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PRACTICAL TRAINING REPORT

(40 WORKING DAYS)


DURATION: - (11th JUNE, 2008 To 26rd JULY, 2008)

TAKEN AT

National Engineering Industries Ltd.


Khatipura Road, Jaipur 302006, India.

Submitted To

Prepared By

Ms. Monika Joshi

Sudhanshu Singhi

Sr. Manager (H.R.D.)


NEI Ltd., Jaipur

B.E. II Yr. (Mechanical Engg.)


M.B.M. Engg. College, Jodhpur

INDEX

Preface
Acknowledgement
Company Profile
Product Information
Ball Bearing
Railway Bearing
Taper Roller Bearing
Large Diameter Bearing
Other Divisions
Maintenance
Industrial safety
Manuals of BB division
5-S plan

PREFACE
Practical training is an essential part of an engineering student as it
adds to the technical knowledge of the student. It gives the student
the much needed exposure to the real world and helps him to relate
his theoretical knowledge with the field conditions. As a part of
engineering curriculum each student has to undertake it for a
prescribed duration.
According to our syllabus each student of B.E. II year Production
and Industrial has to complete a training of 40 days. Therefore,
preferred to undergo my practical training at NATIONAL
ENGINEERING INFUSTRIES LIMITED, JAIPUR which is a
leading bearing manufacturer in Asia. I listed all the departments
of the company and attempt has been made here to prepare
separate operational manual on all the departments.

ACKNOWLEDGEMENT
I feel immense pleasure in thanking Ms. Monika Joshi, Sr. Manager, NEI
Ltd., for giving me an opportunity to take my training in NEI Ltd.
I also extend my thanks to Mr. Thomas for helping me throughout my
training.
I also express my sincere gratitude to Mrs. Meenal, Mr. Rajkumar
Ajmera, Mr. Shashikant Sharma, Mr. Jayant and Mr. Shyam for guiding
me throughout my training.
I also thank all the engineers, supervisors, and workers without whom this
training would not have been a successful one.

I also acknowledge thanks to my fellow student for discussing


various points during the course of training which proved very
useful in preparing this report.

COMPANY PROFILE
This factory was established in Jaipur in year 1946 by Mr. B.M. Birla under name of
National Bearing Company (N.B.C.) limited. In 1950 it manufactured its first bearing and
it was marketed under trade name N.B.C. Company changed its name to National
Engineering Industries (N.E.I.) limited in 1958 but the product is being sold under the
original trade mark of N.B.C. which had now become a symbol of quality.
It is the largest manufacturer of bearings in India. The NEI produces all type of bearings
and axel box completed with roller bearings.
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The branch offices of NEI limited are at Mumbai and Calcutta and the sales
representatives are in Amritsar, Coimbatore, Kanpur and Secunderabad.
The company also has business in United Kingdom, Japan, Germany, Yugoslavia, United
Arab Emirates and Iran. The plant has an area of nearly 15, acres. The company has over
1500 workers working in three shifts for twenty four hours.
The major products of company are as follows:

Ball bearing

Taper roller bearing

Axle box bearing

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.

The NEI Office Network

HEAD OFFICE
The Head Office of the Company is situated at 9/1 R.N. Mukherjee road in Kolkata.

COMPETITORS
(1) S.K.F. Poona
(2) S.B.L. Ranchi
(3) ABC Ranchi
(4) KOYO India , Hyderabad
(5) FAG , Mumbai
(6) Bharat Ball Bearing
(7) Tata, Jamshedpur

PLANT AT JAIPUR

PLANT INFORMATION
The factory is situated at khatipura road about one kilometer west of railway station,
Jaipur. The choice of its location has been so made because of its proximity with railway.
This brings down the cost of material vending from to the factory. The raw material
cheaply and easily obtained by goods train. Similarly the final product can also be
transported to the demanded areas from the factory.

