A REPORT ON PRACTICAL TRANNING NATIONAL ENGINEERING INDUSTRIES LIMITED JAIPUR

SUBMITED TO:DR.AJAY PANDEY DEPARTEMENT OF :

SUBMITED BY:CHETAN KUMAR MITTAL

BACHLOUR OF BUSINESS ADMINISTRATION III YEAR

ST. WILFREDS P. G. COLLAGE, MEERA MARG, N. S. ROAD, JAIPUR

ACKNOWLEDGEMENT
IT was ST . WILFRED P . G . where Chetan was honed from a native archer to an ambidextrous maestro. The story hasnt changed much yet. The training period in NATIONAL ENGINEERING INDUSTRIES LIMITED has been a quantum leap in terms of practical savvy, understanding of labour relations, sincerity, diligence, responsibility and above all self-confidence. For all this, I would like to pay my sincere thanks to: Mr. Ajay Pandey, Sr. Manager (HRD) Mr. Sobhag singh, Training Incharge; Miss Hemant Verma, Training Instructor Once again I would like to thank each and everyone in NEI Ltd. who are doing their earnest and humble efforts to hone the gung-ho elements.

Thanking all.

CHETAN KUMAR MITTAL B.B.A. III YEAR (MARKETING & SALES) ST. WILFREDS P.G. COLLAGE, JAIPUR

PREFACE
This is my immense pleasure that I took my training at NATIONAL ENGINEERING INDUSTRIES LTD., KHATIPURA ROAD, JAIPUR. This company is the bearing manufacturer of India. The bearings of this company are used through out the country and some other parts of world. Companies like Maruti, Telco, and Ashok Leyland etc. are some reputated users of NEI bearings. This report what I am presenting to you is infact the summary of what I saw there during my training. Though the time period was very short and my knowledge which I got up to second year of engineering course was not enough yet I did my best to grasp as much as possible.

COMPANY PROFILE
The renowned industrialist, late Shri B.M. Birla, under the name of National Bearing Company Limited, founded NATIONAL ENGINEERING INDUSTRIES LTD., JAIPUR in the year 1946 as a pioneer industry in the field of bearing manufacture. The first bearing was manufactured in 1950 with a modest start of 30,000 bearings in 19 sizes. The company is now manufacturing nearly 2.2 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 up to 2000 mm outer diameter. At NEI, the development of bearings is a neverending 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, Cylindrical Roller Bearings & Axle Boxes for Railway Rolling Stock including Spherical Roller Bearings, Cartridge Tapered Roller Bearings and Large Dia 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 & Locomotive manufacturers as Original Equipment and Steel Mills, Heavy Engineering Plants, Bulldozers, Shovels, Tillers and Thermal Power Plants all across the country. PLANT AT JAIPUR: (i). Ball Bearing:
Precision Ball Bearings from 6 mm bore to 75 mm bore diameter are manufactured on state of the art manufacturing facilities with in-process

and post-process gauging in grinding and centrally air conditioned assembly lines with auto gauging and testing equipments. The latest advanced techniques for manufacturing and Quality Assurance are implemented to meet the rapid increase 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 and roundness as per ISO standards. This Division is spread over a covered area of 4,700 Sq. Meters.

(iii). Tapered Roller Bearing:

Precision Tapered Roller Bearings are manufactured in Inch and Metric series from 15.875mm bore to 95.25mm bore with technology obtained from our earlier collaborator, Federal Mogul Corporation, USA and now with NTN Corporation, Japan. All major Automobile manufacturers in the country as Original Equipment use these bearings. This Division is spread over a covered area of 11,652 Sq. Meters.

(iv). Railway Bearing: (a) Roller Bearing in Axle Box:

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.

(v). Large Diameter Bearing:

Self-sufficiency in steel is the call of the day, so is the importance of bearings in Steel Mills Equipment. NEI has the distinction of being one of the ten manufacturers of these bearings in the world, who can manufacture large diameter bearings up to 2000 mm diameter. Mr. G.P. Birla released the largest bearing manufactured by NEI for fitment to the Plate Mill of Rourkela Steel Plant in September 1985. 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 carburising 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.

(II) PLANT AT GUNSI (NEWAI):

Established in the year 1980-81 as an expansion project of NEI Ltd. The factory is equipped with fully automated grinding lines with electronic in process & postprocess gauging and centrally air-conditioned assembly lines with auto gauging and test equipments for quality and reliability of the products.

The plant is spread over a covered area of 7,200 Sq. Meters.

