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ACKNOWLEDGEMENT
At the outset we express our deep sense of gratitude to Mr. Ajay Pandey, Human Resource Department, N.E.I. and other staff members who have been the perennial source of inspiration and guidance in completion of this project.
Plant at Jaipur Plant at Gunsi (Newai) Plant at Manesar Research and Development Quality Management System Products Advances
Collaboration
Total Production Management Bearing Designation Rolling Bearing Construction And Classification Heat Treatment Process Laser Marking System Ball Bearing Division Ring Rolling Mill
Miscellaneous
Foreword
National Engineering Industries Ltd. is the largest manufacturer of Ball and Roller Bearings, 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 Assosiation 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.
Introduction
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 was manufactured in 1950 with a modest start of 30,000 bearings in 19 sizes. The company is now manufacturing nearly 3.8 million bearings per month in over 500 different sizes ranging 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 vital industries and manufacturing of Roller Bearing Axle Boxes for Railway Rolling Stock, Steel Balls, Tapered Roller Bearings, Spindle Inserts etc., the name of the company was changed in 1958 to "National Engineering Industries Ltd." retaining its original trade mark 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 bearings such 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 fully equipped 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, Electric Motors, Railway wagon, Coach and Locomotive manufacturers as Original Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and Thermal Power Plants all across the country.
With the production of 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 to Locomotives manufactured by Diesel Locomotive Works , Chittaranjan Locomotive Works, various wagon builders, the ICF broad and meter gauge coaches. Over a million NBC bearings and boxes are in service with the Indian Railways. The development of completely indigenised Axle Boxes and bearings for the high speed Rajdhani Locomotive, the Yugoslavian and Egyptian Railway wagons are the highlights of the design capabilities at NEI. On date more than 100 types of Axle Boxes & Bearings have been manufactured. (b)Spherical Roller Bearing: 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 Tapered Roller Bearing: For fitment to the new BOX-IN Uprated Wagons designed by the RDSO, NEI is the only manufacturer in the country to indigenise these bearings to a high percentage under 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. This Division is spread over a covered area of 4,855 Sq. Meters.
This 4-Row Tapered Roller Bearing measures 1300 mm dia and weigh 4.39 tons. The large diameter bearings are mainly manufactured out of case carburizing steel, 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 2000 mm diameter with electronic sizing and numerical display. Production of these bearings started in 1975 and to date over 100 different types of special large diameter bearings have been manufactured and successfully used, saving considerable foreign exchange for the country. The Large Diameter Bearings Division is spread over a covered area of 2,508 Sq. Meters.
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, our processes now conform to international standard.
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TS 16949: 2002 quality management system is based on ISO 9001: 2000 in which many supplementary and additional requirements of automobile industries have been incorporated. TS quality management system in NEI starts with identification of all customer requirements and ends with ensuring that all customer requirements have been fulfilled. This also requires continuous improvement in all areas. Every process is critically studied and performance indicators for measuring output of those processes defined. Measurement of efficiency and effectiveness of every process only decides how ably the process has been performed. Simplicity, effectiveness & efficiency of processes, error proofing and continuous improvement 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 manufacturing Cylindrical Roller Bearings, spherical roller bearings, cartridge tapered roller bearings, railway rolling stock and spares has also been awarded to ISO 9001: 2000 on 9th October, 2003 by BVQI.
ISO 14001:1996
NEIs everlasting concern for cleaner, pollution free environment has made the NEI to go on the path of Environmental management System. 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.
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Collaboration
(a) BRENCO Incorporated , U.S.A.
Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and Locomotives. www.brencoqbs.com
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PRODUCTS
A BROAD RANGE BORN OF PRECISION
From a few mms to thousands of mms, from a few grams to a few tones, the NBC range is hard at work in some of the most critical areas of Indian industry.
BALL BEARINGS
The initial technology was from Hoffman Manufacturing Company Ltd., U.K. a collaboration, which continued for 20 years. We offer a wide range of both metric and inch series deep groove ball bearings, angular contact ball bearings, self-aligning ball bearings etc. With our tie up with the world's leading bearing manufacturing company NTN Corporation, JAPAN, we have gained access to the most advanced ball bearing technology i.e. thermo mechanical bearings (TMB) and tensioner bearings available today and our wide range of ball bearings is increasing under this collaboration.
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Developed by NBC for the Indian Railways for use in rolling stocks. Excellent performance even in the high speed Rajdhani locomotives, the Yugoslavian and Egyptian Railway wagons. A total of 34 different types of the axle boxes are turned out at the NEI plant in Jaipur. Designs for high speed railway application are being developed together with NTN. More than one million NBC axle boxes and roller bearings are in operation with Indian Railways. We have the privilege of being the single largest source of bearings to Indian Railways, which is one of the largest networks of its kind in the world.
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manufactured in precision lines imported from NTN Corporation, JAPAN. NBC ball bearings are now specially manufactured with high precision steel balls produced in ultra modern plant equipped with high speed headers, electronically controlled flashing, grinding, and lapping machines to ensure accuracies of sub-micron levels.
ADVANCES
The following New Bearings are Developed for Railway Application
SPHERICAL ROLLER BEARINGS 22312D1 22312KD1 22314D1 22314KD1 22222 (Bore 60 mm x OD 130 mm x Width 46 mm) (Bore 60 mm x OD 130 mm x Width 46 mm) (Bore 70 mm x OD 150 mm x Width 51 mm} (Bore 70 mm x OD 150 mm x Width 51 mm) (Bore 110 mm x OD 200 mm x Width 53 mm)
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22222KD1
for
WAG-9
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1.
Focused Improvement
Developing machines for High Equipment Effectiveness Quick process for developing new products
2.