PRODUCT INFORMATION

(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:


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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. These bearings
are used by all major Automobile manufacturers in the country as Original Equipment.
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
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in service with the Indian Railways. The development of completely


indigenized 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 197576 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 Up grated Wagons designed by the RDSO,
NEI is the only manufacturer in the country to indigenized 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

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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.
The largest bearing manufactured by NEI for fitment to the Plate Mill of Rourkela Steel
Plant was released by Mr. G.P. Birla 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 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.

The following New Bearings are Developed for Railway Application

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SPHERICAL ROLLER BEARINGS


22312D1
22312KD1
22314D1
22314KD1
22222
22222KD1

(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)
(Bore 110mm x OD 200 mm x Width 53mm)

CYLINDRICAL ROLLER BEARINGS


NH318 (Bore 90 mm x OD 190 mm x Width 43 mm) Traction Motor Bearings
NU1964 (Bore 320 mm x OD 440 mm x Width 56 mm)
Suspension Bearing developed for Indian Railways for WAG-9 Locomotive
NH1044 (Bore 220 mm x OD 340 mm x Width 56 mm)
Suspension Bearing developed for Indian Railways for WAG-9 Locomotive

SUSPENSION TUBE KIT ASSEMBLY


Suspension tube kit assembly developed for Indian Railways for GM Locomotive WDG4

TAPERED ROLLER BEARING


M244249A/N1060 (Bore 220.662 mm x OD 314.325 mm x Width 61.912 mm)
Suspension Bearing developed for Indian Railways for GM Locomotive WDG-4
N1059/M244210 (Bore 221.17 mm x OD 314.325 mm x Width 61.912 mm)
Suspension Bearing developed for Indian Railways GM Locomotive WDG-4

COLLBORATORS OF N.E.I. Ltd.


The National Engineering Industries Limited the oldest bearing manufacturing industry
established as the National Bearing Co. Ltd. In 1946 at the Pink city of India, Jaipur had
association and technical collaboration with renowned world manufacturers.
1. The Hoffman Manufacturing Co. Chelmsford, U.K. (Now RHP)

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2. Withelm Stahtecker GMBH, West Germany


3. Federal Mogul Corporation, U.S.A.
4. SRO Switzerland
5. Heald Incorp. Ltd, Boston U.S.A.
6. NTN, Japan
7. Brenco U.S.A.

ISO / TS 16949:2002
NEI extensively embarked upon system improvement and implemented modern concepts
of Total Quality Management. NEI has been awarded TS 16949: 2002 on 17th October,
2003- THE MARK OF EXCELLENCE IN QUALITY MANAGEMENT SYSTEMS
by BVQI for design, development, manufacture & supply of Ball Bearing, Tapered

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Roller Bearing and Cylindrical Roller Bearings. NEI Ltd. is the first bearing industry in
India to have been recommended for TS 16949: 2002.
This certificate is awarded to only suppliers of automobile manufacturers. NBC bearings
are used by all major auto mobile companies in India like Maruti Udyog, Hero Honda,
Bajaj Auto, Bajaj Tempo, TVS Motors, Ashok Leyland, Tata Motors, Hindustan Motors,
Yamaha Motors, Eicher Limited, Eicher Motors, Mahindra & Mahindra Auto & Kinetic
Motors etc.
In addition customers like Eicher Tractors, Punjab Tractor, Escort Tractor, International
Tractors, New Holland Tractors, Electric & Pump Motors, Crompton & Orient Fans and
many more in Automobile, Electric Motors & Pump, Fans, Conveyors, Steel Plants, and
Thermal Plants also use NBC bearing regularly.
The recommendation was made by BVQI after 15 days of detailed audit in all areas of
NEI including their Gunsi plant.

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

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plantation. The efforts at NEI have saved precious natural resources like water, oil and
power etc.

BALL BEARING
There are four major parts in a standard ball bearing: balls, the inner race, the outer
race and the cage.