RESEARCH & DEVELOPMENT AT JAIPUR: (a) Design & Development:

Complete in-house facility for design development of all types of bearings and tooling is available. The design of all types of bearings is done on proEngineer 3D Modeling & Analysis Software. Complete engineering and research facility is available to solve intricate problems with expert advice on design, development, manufacturing, installation and maintenance of bearings. With the signing of the technical collaboration agreement with NTN Corporation, Japan & BRENCO Inc of USA, the capability to offer finest engineering services in the bearing industry has enhanced. Services of team of experienced engineers are available for selection of bearing as per application.

(b) Machine Building:

NEI has the capability of machine building to design, develop and manufacture special purpose CNC Grinding Lines, HT Lines, Material Handling Equipments and other special purpose machines which have been made for its captive use to keep pace with latest technology. A well-equipped electronic design, development laboratory with all testing facilities supports the Machine Building Division. Machine Building has the capability and supports the Manufacturing Divisions by overhauling and retrofitting of the existing equipments, resulting in upgraded quality and improved productivity. R&D Division is spread over a covered area of 2,007 Sq. Meters.

QS 9000/ISO 14001:
NEI extensively embarked upon system improvement and implemented modern concepts of Total Quality Management. NEI has been awarded QS 9000 certificate - THE MARK OF EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS by the renowned Certification Agency, BVQI of the UK, for design, development, manufacture & supply of NEI's complete range of products. NEI was awarded ISO -14001 certificate by BVQI in the month of April '2001 for Environment.

SAP - ERP:
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.

N.E.I. NETWORK ALL OVER INDIA

DELHI JAIPUR NEWAI FARIDABAD

I N D IA
MUMBAI PUNE

CALCUTTA

CHENNAI

MILESTONES

COMPANY ESTABLISHED AS NATIONAL BEARING COMPANY (NBC) UNDER TECHNICAL COLLABORATION WITH HOFFMAN, UK.

1946-

1950- BALL BEATING PRODUCTION STARTED. 1951- RAILWAY BEARING PRODUCTION. 1957-

COMPANY NAME CHANGED TO NATIONAL ENGINEERING INDUSTRIES LTD. (RETAINING NBC AS TRADE MARK). TAPER ROLLER BEARINGS UNDER TECHNICAL COLLABORATION WITH FEDRAL MUGGAL CORPORATION, U.S.A. ESTABLISHED DEVELOPMENT DIVISION.

1967-

19711971-

RESEARCH

&

ESTABLISHED

MACHINE

BUILDING

DIVISION.

1975- LARGER DIAMETER SPECIAL BEARINGS. 19761981-

SPHERICAL ROLLER BEARINGS WITH TECHNICAL KNOW HOW FROM FAG-SRO. SEPRATE FACTORY BEARINGS AT GUNSI (NEWAI). FOR BALL

1982-CARTRIDGE TAPER ROLLER BEARINGS IN

WITH BRENCO

TECHNICAL COLLABORATION INCORPORATED, U.S.A.

LARGEST BEARING WITH O\D1.3 METER & WEIGHT 4.39 TONS (4390 KGS) PRODUCED.

1985-

1986- TECHNICLA COLLABORATION WITH NTN

CORPORATION OF JAPAN FOR BALL, CYLINDRICAL & SPHERICAL ROLLER BEARINGS.

1990 TO 1995-

MODERNISATION IN THREE

PHASES.

1995- IS0-9001 CERTIFICATE. 1996-

TECHNICAL COLLABORATION WITH IZUMI KINZOKU LTD., JAPAN FOR MACHINE RETROFITTING AND OVERHAULING OF GRINDING AND SUPERFINISHING MACHINES FOR BEARING RACES. TECHNICAL COLLABORATION WITH NTN CORPORATION OF JAPAN FOR TAPERED ROLLER BEARING AND HUB BEARINGS.

1997-

1998- IV PHASE MODERNISATION STARTED. 1999-IMPLEMENTED

Ist PHASE OF E.R.P. SAP

SOLUTIONS.

2000- OS-9000 & ISO-14001 CERTIFICATION.

5 'S' of the Company:For implementing the practices of well known Japanes management technique of 5'S' the company was taken several steps. 5 'S' consists of the following:-

1)

S "SEIRI" (Straighten up)

Differentiate between the necessary and the unnecessary and discard the unnecessary. * * * * * Work in process Unnecessary tools Unused machinary Defective products Papers and documents

2)

S "SEITON" (Put things in order)

Things must be kept in order to that they are ready for use when needed. There should be place for everything and everything should be in its place.

3) 4) 5)

S "SEISO" (Clean up)

Keep the work place clean.