Autonomous Maintenance
Maintain Basic Conditions on shop floor and in Machines All over participation through TPM circles
3. Office TPM
4. Local Analysis Real Causes for Real Countermeasures Focus on Prevention
Quality Maintenance
Skill Development for uniformity of work practices on machines Skill for zero accidents, zero defects and zero break down Multi-Skilled employee in all departments
5.
6.
Planned Maintenance
Improvement is Everyone Activity Improvement is to eliminate production issues and Reduce cost
7.
8. Development Management 1S 2S 3S 4S 5S
Offices oriented for excellent support for manufacturing Improving offices and man-hour efficiency Seiri Clean Up Seition Make Convenient Seiso Maintain Cleanliness Seiketsu Healthy Environment Shitsuke Promote Good Habits
Bearing Designation
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Rolling bearing part numbers indicate bearing type, dimensions, tolerances, internal construction and other related specifications. The first letter (digit) indicates the bearing type. The second digit indicates the width (or height) series and the third indicates the diameter series. The last two digits indicate the bore diameter by multiplying the last two digits by the five for bearing bore diameter original 40 mm and above. This method is applicable for metric series bearing only.
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Rolling bearings are generally composed of bearing rings, rolling elements and cages. Several rolling elements are placed between two bearing rings and cages prevent the rolling elements from contact and with such a structure, a smooth rolling action becomes possible. Rolling bearings are divided into radial bearings and thrust bearings, mainly depending on the applicable load direction. Radial bearing mainly take radial loads. Most types of radial bearings can also take thrust loads. Thrust bearings generally take thrust loads only and not radial loads. Rolling bearings are largely divided into ball bearings and roller bearings in accordance with the types of rolling elements, Roller bearings are further divided depending on the shape of the roller into the cylindrical roller bearings, spherical roller bearings and needle roller bearings. Ball bearings are divided into several types, depending on the shape of bearing rings and the contact position between the balls and the raceway. The cages of rolling bearings are divided into pressed and machined ones with the shapes differing according to the bearings types and conditions of use.
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Bearing
with
The double row self aligning ball bearings with tapered claming sleeve and nut are identical to double row self-aligning ball bearing except that these have a tapered bore, which is used for easier mounting and also a clamping sleeve and nut to clamp the bearings on the shaft. The tapered bore is also used for the adjustment of radial clearance.
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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 tapered 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 tapered roller bearings with exceptionally steep cone angle enables the bearings to take heavier axial load. The bearings are of separable type, enabling separate mounting of cones and cups. Since the tapered 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 tapered roller bearings are also widely used for heavy loads such as rolling mills. A single row tapered roller bearing can be located endwise in one direction only.
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Process
Quenching Fast cooling 600 C Oil Quenching 1800C Salt Bath 62 66 HRC
Procedure
Hardness
------
60 64 HRC
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Time
5-15 min.
150 min.
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Hardening Procedure
Steel Material LC Steel (Low Carbon Steel)
Process
Hardening Furnace temperature at 8500 C 8700 C -----35-60 min. According to the job.
Quenching Fast cooling 600 C for oil quenching only 60 64 HRC 5-15 min.
Procedure
Hardness Time
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Heat Treatment
Raw Material
(Carbon Steel)
Carburizing
(Carbon Shield Layer increases Hardness) (10 12 hrs.) (940 0C) (GC Furnace)
Hardness I
(Revolving Furnace) (920 0C) (Time Dependent on Job)
Annealing
(6 hrs.) (650 0C)
Shot Blasting
Hardening II
(Revolving Furnace) (820 0C) (Time Dependent on Job)
Sub-Zero Treatment
(-60 0C) (Increases Toughness)
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Tempering
(160 0C) (4 hrs.)
Shot Blasting
(Wheel Abrator)
Hardness Inspection
(60 HRC)
Laser Marking System A Laser marking system marks a highly visible mark on the job without touching it. Job Number NBC INDIA Date Code Important parts a) Marker b) Controller c) Water-cooled Unit d) Filter Kit e) Console f) Control Panel g) Mechanical Handing System The Laser is produced with the help of a diode which is focused on the job by using a lens. The Laser beam produces a external high thermal energy; this thermal energy marks a dark mark on the job extra thermal energy is then absorbed through the cooling system. Thus, in this form the laser beam produced from a diode marks a dark mark on the job. With the help of the machine customer requirements like; customer code, part number etc. can be marked accordingly.
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Wire
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Heading Machine
Soft Grinding
(Scale : 0.001-1mm) (High Grind Oil + H2O)
Heat Treatment
Visual Inspection
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2. 3. 4. 5.
Inspection/Testing
Analysis of Rejections ECT / EVT
Heading Defects Flashing Damages Pitting Defects Odd Shaped Balls
EOT
Dirty Material Rusty Balls Pitting Defects Black Surface Balls
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Fretting wear particularly tends to occur on the raceway of DRAC Bearing during transport of finished automobiles. Therefore the fretting resistance property of the Lubricant should be taken into account while selecting lubricant for DRAC Bearings.
DRAC Seals
A special Low torque high performance (LTHP) seal on both sides of the DRAC Bearings prevent water ingress in the bearing and have low torque. It consists of 3-lips-Grease Lip, Dust Lip and Side Lip. A Stainless Steel Slinger is added to the 3-lip seal sliding part, which dramatically enhances rust resistance of the sliding part of the lips. Side lip is added for improving the sealing performance.
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Lapping
Paste Composition L1
7/32 9/32 1500 gm (Green Powder) (Cr2O3) (Chromium Oxide) + 2 liter (Honilo) + 1 liter (Oleic Acid)
L23
7/32 3/4 600 gm + 1 liter (Honilo) + 1/4 liter (Oleic Acid)
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