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BALLS
The Manufacturing Proces

HEADING - The balls are a little more difficult to make, even though their
shape is very simple. Surprisingly, the balls start out as thick wire of high
chromium high carbon steel. This wire is fed from a roll into a machine that cuts
off a short cylindrical piece, and then smashes both ends in towards the middle in
between a steel die and punch giving it its round shape. This process is called cold
heading. Its name comes from the fact that the wire is not heated. The ball formed
has a ring like shape called flash, around its surface due to the fact that the
volume of wire fed into the die and punch is more than the volume of ball to be
made and this excess of metal forms this ring. The excess metal is given so that no
defect occurs in ball during heading.

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Ball Machine

Rill plates for ball machine

FLASHING - The first machining process removes this flash. The balls are put
between the faces of two cast iron disks, where they ride in grooves. The inside of
the grooves are rough, which tears the flash off of the balls. One wheel rotates,
while the other one stays still. The stationary wheel has holes through it so that
the balls can be fed into and taken out of the grooves. A special conveyor feeds
balls into one hole, the balls rattle around the groove, and then come out of the
other hole. They are then fed back into the conveyor for many trips through the
wheel grooves, until they have been cut down to being fairly round, almost to the

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proper size, and the flash is completely gone. Once again, the balls are left
oversize so that they can be ground to their finished size after heat treatment. The
amount of steel left for finishing is not much; only about 8/1000 of an inch (.02
centimeter), which is about as thick as two sheets of paper.

1.
2.
3.
4.
5.
6.

HEAT TREATMENT - Various operations in heat treatment:


Loading
Pre-washing in hot water to make it fully clean
Hardening in furnace at 850-900 Degree Centigrade
Quenching in oil at 105-110 Degree Centigrade
Washing in hot water with soda to remove oil
Tempering at 150-200 Degree Centigrade to remove stresses developed in
quenching

This is done in CHUGAI-RO furnace which is completely automatic plant for heat
treatment which requires least space, manpower and time.

GRINDING - After heat treatment, the balls are put back into a machine that
works in the same way as the flash remover, except that the wheels are grinding
wheels instead of cutting wheels. These wheels grind the balls down so that they
are round and within a few ten thousandths of an inch of their finished size.

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LAPPING - After this, the balls are moved to a lapping machine, which has
cast iron wheels. Here, they will be lapped for 8-10 hours, depending on how
precise a bearing they are being made for. Once again, the result is steel that is
extremely smooth.

RACES

HEAT TREATMENT - Manufactured races are heat treated. They undergo


the same operations as the balls.

FACE GRINDING - Next process is face grinding. There are two kinds of
machines used for face grinding. The first kind is in which there is only one
grinding wheel and thus one face is grounded at a time. To reduce this time
taken, a new machine has been introduced in which there are two grinding
wheels rotating in opposite directions with same speed so that both the faces can
be grounded simultaneously. There are two machines of this kind, first,
ROWLAND MACHINE, having grinding wheels with horizontal spindle,
which is used for rough face grinding, and the other one is DISCUSWERKE
MACHINE, having grinding wheels with vertical spindle, which is used for
finish face grinding. A diamond point tool is used for dressing the grinding
wheel as it wears out due to continuous working and looses its shape. A coolant
is used to prevent the heat generation due to grinding.

O.D. GRINDING - After face grinding outer diameter of inner and outer
races is ground. For this purpose centreless grinding machines are used. There
are two wheels, grinding and regulating wheel, in the machine. The centres of
these two wheels are not aligned and thus the job is not centered between the
two wheels, so it is called centreless machine. The job is held against the face of
grinding wheel by the combination of supporting rest and a regulating wheel.
Both wheels rotate in the same direction, but the speed of regulating wheel is
very less than grinding wheel. Grinding wheel rotates about its horizontal axis
during working process. The work piece is supported on a work rest blade and
regulating wheel which hold it against the horizontal force of action controlling
its size. Relational and longitudinal feed are given to the races. The edge of the
work rest blade is beveled, so it makes a v formation with the regulating
wheel, when races are set. A roller of very small diameter compared to its length
is provided for loading of the races. This rotates at very slow speed in the same
direction of rotation to that of regulating wheel. Work pieces are loaded
manually on this roller.

