practical training report on ball bearing
TRANSCRIPT
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PRACTICAL TRAINING REPORTTAKEN AT
NATIONAL ENGINEERING INDUSTRIES LTD JAIPUR(KEEPING THE NATION ON THE MOVE)
Prepared By
Prem Prakash KhatriB.Tech. IV Yr. (Mech. Engg.)
Vivekanand Institute
of Technology-East ,jaipur
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COMPANY PROFILE
Founded in 1946 by B. M. Birla.
Renew name in 1958 from NBCL to NEIL.
Producing 1.9m bearing from 20mm to 1350 mm in 500different sizes
Spread 118 acres in jaipur & 56 acres in newai Production of Ball Bearing , Cylindrical roller Bearing ,
Tapered Roller Bearing , Cartridge Tapered Roller , steel balls.
Largest bearing given to Rourkela Steel Plant .
Raw material from tisco,west germany,japan &Holland.
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The NEI Office Network
Head office-9/1
R.N. Mukherjee
road in Kolkata.
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NEI PLANT AT JAIPUR
PLANT INFORMATION:situated at khatipura road from 1 km of westrailway station
PLANT INFORMATION (NEWAI):establised in 1980-81.
SHIFTS:
Production goes in three shifts and one General Shift. 1st shift from 06.0014.30 Hours
2nd shift from 14.3023.00 Hours
3rd shift from 23.00
06.00 Hours General shift from 08.0017.00 Hours
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COLLBORATORS OF N.E.I. Ltd.
The Hoffman Manufacturing Co. Chelmsford, U.K.
(Now RHP)
Withelm Stahtecker GMBH, West Germany
Federal Mogul Corporation, U.S.A.
SRO Switzerland
Heald Incorp. Ltd, Boston U.S.A.
NTN, Japan
Brenco U.S.A.
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DEPARTMENTS IN NEI LTD., JAIPUR
BALL BEARING DIVISION
TAPER BEARING DIVISION
AXLE BOX DIVISION
TOOL ROOM ELECTRICAL AND MAINTENANCE
MACHINE BUILDING
LARGE DIA BEARING
STEEL FOUNDRY RESEARCH n DEVELOPMENT HRD
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BALL BEARING DIVISION
Four major parts-balls,inner and outer race,cage.
HEADING
FLASHING
SOFT GRINDING
HEAT TREATMENT
WORK HARDENING
HARD GRINDING
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BALL BEARING DIVISION
FINISH GRINDING
LAPPING
SUPER FINISHING
ULTRA SONIC WASHING
VISUAL INSPECTION
ANTIRUST OILING, COUNTING, PACKING
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The Manufacturing Process
OPERATIONS: -
1) HEADING:- This is the foremost operation to manufacturethe balls. This machine cuts the wire with the help of cutter andthen the cutes piece is drawn into the spherical shape by theapplication of the punch &die arrangement. This process mainlyconsists of three main steps: -a) Wire feeding
b) Cutting of the wire.c) Turn into spherical shape.
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Ball Machine
2) FLASHING : - The balls
obtained by the above
operation are not perfectly
spherical but it consists of
collar or flash in the centralperiphery. So, to achieve a
spherical shape some
material is removed from its
surface with the help offlashing machine. In this
machine there are two plane
plates. Balls are made to roll
between these plates again
and again until the proper
shape of the balls is achieved.
To make it cool some coolant
is also provided.Rill plates for ball machine
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3)SOFT GRINDING- In this operation grinding wheels used is
made of soft material and have grooves on its surface. Balls
are made to rotate in these groves. It removes extra material
and makes the ball spherical.
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4)HEAT TREATMENT:- The heat treatment operation can be accomplished
by Chugai Ro furnace. During this process the balls are first of all washed
by water at 60c and are then supplied to the hardening furnace in which
there are total of four zones consisting of different temperatures.
Temperature of the zone depends upon the type of job. After that these
are passed through quenching oil tank so that the job get cool. In tank
there is a agitator to maintain the temperature of oil uniform. Then these
are further cooled with dry air and proper washing. At this time five balls
are taken from sample box and are checked against their hardness testing
m/c. Stresses are developed during the hardening and quenching process
these stresses are relieved by tempering operation. So after checking
hardness they are further sent into a tempering furnace by which the
temperature is to be supplied to the job or material (ball). The
temperature of tempering furnace is about is about 170C for somespecified time limit. These balls are again checked for their hardness by
hardness tester m/c.
