A project report on nbc
- 1. 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. VINIT 2012BTME024 DEPARTMENT OF MECHANICAL ENGINEERING DR K.N. MODI UNIVERSITY(NEWAI)
- 2. 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 Classificationof Bearing Types & Features of Rolling Bearing
- 3. Bearing Designationin NBC Ball Bearing Manufacturing Inner & Outer Ring Manufacturing Cage Manufacturing Ball Bearing AssemblyLine 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 EXECUTIVESUMMARY 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 stringentinternational quality standards. NBC manufacturing plants, located at Gunsi (Newai) Rajasthan, Manesa
- 4. r Haryana &Jaipur - was incorporated in the year 1946. Its feature the most advanced manufacturingtechnology. The company is certified 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 ot her local brands. OBJECTIVE: The main objective of this training is to learn different engineering processes and to develop skills and with that attitude. 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. It 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 Company As 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 thesu ccessfu l co mpletio n o f any task wo u ld no t be co mplete witho u t theexpression of appreciation of simple virtues to the people who made it possible. So, with reverence honor I acknowledge all those guidance a ndencouragement has made successful completion of training.I am thankful to Mr . Ankit purohit for her constant cooperation and able guidance & without his support this work would not have been so understandable.
- 5. 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 IzumiKogyo Co. Ltd., Japan for Machine Retrofitting/Remanufacturing & OverhaulingTechnicalCollaboration with NTN Corporation, Japan for TaperedRoll er Bearing & Hub BearingIV-PhaseModernization StartedImplemented st Phaseof SAP-ERP SolutionsQS-9000 & ISO-14001 CertificationTs-16949 CertificationAAR Certification M-1003 for CartridgeTapered Roller Bearing17 Projectreport on training in National engineering industry Company Profile National Engineering Industries Ltd., Jaipur was founded in the year 1946 as a pio neer industry in the field of bearing manufactureby the renowned industrialist, late ShriB.M.Birla, under the name of "National Bearing Company Limited." The firstbearing wasmanufactured in 1950 with a modest startof 30,000 bearings in 19 sizes. The company isnow manufacturing nearly 3.8 million bearings per month in over 500 differentsizesranging from6 mm boreto 1300 mmouter diameter and has the capacity to manufacturebearings upto 2000 mmouter diameter. At NEI, the development of
- 6. 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 widevariety and rangeof bearingssuch as Ball Bearings, Steel Balls, Tapered Roller Bearings, and Cylindrical Roller Bearings & Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings,CartridgeTapered 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".NBCBearings are widely used by 2 and 3 Wheelers, Cars, Trucks, Tractors, ElectricMotors, Railway wagon, Coach and Locomotive manufacturers as OriginalEquipmentand Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and ThermalPower Plants all across the country. Mission of Company “Keeping Nation on the Move” PLANTAT JAIPUR i)Ball Bearing Precision Ball Bearings from 6 mm bore to 75 mm borediameter 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 Assuranceareimplemented to meet the rapidincreasein demand for Quality, diversity of specifications and new types of bearings.This Division is spread over a covered area of 14,694 Sq. Meters.
- 7. 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 projectof 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 Projectreport on training in National engineering industry Collaboration BRENCO Incorporated , U.S.A. Since 1982-For CartridgeTapered Roller Bearings for Railway wagons and locomotives. NTN Corporation , Japan Since 1985-For BallBearings, Cylindrical& Spherical Roller Bearings. Since 1997- For Tapered Roller Bearings. IzumiKinzoku Kogyo Co. Ltd., Japan
- 8. 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 fromOutsideVendor such as Races (Inner & Outer), Cages, Retainers etc Store Housefor 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
- 9. The following Operations aredone: Domestic customer . Ashok Leyland . Bharatbenz . Bajaj auto . Escort tractors . Hero motocop . Honda motorcycls . Indian railway Maruti suzuki Tata motors International customers Amstedrail (usa) Agrale brazil Bonfigliooil (itly) Con met (usa) Nissan(japan) Riotinto( australia)
- 11. 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
- 12. Outer grinding
- 13. Grinding process Izumi (kN2130)
- 16. The Digits & Indications are:- 1stDigit– Bearing Type 6207 6- deep grooveball bearing 2ndDigit– Width or Height Series 2 – diameter series 2 3rdDigit– Diamete Series 07- nominal borediameter (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 52100steelare 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 &
- 17. 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.TheHardening of steel is achieved by heat treatment process in which t he steelmicrostructureis manipulated by cycles of heating & quick cooling to obtain theoptimum hardness rangefor steel – usually on the order of 60 to 64 on Rockwell CHardness Scale. When slowly quenched it would formAustenite & Pearlite which is a partly hard and partly soft structurerespectively. Hardening of steel requires a changeinstructurefrom Body Centered Cubic Structure found at room temperature to FaceCentered Cubic Structurefound 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:
- 18. Face Grinding – Itis the first operation for both inner & outer rings. Both facesare ground simultaneously to give the final width. Outside/ Center less Grinding – Outsidediameter 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 byformdressed grinding wheels. After grinding Operation, Honing is done. After Honing the rings are thoroughly washed with water based cleaning medium soRings get perfectly cleaned beforeAssembly. Cage Manufacturing Flow Chart Raw Material (Narrow width Cold Rolled Sheet IS 4397) Blanking & Punching Forming (Pocketing)
- 19. Inspection & Batch Checking Shot Blasting/Vibro Theory The cages for various bearing sizes are manufacturefromCold Rolled (C.R.) & ColdAnnealed narrow width sheets IS 4397. TheC.R. sheet is converted in the cage in PressMachinein SuccessiveOperations: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
- 20. Projectreport on training in National Bearing CompanyFinally the rings, balls & Cage which havebeen 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 consistof number of checkssuch as running accuracy, vibration level, outside and bore diameters and
- 21. radial clearanceof bearings.Thebearings 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
- 22. Packaging of Bearing in Pillow Wrapping Machine & Ready to Dispatch Theory CageRivetOuterInnerBallcRaceways & Rings areOptically 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 Procedurefor High Carbon Steel ( C – 0.9%to 1.10%) ProcessHardeningQuenchingTemperingAirCooling Procedure Heat theFurnace850-870 O CFastcooling60 0 C – OilQuenching180 0 C – SaltBathFurnaceHeating165 0 -180 0 CCool atRoom Temperature Hardness------
- 23. 62 – 66 HRC 60 – 64 HRC ------Time 35-60 min.According tothejob5-15 min. 150 min. ------ Hardening Procedurefor LC Steel (Low Carbon Steel) 52 getherarried for any deformitybly is done. Project report on traininginNationalENGINEERING INDUSTRY Conclusion This reportdescribes 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 widevariety and rangeof bearingssuch as Ball Bearings, Steel Balls, Tapered Roller Bearings, Cylindrical Roller Bearings& Axle Boxes for Railway Rolling Stock including SphericalRoller Bearings, CartridgeTapered Roller Bearings and Large diameter special Bearings in separate
- 24. 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 fromreputed manufacturersfromEuropeand Japan .Ithas 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. Webelieve that this organization has been handed to us by the various stakeholders in "trust” and we as professionalmanagersarethe"trustees" of those stakeholders. Itis therefore our responsibility to ensure that theorganization is managed in a manner that protects and furthers the interests of our stakeholders