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INNER RACE TRACK GRINDING IZUMI KN 312 is used for track

grinding of inner race. A large diameter grinding wheel, having proper shape for
track grinding, rotates at high speed. Inner race is fed through a channel in the
machine and clamped in magnetic chuck. Grinding wheel then moves towards
the race and grounds it. After grinding, grinding wheel moves back and race
comes out through another channel. Grinding on surface is maintained through a
MARPOSS GAUGE. A skilled operator sets this electric gauge according to the
required finished size. It consists of a thin resistance wire which is connected to
a diamond point tool. After rough grinding of the job surface, this tool comes
automatically in surface contact. As the metal is removed continuously by
grinding wheel, this diamond point tool moves in the direction of Depth of
Cut and this movement increases the length and resistance of wire as well,
related to the number appeared on the screen, shows the limit of grinding.
Machines are connected with PLCs for automatic control.

OUTER RACE TRACK GRINDING CINCINNATI MILACRON

machine consists of a grinding wheel smaller in diameter than outer race track
diameter. Initially, race is clamped in a chuck through a channel and then wheel
enters into race according to feed. Race is supported by bush and backing plate.
Now wheel reciprocates along the direction of its axis.

BORING The bore of the inner race is also grounded in the similar fashion.

The diameter of grinding wheel is slightly less than that of bore. Rest is similar
to outer race track grinding.

HONING It is the process super finishing the surface of the tracks. Types of

stones are used for rough and final finishing. They are made of aluminium oxide
and chromium oxide respectively. These stones rub the surface of the track
giving it a polished look.

CAGE

Steel cages are stamped out of fairly thin sheet metal, much like a cookie cutter,
and then bent to their final shape in a die. A die is made up of two pieces of steel
that fit together, with a hole the shape of the finished part carved inside. When the
cage is put in between and the die is closed, the cage is bent to the shape of the
hole inside. The die is then opened, and the finished part is taken out, ready to be
assembled.

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Plastic cages are usually made by a process called injection molding. In this
process, a hollow metal mold is filled by squirting melted plastic into it, and
letting it harden. The mold is opened up, and the finished cage is taken out, ready
for assembly.

ASSEMBLY

Now that all of the parts are made, the bearing needs to be put together. First, the
inner race is put inside the outer race, only off to one side as far as possible. This
makes a space between them on the opposite side large enough to insert balls
between them. The required number of balls is put in, then the races are moved so
that they are both centered, and the balls distributed evenly around the bearing. At
this point, the cage is installed to hold the balls apart from each other. Plastic
cages are usually just snapped in, while steel cages usually have to be put in and
riveted together. Now that the bearing is assembled, it is coated with a rust
preventative and packaged for shipping.

A Completely Assembled Bearing

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AXLE BOX DIVISION

INTRODUCTION The axle box division is spread in a vast area and is equipped
with modern CNC machines where the spherical roller bearings, taper roller bearings,
cylindrical roller bearings and, ruction motor bearings are manufactured to provide
bearings to Indian Railways and for exporting.
The axle box division mainly consists of three sections as heat treatment, grinding and,
assembling.

HEAT TREATMENT The races are first of all heat treated in various furnaces
according to the material they are made up of, high carbon steel or low carbon
steel.

