fed between the rings and spaced equally before the two cage halves are fittedand riveted toHeat Treatment Process

Chugai – Ro Heat Treatment

FurnanceHardening Procedure for High Carbon Steel ( C – 0.9%to 1.10%)

ProcessHardeningQuenchingTemperingAirCooling

Procedure

Heat theFurnace850-870

O

CFast cooling60

0

C – OilQuenching180

0

C – SaltBathFurnaceHeating165

0

-180

0

CCool atRoom Temperature

Hardness------

62 – 66 HRC 60 – 64 HRC

------Time

35-60 min.According tothe job5-15 min. 150 min.

------

Hardening Procedure for LC Steel (Low Carbon Steel)

52

getherarried for any deformitybly is done.

Project report on training in National ENGINEERING INDUSTRY

Conclusion

This report describes the NBC bearing industry and its technology. The industry is spreadover 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 bearingssuch as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical Roller Bearings& Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings, CartridgeTapered Roller Bearings and Large diameter special Bearings in separate fully equippedfactories. NEI has set up its third Ball Bearing manufacturing plant in the fastest growing industrialtown of Manesar in Haryana. The plant is having a covered area of 5200 sq. meters. withthe most advanced and

sophisticated machines imported from reputed manufacturersfrom Europe and Japan .It has been long pursued policy and commitment of National Engineering IndustriesLimited (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 managersare the "trustees" of those stakeholders. It is therefore our responsibility to ensure that theorganization is managed in a manner that protects and furthers the interests of our stakeholders