S "SEIKETSU" (Personal Cleanliness)

Make it a habit to be clean and tidy

S "SHITSUKE" (Discipline) s

PRODUCT RANGE
A BROAD RANGE BORN OF PRECISION:
From a few mms to thousands of mms, from a few grammes 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.

They offer a wide range of both metric and inch series deep groove ball bearings, angular contact ball bearings, self-aligning ball bearings etc. With their 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 their wide range of ball bearings is increasing under this collaboration.

TAPERED ROLLER BEARINGS:

Manufactured at an ultra modern plant, with technology obtained from our earlier Collaborators, Federal Mogul Corporation, USA and now with NTN Corporation, JAPAN, these bearings are used by all major automobiles, truck and tractor manufacturers in the country as original equipment.

SPHERICAL ROLLER BEARINGS:

Originally developed in collaboration with Swiss leaders FAG-SRO. Vital for broad gauge and meter gauge coaches manufactured by ICF, Chennai and RCF, Kapoorthala for the Indian Railways. Now new sizes are being developed with the help of NTN Corporation, JAPAN.

ROLLER BEARING AXLE BOXES:

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.

CARTRIDGE TAPERED ROLLER BEARINGS:

Successful Track record in the Railways for the past 30 years, these require no field lubrication.

Developed in collaboration with BRENCO Inc. USA, these bearings are being used in all broad gauge wagons of Indian Railways.

PRECISION STEEL BALLS:

Manufactured using the most modern facilities available in India, Quality steel balls, up to 25 mm in diameter for NBC bearings are 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 submicron levels.

LARGE DIAMETER BEARINGS:

We have the distinction of being one of the few bearing companies in the world to manufacture bearings up to 2000 mm outside diameter developed with indigenous technology.

Bringing Shri B.M. Birla's vision of self-reliance to fruition, NBC large diameter bearings contribute to steel production and thermal power generation in India.

ORGANISATIONAL STRUCTURE
The division functions is carried out by various division and departments and are line with the organizational objectives. Gives below is a birds eye view of major functions of the divisions. A division is bifurcated to departments and sections, segments, handled by departmental managers and sectional heads. An out line of the structure is given below:

S.NO. DIVISION I ADMINISTRATIVE & COMMERCIAL

I. a. I. b. I. c. I. d. I. e. I. f. II II. a. II. b. III GENERAL MANAGEMENT FINANCE COSTING & BUDGET CONTROL PERSONNEL & ADMINISTRATION MARKETING & SALES PROMOTION

DEPARTMENT

MANAGEMENT ACCOUNTING, EDP

HRD, IR, FACTORY ADMN. SALES PROMOTION MARKETING & SALES ADMN. CENTRAL PLANNIG & MRP, PURCHASE & SUPPLY STORE TECHNICAL RESEARCH & DEVELOPMENT MACHINE BUILDING MANUFACTURING

III. a.

BALL BEARING

III. b. III. c

III. d. III. e. III. f.

TURRET, GRINDING CAGE, BALL, MAINTENANCE& ASSEMBLY RAILWAYS AXLE BOX & RING RING ROLLING TAPER ROLLER TURNING, GRINDING, BEARING RETAINER, HEAT TREATMENT, MAINTENANCE & ASSEMBLY LARGEDIAMETER BEARING QUALITY ASSURANCE METALLURGY

LAYOUT OF ORGANIZATIONAL STRUCTURE

BEARING CLASSIFICATION
Rolling bearings are generally composed of bearing rings rolling elements and cage. Several rolling elements are placed two bearing rings so that cages prevent the rolling elements from contacted with such a structure, a smooth rolling action possible.

CLASSIFICATION OF BEARINGS SINGLE ROW RADILA BALL BEARING

It accommodates pure radial, pure axial or combination of radial & axial loads within its capacity. These can operate at very high speeds. For these reasons and its economical price, it is the most widely used bearing.

SINGLE ROW RADIAL BALL BEARING WITH TAPERED BORE

It is similar to the single row radial ball bearing except that these have tapered bore which is used for easier mounting and for adjustment of radial clearance. Dimensions of the tapered bore diameter refer to small bore.

SINGLE ROW ANGULAR CONTACT BALL BEARING

It has higher axial load capacity than the single row ball bearing. The radial load capacity higher than the single row ball bearing.

SINGLE ROW EXTERNALLY ALIGNING BALL BEARING

This bearing is used where accurate alignment cannot be guaranteed between bearing positions. It can take radial loads. Axial loads can also be accommodated.