1. HEAT TREATMENT BY ROTARY FURNACE The job is taken inside the


rotary furnace maintained at a temperature of 850 Degree Centigrade. This
furnace is generally driven by LPG and here the job is heated for about 45
minutes. Now the job is Quenched into the oil having a temperature of about 6070 Degree Centigrade for about 2 minutes. The job is now subjected into the
chiller unit for its cold treatment in which the total heat is reduced for 2 minutes.
Now the job is sent to the tempering furnace at a temperature of 250 Degree
Centigrade. Finally it is sent to the hardness testing machine.
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2. HEAT TREATMENT BY GAS CARBURIZING FURNACE After stamping


process, the raw material is sent to this furnace where the job is to give high
carbon content at a temperature of 940 Degree Centigrade for about 8 hrs so that
the percentage of carbon increases to 80 90%. This furnace uses a mixture of
LPG and endo gas as the fuel. LPG acts as the source of carbon and endo is used
to extract carbon from LPG and to provide inert atmosphere in the furnace. The
job is then sent to rotary furnace for heating at 850 Degree Centigrade and is then
Quenched in oil and is further chilled. The job is then sent to the tempering
furnace maintained at 250 Degree Centigrade for 2.5 hrs. The job is finally sent to
the hardness testing machine.
3. HEAT TREAYMENT BY REVOLVING FURNACE The revolving furnace is
the heat treatment electric furnace which is used to harden the job placed in a
circular plate and revolve by the gear arrangement at a temperature of 840 850
degree Centigrade. The job is then Quenched in oil at a temperature of 60 90
Degree Centigrade and is further sent to tempering furnace, followed by hardness
testing machine.
4. SALT FURNACE-This furnace is used for hardening high carbon steel jobs,
where first of all the job is heated in a furnace at a temperature of about 840
Degree Centigrade for some time and is then quenched into a chromium salt
container at a temperature of 180 Degree Centigrade and is then send for grinding
process.
5. SHOT BLAST MACHINE The job as hardened by the revolving or salt bath
furnace is sent to the shot blast machine where the job is rotated in presence of
chilled iron. During this process all of the dust is removed and we obtain a
polished surface over the job.

RACE GRINDING The race grinding follows the same order to that of ball
bearing, i.e. face followed by O.D. and track grinding.

1. SPHERICAL ROLLER BEARING The face and O.D. grinding is similar to that
of ball bearing races grinding. For track grinding, grinding wheel is fed into the outer
race such that the axis of the grinding wheel crosses the axis of the outer race
normally. In case of inner race, both the lips touching the rollers are grounded
together followed by track grinding.
2. TAPER ROLLER BEARING It consists of a cup (outer race), and two cones
(inner race). In case of cup, first of all O.D. is grounded, followed by the track. The
grinding wheel is similar to that of track in shape, i.e. it is tapered such that it easily
feeds into the cup. In case of cone, face is grounded followed by the flange where the
cage touches the cone. After that track and the lip (where rollers touch) are grounded
simultaneously so that the angle between lip and track is constant. The shape of the
grinding wheel is maintained such that these two surfaces can be grinded together. It
is followed by boring.

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3. CYLINDER ROLLER BEARING The races are grounded in similar fashion to


that of ball bearing races. Flange and lip may or may not be grounded as according to
the requirement of the final bearing.

ROLLER GRINDING The grinding wheel is given the particular shape with
the help of diamond point so that the rollers can be given the required shape. The
process starts with grinding twice and then honing is done.
PHOSPHATING The bearing races undergo phosphating, i.e. phosphate
coating is done, to avoid rusting.
ASSEMBLY Various kinds of bearings are assembled in different ways. The
assembling of taper roller bearing starts with the assembling of rollers in a metal
cage and the inner i.e. cone. Final assembly has two such kind of assembled cones
which are held in a cup separated by a spacer (which is used to give the rollers
enough space for movement even when they are expanded due to heat and other
reasons). Further this assembly is greased and then rubber seal is placed on it
covering the grease and securing the bearing from dust and other such things. The
other kind of bearing assembled is spherical roller bearing. Assembling of such
roller starts with the rollers being put into a split brass cage which is further put
into the outer race. The complete assembly consists of two split cages. Further the
inner race is assembled in the above assembly. Brass cages are used owing to the
fact that they are weaker as considered to metal and they would be the first to
break in case of any damage to the bearing. Besides, split cages play the roll of a
complete cage quite efficiently, and also, bearings weigh less. The other kind of
bearing is cylindrical roller bearing. The assembling of such kind of bearing starts
with the assembling of a cage, rollers and outer race. The outer race consists of
two tracks. And thus, two cages are used. Two inner races with single track are
used, one being a plane inner race and other consisting of a lip. The reason for
using this combination is the fact that it would be easier to fit on the place of its
application.