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5)WORK HARDENING PROCESS: - This process takes place in WHT (work
hardening tumbler) machine. By this operation case hardening is done of
balls by dropping balls from a certain height. Also desiccating is done by
this operation.
6) HARD GRINDING (G2): -It is a process of grinding in which grinding
wheel is made of hard material and have groves on its surface where the
balls are ground to achieve or acquire a good & smooth surface finish by
removing the material from its surface. By this process we can grind the
balls so as to reduce the size from 100 to 30.
7) FINISH GRINDING (G3): -It is a grinding process in which some material
is again removed from the surface of balls to achieve a good or high
surface finish. By this process the size of material is further reduced is
about 7.
8) LAPPING (L1): - Here balls are passed through a paste containing
(cr2o3 + 2lt honilo oil +1/2lt olic acid). Function of cr2o3 is to remove
extra material and of olic acid is to provide brightness. So that it have a
good surface finish.
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9) SUPER FINISHING: - Now the balls are the in honilo oil. It also contains
cr2o3 and olic acid but in very small quantities. Here finished touch to the
balls is given.
10) ULTRA SONIC WASHING : - The balls are now washed with MTO(mineral terpentine oil). The balls are then further washed by MTO moving
with ultrasonic wave produced by generators situated below the machine.
11) VISUAL INSPECTION: - The balls are now inspected visually in the ball
inspection area. Inspection take places through instruments are: - a) Microscope- surfaces of the balls are inspected.
b) Militrone gauge- checks the size of the balls.
c) Vibration tester- Capacity to withstand with vibrations and noise is
tested
in terms of decible.
d) Tele roundness machine- checks the roundness and surface finishing.
12) ANTI RUST OILING, COUNTING, PACKING OPERATION: -
The balls are oiled to prevent rusting then counted and packed.
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TAPER DIVISION
Parts:-cone,cup,roller&retainer.
Working section-
Roller section
Heat treatment
Grinding section
Retainer section
Assembly section
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AXLE BOX DIVISION
The axle box division mainly consists of the three sections
as: -
1. AXLE BOX HARDENING
2. RACE GRINDING
3. ASSEMBLY
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MACHINE BUILDING
The following m/c are present in this department :-
LATHE M/C, MILLING M/C
SLOTTER M/C, SHAPER M/C
BEND SAW, POWER SAW
TOOL GRINDER, BORE GRINDER
DRILLING M/C, CNC MILLING
ANGULAR SURFACE GRINDER, BEARING LIFE
TESTING M/C
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LDB (LARGE DIAMETER BEARING
DIVISION)
Stages of making LDB-
raw material from the steel foundry is taken , passed overdifferent rotary furnaces at different temp , then it is sentto the grinding section
Grinding:-BORE GRINDING M/C (SL 400*500?)
OD GRINDING M/C BUA 63(T)
COPPER BORING
RUSSIAN BORING
ROLL CLEARANCE
BERTHIEZ GRINDING M/C ASSEMBLING
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TOOL ROOM
The tool room of NEI consists of following machine
LATHES
MILLING MACHINE ,SHAPER MACHINE
UNIVERSAL GRINDING MACHINE
HEALD MACHINE , SLOTTER MACHINE
SURFACE GRINDING MACHINE
JIG BORING MACHINE
SPARK EROSION MACHINE
CNC LATHE MACHINE
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LABORATORY/METALLURGY SECTION
HONSFIELD TENSOMETER
UTM-40 TESTIMNG M/C
CLEMEX IMAGE ANALYSIS SYSTEM
CLEMEX CAT (MICRO HARDNESS TESTER)
ROCKWELL HARDNESS TESTER M/C
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RESEARCH AND DEVLOPMENT
Technical collaboration agreement with NTN
Corporation, Japan and Brenco. Incorporated
of USA.
design is done on CAD
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MAINTENANCES
Electrical maintenances-winding, wiring etc.
PREVENTIVE MAINTENANCE
RUNNING BREAKDOWN MAINTENANCE
Mechanical maintenances-used different machines like lathe,shaper,boring etc.
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INDUSTRIAL SAFETY
Preventive measures
Use of safety guards for reciprocating machine component e.g. drophammer paper cutter etc.
Fencing of dangerous and rotating parts like revolving shafts.
Rigid construction of heave items like hoists, cranes etc.
Proper insulation of electric wire & earthlings of electric appliances.
Wearing appropriate safety shoe and other necessary items for bodyproducts.
Maintenance clearness of shop floor.
Avoiding fire hazard.
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Thanks