DOUBLE ROW SELF-ALIGNING BEARING

The double self-aligning bearings have the common outer spherical race for both the rows. This feature gives the bearings self-aligning properties. The bearings have the same external dimensions as their equivalent single row radial ball bearing. They can take radial loads and very light axial loads.

DOUBLE ROW SELF ALIGNING BALL BEARING WITH TAPERED CLAMPING SLEEVE AND NUT
The double row self aligning ball bearing with tapered clamping sleeve and nuts are identical to double row self-aligning ball bearing expect that these have a tapered bore, which is used for easier mounting and also a clamping sleeve and nut to clamp the bearing on the shaft.

THRUST BALL BEARING

The ball bearings are used for high axial loads at low speeds. These cannot operate on high speed, as it will give rise to centrifugal or radial forces, which cannot be taken by the bearing.

CYLINDRICAL ROLLER BEARING

The cylindrical roller bearings have greater radial load capacity than ball bearings of same axial dimension and are particularly suitable for arduous duties. The bearing features a modified line contact between rollers and raceways to eliminate edge stressing. These bearings have a high radial load capacity and are suitable for high speeds.

TAPERED ROLLER BEARING

Tapered roller bearing are designed in such a way that vertices of the cone for each roller and those for the inner an outer raceways coincides on the bearings axis or the extensions of the raceways and roller coverage 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 supports radial and axial loads from one direction only the line contact between rollers and raceways provide the bearing with a high load carrying capacity. Steep angle tapered cone angle enables the bearings to take heavier axial loads.

SPHERICAL ROLLER BEARING

Spherical roller bearings are particularly suitable for carrying heavy loads. They are usually of the double row design, both of the rows of the roller shaving common spherical raceways in the outer ring. This feature of this bearing has great practical importance in those cases where it is difficult to obtain exact parallelism between the shafts housing bore axis. So these bearing are suitable where misalignment can arise from mounting errors or from the deflection of the shaft.

COMPOSITION OF THE MATERIAL OF THE BEARING

In fact the process of manufacturing bearing steel does not start at any bearing plant but it starts at the steel mills where the bearing steel is manufactured to SAE 52100 standard. Bearing steel contains varying amount of C, Fe, Cr, Mn, P, S, and Si etc. The chemical composition of SAE (Society of Automotive Engineers) 52100 is as follows:

ELEMENTS CARBON CHROMIUM MANGANESE SILICON SULPHUR PHOSPHORUS NICKEL COPPER MOLYBDYNUM

AMOUNTS (%) 0.98-1.1 1.3-1.6 0.25-0.45 0.28-0.35 0.025 max. 0.025 max. 0.025 max. 0.35 max. 0.10 max.

BEARING DESIGNATION
ROLLING BEARING parts numbers indicate bearing type, dimensions, tolerances, internal construction & other related specifications. The first letter (digit) indicates the bearing type, the second digit indicates the width (or height) series & the third indicates the diameter series. The last two digits indicate the bore diameter by multiplying the last digit by five for bearing having bore diameter between 20 to 490-mm. This method is applicable for metric series bearing only.

EXAMPLE: 1) 6 2 0 7 Z C3 Radial Internal Clearance C3 Shielded (one side) Nominal Bore Diameter 35mm (07*5) Diameter Series 2 Deep Groove Ball Bearing 2) 22328 Nominal Bore Diameter 140mm Dimension Series 3 Width Series 2 Spherical Roller Bearing

BEARING NOMENCLATURE
Light Duty 6200 6201 6202 6203 6204 6205 6206 6207 6208 6209 6215 Bore Dia (mm) 10 12 15 17 20 25 30 35 40 45 75 Heavy Duty 6300 6301 6302 6303 6304 6305 6306 6307 6308 6309 6315 Bore Dia (mm) 10 12 15 17 20 25 30 35 40 45 75 Extra Duty 6500 6501 6502 6503 6504 6505 6506 6507 6508 6509 6515 Bore Dia (mm) 10 12 15 17 20 25 30 35 40 45 75

Raw Material: High carbon Steel (SAE-52100)

Carbon Content: 0.92% to 1.02%

Tool Material: Tungsten Carbide

GRINDING SECTION
INTRODUCTION
This section deals with all components of bearing, which require grinding operation. It is considered as a machining process with good surface finish, accuracy of shape & dimensions. Grinding and heat treatment are very important processes to prepare a race with great accuracy that cannot be achieved by turning process. Grinding process is generally performed on the hardened work-piece after its heat treatment. A grinding wheel is a multi tool cutter having hard particles known as abrasives, which do the grinding process. The speed of the grinding wheel depends on the condition of m/c, method of grinding and the required surface. The wheels, which are being used in the grinding section, are the product of carborundum. The systematic machines are as follows: 1. HEALD machine 1-cf-90 &1-cf-91 2. IZUMI machine kn-312 3. N.B.C.s machine 4. LANDIS machine 5. HONNING machine