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TAPER ROLLER BEARING

INTRODUCTION - A taper roller bearing has four main components cone (the inner
race), cup (the outer race), rollers (the rolling element in between the races) and, the cage
or the retainer which holds the rollers on their track.
These bearings are so designed that when the construction lines are projected
corresponding to the contact surface of rollers and races, they meet at an apex point on
the bearing axis.
Taper roller bearing can take both types of loads, radial and axial, which is why they are
used in gearboxes, heavy trucks, bevel gears, lathe spindles etc.

ROLLER SECTION The raw material in order to manufacture is High Carbon


Chromium, found in the form of wire. First operation for manufacturing the roller
from raw material is performed on Cold Header Machine. Firstly wire is fed from
drawing machine to cold heading machine. The function of drawing machine is to
feed the wire with uniform cross section and without any bend. In the cold heading
machine, a cutting tool called Shear Cutter cuts a certain length of the wire and
transverse it to the die having tapered hole. A punch strikes that wire and a tapered
roller is produced. This way a roller is constructed in two strokes.
HEAT TREATMENT Heat treatment is an important part of the production of a
taper roller bearing. As they bear loads in both axial and radial directions, they require
good strength which is given to them by hardening process. Due to heating in
hardening furnace, quenching is required which further generates brittleness in the job
and to remove this brittleness, tempering is done. Tempering also decreases the
internal stresses and increases the flexibility and toughness.
RACE GRINDING The race grinding is quite similar to that of axle boxes
grinding. It starts with O.D. grinding, followed by track grinding but there is a major
difference in lip grinding which is not done simultaneously with track grinding while
in case of axle boxes grinding, it is done simultaneously owing to the fact that the
angle between the lip and the track plays a major role in these types of bearings. Here
the track is grounded 1st of all followed by the lip grinding. It is done this way
because qualitatively it is better. It is followed by boring and then honing. Major
attractions in this department are the new robotic machines which are just loaded in
the start and unloaded in the end of the whole process giving the final product. Also,
the product is better finished than the old machines products.
ASSEMBLING The assembling starts with the assembling of rollers in a metal
cage and the inner race. The outer is simply put onto the assembled part without press
fitting. It is left like this so as the bearing can be fitted on its place of application
easily.

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LARGE DIAMETER BEARING

The manufacturing of Large Diameter Bearings (or LDB) follows the same procedure as
other roller bearings. The different parts of the bearing are manufactured by other
companies on order by NEI Ltd., which further undergo heat treatment similar to that of
other bearings. The different parts are than grounded in various machines like HMT but
the most important machine is BERTHIEZ which can ground any surface with any
angle. It is one of the biggest machines in the plant. Assembling of the LDBs is done
according to the requirement. The first bearing that was assembled consisted of three
cups, one consisting of two tracks and the other two consisting of single tracks, and two
cones, both consisting of two tracks. The cones and cups are separated by cone and cup
spacers respectively. The second bearing consisted of three cones, one double track and
two single track, and two cups, both double track. The third kind was simple cylindrical
roller bearing. The rollers it contained had a hole in which a pin is passed through. This
pin has threads on one end. The diameter of this pin is less than the diameter of the hole
in the roller, so that when the pin is locked with the cage, the roller can easily move. The
pin is locked with the help of threads on the one side while it is welded on the other. The
fourth kind was a thrust bearing which had horizontal rollers. The cages used are split
cages, the reason being the rollers can be easily fitted inside cages this way rather than
the other way. The two parts of the cage are locked with the help of a lock pin. It further
consists of two discs, one above and one below the cage.