HONNING MATERIALS: COLOUR OF STONE

Yellow Green

PURPOSE
Rough honing Finish honing

MATERIAL
Aluminum oxide Chromium oxide

SYSTEMATIC PROCESSES OF GRINDING OPERATION: (A) 1) PART: Inner Race 2) MATERIAL: high Carbon Steel (SAE-52100) 3) OPERATION: Inner Race Grinding Outer Diameter Grinding Tracking Bore grinding Honing I. Rough II. Finish (B) 1) PART: Outer Race 2) MATERIAL: High Carbon Steel (SAE-52100) 3) OPERATION: Face Grinding Outer Diameter grinding Track Grinding. Honing I. Rough II. Finish

PROCESSES FACE GRINDING

This process is carried on grinding machine ( BLANCHARD GRINDING M/C), which has a magnetic chuck. The rotating shaft on which the grinding wheel is mounted is kept vertical. When the process is to be carried out no. Of races are adjusted on the magnetic chuck and then is allowed to fall on the races. Then the rotating grinding wheel is brought over the races performing its job.

OUTER DIAMETER GRINDING

This process is carried out on the center less machines. These machines have two rotating grinding cylinders with different r.p.m. these cylinders are at an angle of 5 to 10 degree to make the movement of bearing easy. The cylinders are more or less kept in horizontally.

TRACK GRINDING
The next operation in grinding is profile grinding of the track. Profile grinding is the most important grinding operation as bearing quality depends on it. Track grinding is carried out on a CNC grinding machine IZUMI (Japan make). TRIMOFIN-23 is used as coolant for inner & outer track grinding. The machine is basically a cylindrical grinding machine. A diamond tracer is used for dressing the grinding wheel after every definite time interval.

BORE GRINDING

This process is carried out for the inner races to get close to required diameter. This operation is carried out on HEALD (CINCINNATI MILACRON) MADE IN U.S.A. This machine is fully automatic. A special hydraulic and pneumatic pressure clamp clamps the work against a rotating backing plate. HOCUT B-60 with water is used as coolant used for this purpose.

HONING
HONING operation is super finishing operation, which is used for super finishing the profile of the tracks of the inner and outer races. Honing operation is carried on NTN machines. Honing operation takes place in two phases. Firstly rough honing operation takes place followed by finish honing. For rough honing strips made of aluminiumn oxide is used which is yellow in color. For finish honing

green strips are used to 0.8 microns material is removed where as in finish honing .03 to.04 microns material is removed. TRIMOFIN-23 with kerosene & TRIMOFIN-20 is used as coolant for honing.

WASHING
Finally the races are washed with kerosene & a soft brush is rubbed over the races before sending for assembly.

AXLE-BOX-HARDENING
Different processes done in axle box hardening are

:ANNEALING:-cutting

2:STAMPING:5:TEMPERING:-

To increase ductility tempering is done. It consist of heating the work piece at about 180c for about one hour to produce tempered martensite the different objectives achieved by tempering are

FURNACES:
Furnaces are an integral part of an industry like NEI . Bearing being a loadcarrying component needs hardness , while brittleness is not desired . Thus to give the desired properties like the carbon content or hardness . These furnaces are very essential . There are various types of heat treatment operation and various furnaces are used to perform these operations . The bearing being an integral part of all machinery and are also active i.e. load carrying members is supported to have hardness .

CONTINUOUS FURNACES
Heat treatment of ball bearing inner and outer races and balls is performed on CHUGAI-RO-FURNACES , which is the latest plant made in Japan . Operation sequence in this furnaces are :

Loading
Pre-washing in hot water to make it fully clean Hardness in furnaces at 850-900 Degree Centigrade Quenching in oil at 105-110 Degree Centigrade Rewashing in hot water with surf to r

stresses developed in quenching. (1) Tempering at 150-200 Degree Centigrade to remove

Above entire takes three hours. All above operations are performed in once after loading, which capacity is 450 Kg./hr. and we have final product . It is completely automatic plant for heat treatment. It requires least space , manpower and time .

STANDARD
For inner AND outer race: Parameter Quenching Hardness Tempering Hardness Microstructure Standard 62-65 HRC 60-64 HRC Uniform distributed Carbon tempered Martensite matrix in Inspection Method Hardness Tester Hardness Tester Metallurgical Microscope

HARDENING FURNACES
The furnaces used commonly for purpose of Hardening is called Cast Link furnace . The operating temperature of this furnaces are for low carbon steel 300oC and for high carbon steel is 840OC in this furnaces also the inner walls are made of a thick layer of fire insulating bricks . Fans are provided for uniform heating .There are three zones and in all , six thermos couples are installed at various places to indicate the temperature and to control it . Five of them control a display and one records . Three thermoscopes are for three zones and apart from these two couples are provided between first -second and second - third zone . The sixth one is used

for checking the temperature of quenching oil . Oil quenching and diepressing are done . Simultaneously after the hardening process . Four process plugs are used to press the job and to remove avality that comes in the outer and inner race as a result of the heat treatment operation . Although the time of operation depends upon the size of job , the normal durations are around 45 minutes . The job takes this much time to cross the three zones of the furnace and conveyor that takes them to exit . This is driven by a controlled speed motor, which is controlled by eddy current coupling . There is manual feeding and discharge in this furnace . The furnace has toshniwal manufactured temperature controls, which cut off the power supply when the surface temperature reaches a critical limit . Immediately after the hardening process , oil quenching and pressing is done .

TEMPERATURE FURNACE
After the heat treatment , temperature is done . It is define as the reheat process used to modify the properties of steel hardened by quenching for the purpose of increasing its usefulness and decrease hardness upto 1-3 HRC after quenching . The average operating temperature is around 160O C and thus the ironconstenton thermocouple along with toshniwal display cum convert type temperature indicator is used .There three zones in the furnace also , the body is a long one and the discharge is done by a slow conveyor , from which the

jobs are controlled and collected . The discharge conveyor is an extremely slow moving device driven by an electric motor and gearbox combination coupled with a chain. The temperature is kept uniform through out by fans and the jobs are fed by hand or manually. The inner position of the furnace is again made up of fireproof bricks.

CARBURISING FURNACE
It is used for case carburising of outer races of the taper roller bearing. For this purpose it utilize the HYENGAS (A part of air + A part of LPG). This is generated separately by a Rx gas generator at a temperature of about 1150OC . The operating temperature of this about 920OC . It consists of two zones. The first zone has a temperature controller, which is electronic dial indicator type. It does not record. The temperature variation is not of much importance in this zone and thus a recorded type is not used. On the other hand for the second zone there is a recorded cum controller type temperature indicator, which has a Ni-Cr thermocouple element associated with it. The two zones of the furnace have sixteen mesh boxes at a time, which are accommodate in two rows of eight boxes. There is a continuous and automatic feeding and discharging. The time for which the jobs remain inside the furnace is about 16 hours. They are heated in an atmosphere of hygen gas in this duration. This provides a greater construction of carbon upto 0.04 0.08 depth of the outer race of the bearing. This is called as the case depth.

Immediately after carburising oil quenching is done. There is one separate thermocycle couple for checking of quenching oil temperature. Total four thermocouple is in the furnace. One each for the two zones, one excess for the precautionary measure, and one for the oil. In each side of the furnace there are three control switches to control the oiling and carburising operating time. Fans are provided of the furnace is made of fireproof bricks.

For carburising compound is used which is placed along the tray along with the job and then heated.

ROTARY FURNACE
In this furnace hardening of plane rollers, inner and outer races of axle boxes are done. Twelve rollers are kept in every cast iron basket and 18 baskets are placed inside the furnace. The baskets are taken out after one hour by tong manually. Baskets are placed inside the furnace on the revolving base plate rotates at 1 rpm. These furnaces are electrically heated with the resistance. The opening and closing of door is pneumatically controlled. The rollers after hardening for one hour are quenched in quenching oil for 15 minutes in the rotating drums, which kept half in the oil and half in atmosphere. After quenching the work pieces are sent for following operations as Tempering, Tumbling. In tumbling pieces are washed by caustic soda and water where black spots are removed. Before and after the tumbling Rockwell hardness tests are being done, pieces having 62 Ra. and O.K.