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TOOL ROOM

The tool room of NEI consists of following machines which are used for making different
parts like blocks, splines, shoes and, different other tools

LATHE Any job can be turned down with the help of lathe machine. The main
parts of a lathe machine are Tailstock, Headstock, Chuck, Spindle, Lathe Bed,
Carriage, Lead Screw, Tool post and, Cross slide.
MILLING MACHINE The milling machine is employed for the processes like jig
boring, gear cutting, step milling, angular cutting, keyways, splines, notch, and flat
surfaces. All kinds of milling machines are there, i.e. Universal, Vertical and
Horizontal Milling Machines.
UNIVERSAL GRINDING MACHINE This machine is generally used for the
purpose of making gauges, forming dust seals, punch, harbour, spindles etc. Ordinary
wheel is used for grinding common materials while diamond wheel is used for cutting
carbide tools.
SURFACE GRINDING MACHINE This machine is used for removal of material
from the surface of job by rotating a grind wheel against the surface of job.
SHAPER MACHINE It is generally used for making square, rectangular boxes
and, angle cutting. In this operation, the job is fixed while the workhead slides against
the job so as to remove the material from its surface.
JIG BORING MACHINE It is used for precision work. It is used to produce jig.
The tool is held in vertical chuck eccentrically. Its least count for angle is 1 inch and
for longitudinal distance is of 0.2 inch. The table can be lifted to a maximum distance
of 18 inch from the bed of machine.
JIG GRINDING MACHINE It is used for grinding the bore that is to enlarge. The
maximum speed of jig tool is 75000rpm. It rotates at a high speed to grind the bore
against the job, which is held against the chuck by clamping arrangement.
CNC LATHE MACHINE The computer numerical control lathe machine is used
for turning operations on a job. It can turn the job with fine quality. In this machine, a
program is fed into the machine as per drawing and the job is finally turned down.
DRILLING MACHINE It is used for drilling holes into the job.

28

MAINTENANCE & ELECTRICAL

The name of this section itself suggests that the purpose of this is to maintain the
machines in the proper running position. In this section, damaged or broken parts are
either repaired or replaced by new ones produced in the shop itself. For this purpose
section is equipped with various types of machines. For making any part of machine first
blue prints are made and then experienced skilled persons manufacture it on these
machines.
The various types of maintenance are as follows

Preventive maintenance
Running breakdown maintenance

PREVENTIVE MAINTENANCE
It is general checking of the machine in which all defects of the machine, due to which it
is not running properly, are eliminated.
The following defects of the machine are observed
1.
2.
3.
4.

Cleaning
Lubrication Oil level, lubrication line to check and repair, oil line to all points
Pneumatic system air filter to be cleaned, lubrication to be checked
Checking of brakes, slides, gears, belts etc.

RUNNING BREAKDOWN MAINTENANCE


When any machine stops suddenly, it is required to eliminate the defect instantly, and for
this purpose running breakdown maintenance is done.

DIESEL GENERATOR

29

The electricity used in the entire plant is not taken by RSEB completely but a certain
amount is produced in the plant itself with the help of diesel generators. A number of
diesel generators are there which are controlled by an electronic panel. This panel
controls the amount of electricity generated by the entire number of diesel generators in
accordance with the requirement of the plant by controlling the number of generators in
operation at a time.

AIR COMPRESSOR
It is one of the major requirements of the plant as almost all the machines work on
pneumatic power. A number of air compressors are there which are driven with the help
of diesel generators. Several pipelines take this compressed air to different departments
which are further connected to the machines.