SALT BATH FURNACE

In this furnace heat treatment of spherical rollers. Spherical inner and races are done. Before hardening in salt bath furnace work pieces are preheated in preheater, furnace which is electrically heats. The piece is preheated for 45-60 minute depending upon job size at 400-450OC . In this furnace salt is kept inside the double line pot having the inner side of stainless steel and outer of MS The composition of salt is Nacl, Kcl & Bacl2. The temperature of salt bath furnace is 860OC hare pieces are kept generally 45-60 minutes in it. There are 3 electrodes having composition of 30%Cr, 15%Ni, 2% remainining Fe. For heat treatment in salt bath furnance following sequence of operations are done: 1: preheat at 400-500 c 2:heated in salt bath at 860 c 3: quenching at 180 c 4: air cooling

STEEL FOUNDRY DEPARTMENT

INTRODUCTION:Steel foundry or ring rolling shop is the shop where race of cylindrical bearings and cone of cartriage bearing are produced. The principle on which it works is the hot working process. To make required objects, metal bars are used as raw material. It is very small section and it contains only a few machines and workers. Machines available in ring rolling are listed as: press (3-steps forging) rolling mill press (size setting) induction furnance The total operation of making a ring or a race constituents of four steps: heating forging ring rolling sizing

HEATING:
This is done in indution heating furnance in which metal bars are heated up to 1100c by using eddy current heating. This heating is done to soften the metal to ease the operation of forging.

FORGING:
In this process forging press is used. The bar is heated at 1100c and a piece is cut from it. The heating of bar is done by induction hardning. In this process the bar is passed through a coil and due to its temprature rises upto 110c. the piece is cut or parted off by shearing mechanism.

Now the piece or slug is forged in forging machine in three steps, which are upsetting, prepunching and finishpunching. The machine is auto transfer type. The feed or auto trnsfer of the job from one station to other station is done by feed or transfer finger, which clamps the job from one station and transferit to next station. It is a mechanical system and the punching system is hydraulic. In upsetting the shape of slug is changed into a rough shape of the ring. In pre-punching, the shape is improved and a hole which is incomplete is done by a closed die.

Now, in finishing punching, the hole gets completed and desired shape is obtained.

ROLLING:
Finished punched piece is now put on rolling machine, which consists

of a horizontal table which rotaes at 900 rpm and is eccentric, it is called a central forming roll.

Simultaneously a supporting arm mounted on rotating table made pressurized due to the action of the cam. Now, the piece gains the shape of the race. A collar controls the height of the rolled piece for forming roll and supporting arm.

SIZING
After rolling the outer diameter of race and height of race is made accurate by sizing machine, which is also a press, in which a die is also available. In this, the punch pushes a piece into a sizing die, whose outer diameter is same as the required outer diameter. Now the punch presses the piece and the piece gains the required outer diameter and height.

SPECIFICATIONS

For forging press:pressure power : 630 height of stroke : 450mm no. of idle strokes 16-25 per minutes max. ram adjustment : 140mm clamping plate : 2050mm

For sizing press:(1)working pressure (2)height of stroke (3)no. of idle strokes (4)ram displacement (5)max distance : 20,000kg : 250mm : 22 per minute : 150mm : 700mm

BALL DEPARTMENT
INTRODUCTION

In this section, Balls of different diameters are manufactured by cold heading process. Raw material for Ball manufacturing is High Carbon Steel wires in the form of coils. Two types of balls are manufactured, one for Antifriction Ball Bearings, which are used in the factory itself and other type for cycle industry called Bicycle Balls. Following are various operations in which the raw material has to be passed.

WIRE

BALL HEADING

FLASHING

FLASHING

ROUGH L

SOFT GRINDING

HARD GRINDING

TUMBLING

SUPER FI

ULTRASONIC WASHING

INSPECTION

PACKING

(FLOW CHART OF BALL MANUFACTURING PROCESSES)

COLD HEADING
This is the first operation of the series. Raw material in the form of coils put on a revolving drum. One end of it is fed in heading machine in which a much die with shear mechanism allows to obtain piece (not exactly round), which are used for ball manufacturing. Cold heading machine is used to get small pieces of wires. Motor transmits motion to the main shaft of the machine, through belt drive. Rotary motion of shaft is transmitted to ram as reciprocating motion by means of eccentric mechanism. A punch is fitted to the Ram except this a shear mechanism is also used. This is obtained by crank which gives reciprocating motion in

a direction perpendicular to main shaft, while shear mechanism is obtained by converting the motion of main shaft to reciprocating motion of the cutter. For this purpose, a plate cam, especially cylindrical cam, is used, so that the cutter attached to it shears off the bar and due to particular shape of cutter, it leads the piece to die, where the punch strikes the bar piece and at the returning stroke of ram, spring in the die ejects the piece into container. Timing of all cutter and punch is set such that immediately after shearing the bar, pieces reach at the die and at the same time, punch strikes to that. The process consist mainly three steps:Wire feeding Cutting and transfer to the maximum displacement of the cutter. Heating and removal of balls. Wire feeding is achieved by rollers motion arrangement, in which motion is provided from shaft and gear arrangement, with a ratchet, which facilitates unidirectional motion.

The characteristic features of cold heading are as follows:(1)Saving the material (2)Very little or no scrap. (3)Hich speed, automatic production process. (4)Lower labour cost. (5)Better structure of metal. (6)Stronger production with close tolerances.

FLASHING After cold heading we do not get perfect spherical shape but it consists but it consists of coller or flash in the central periphery which is required to be removed. So in this operation, central extra material is removed an it comes in spherical shape, this processes is done on flashing machine. Principal feature of the machine is that it consists two metal plates mounted vertically. Both plates have annular groove cut all over its face according size of ball. The grooving position of ball size plates face each other. One plate is made to rotate by means of eccentric motor through proper gear arrangement. Balls enter from one side and other side is operated ball discharging side which are recirculated again and again, until proper shaped balls has achieved The arrangement for changing the pressure between plates is also provided. A coolant is also used. SOFT GRINDING This operation is achieved for removing excess material from the balls. This operation is done on Lapping machine. The difference between Lapping and Flashing is that the Lapping machines have one metallic plate instead of two, and other one is made of abrasives. The metallic plate is fixed and abrasive plate is used for material removing. The process is performed before heat treatment process because of easy removing of material in soft stage. HEAT TREATMENT

After soft grinding, balls are send for heat treatment. Bicycle Balls are treated in the same section but Bearing Balls are heat treated in separate section. Hardning is done by heating the balls at 850 Degrees Centigrade for three hours in electric are furnace and then they are Oil quenched. Oil for quenching is known as Fausion 40 oil. Feeding of balls is done by vibrating sheet. After hardening, tempering is done in which balls are heated to 180 Degrees Centigrade slowly and maintained for two and half hours then cooling is doe slowly. This purpose is completed in rotarary electric furnaces. After this balls are washed in sode and water mixture. Then goes for tempering and after this final washing is done before leaving furnance room. TUMBLING This is called TTS operation means Tumbling Test for Soft Balls for softness. The purpose of this sectional operation is to remove all scale nearly, which have deposited due to heat treatment. This is achieved in tumbler, which are octagonal bodies having lesser dimensions of upper part as compared to lower one. These are inclined at certain angle and then are made to rotate by means of motor and pulley arrangement. Inside the tumbler balls with some abrasive material are allowed to rotate together, which gives the better surface finish. Caustic sode and water in fixed proportion is used for washing in tumbling process. FINISHING PROCESS After tumbling, balls come into grinding section here they first send to visual Inspection, where Balls are rolled over a plane paper under a beam of light. Here balls with irregular shaper are drawn out. Remaining Balls passed through different operations which are:-

HARD GRINDING Specifications of N G 800 Machine used for hard grinding. Load size (+100M + 5) Finish size (+30 + 5M) Pressure 10 to 20 kgf/cm2 Time required 20 hours Dressing pressure 8 kgf/cm2 R.p.m. of machine 90 Batch weight 800 kg Coolant is similar 2% FINISH GRINDING It is also NG 800 but having different grinding wheel in the machine load size +30 M, Finish +7 M, Pressure required 8 to 15 kgf/cm2, Finishing pressure 8 kgf/cm2.

CONCLUSION

The information gathered from the secondary data survey of the national engineering industry limited, I found that all department are taking active participation in this and enjoys maximum employee and workers involvement. Every year maximum training taken by the internal and external faculty. Maximum training programmes attended by manufacturing department i.g. ball bearing, taper, railway bearing and research and development department. As per seeing the data of NEI Ltd., it seems that management is quite satisfied with the training procedure. Which leads to the employee encouragement through making good training, their creative and innovative ability, motivation toward work to do harder and harder. They take active participation in the company growth and achievements of goals and objectives.

Bibliography -2
I. II. III. IV. V. Mamoria C.B., Personnel Manaement, Himalaya Publisher House, Mumbai, 1984. Aswathappa K., Human Resource & Personnel Management, Tata MC Graw Hill, New Delhi, 2001. Dwivedi R.S., Managing Human Resource, Personnel Management In India Enterprises, Galgotia Publishing Company, New Delhi, 1997. Tripathi, Personnel Management & Industrial Relation, Sultan Chand & Sons, New Delhi, 1999. Gupta C.B., Human Resource Management, Sultan Chand & Sons, New Delhi,2003. OTHERS Annual report of the NEI Ltd. Records of NEI, Jaipur.