30

RING ROLLING SHOP


NEIs Wagner Ring Rolling Line is the first of its kind in India & has a Leading edge on
World Market. Ring Rolling Line consist of : Automatic bar stacker, bar feeding device,
Induction heating plant, Automatic multi-station ring blank hot working press with shear
and automatic advances, Radial ring rolling mill, Calibrating (Sizing press) for
manufacturing Seamless rings for Bearings, Automobiles and general Engineering
Applications. Distinctive feature of rolled rings is superior grain structure and are free
from Surface defect.

In this section, rings are made from steel bars with the help of forging press.
A systematic mechanism of rolling machine is as follows

5 ton E.O.T. crane for loading

Bar stand

Bar plate form

Bar feeding stand

Induction furnace

Forging press

31


Rolling mill

Calibration mill

A systematic process of rolling machine is as followsRaw material

Induction heating

Bar cutting

Upsetting

Pre punching

Punching

Rolling

Calibration

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Specification for forging press


Pressure power

630

Height of stroke

450 mm

No. of idle stroke

16.25/min

Max. ram adjustment

140 mm

Clamping plate

2050 mm

Size Range

Min.

Max.

Outside Diameter (mm)

130

350

Height of Ring (mm)

64

100

Ring Weight (Kg)

3.5

15

.Capacity
Installed Capacity 3000 Ton/ Year
Available Capacity 1600 Ton/ Year

Advantages
Superior quality, improved material yield, shorter production time, reduced costs
Upsetting, forming and piercing of the blank under the press, rolling on ring rolling mill,
and subsequent sizing are done in one heat.
A quality benefit of ring rolling is grain flow adapted to most kinds of stressing. Grain
orientation is not only parallel with the surface but is also circumferential. This leads to
decisive improvements: Life of rolled ring is considerably increased, their mechanical
and physical properties are substantially improved, minimum machining allowances are
possible, surfaces become smooth, irregularities being eliminated in the pass.
Ring Rolling Plant is certified for both QS 9000 and ISO 14001

33

MAINTENANCES
INTRODUCTION
Maintenance department is the inevitable for any factory for uninterrupted production. In
a factory there are numerous machines for various purposes. A machine is a complex
device involving various mechanisms, if any of the mechanism stops working properly
the machine becomes absurd. Maintenance department mainly deals with the repairing of
machines. For this maintenance engineer are required. There duty is to find the fault the
fault in the system and then to correct it. Hundreds of engineers, workers technicians are
employed in this department.
In this department experienced and efficient workers repair or produce the machine part
which is damaged. For this rout design made by engineers or the original blue print is
supplied by research and development department. This is handed over the worker which
has to make the part or component. In maintenance department there are separate
electrical and mechanical winding, wiring etc. are done. The departments have large
number of catalogues and manuals of all machines. This helps in getting any required
information about the machine and its circuit.
The mechanical department deals with the machine parts. Here a very close component
various operations are required like truing, boring, slotting, making keyways, threading
grinding milling, drilling etc.
For the maintenance purpose various machines are used as listed below

Lathe machines

Shaper machines

Boring machines

Planners

Grinding machines

34

1. Internal grinding machines


2. Surface grinding machines
3. Cylindrical grinding machine

Horizontal boring machines

Slotter

Milling machines
1. Plain milling machines
2. Vertical knee and column type
3. Universal

35

INDUSTRIAL SAFETY
Preventive measures

Use of safety guards for reciprocating machine component e.g. drop hammer
paper cutter etc.

Fencing of dangerous and rotating parts like revolving shafts.

Incorporating safety devices.

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 body products.

Maintenance clearness of shop floor.

Removal of metal chips with proper protection

Avoiding fire hazard.

Electrical safety

All metallic parts, externally accessible must be earthed.

Defective and worn out fitting must be replaced promptly.

Inflammable material should not be kept near electric appliances, live wires or
electric control panels.

36

Safety devices like fuse, circuit breaks, and overtripping switches must be used when
required.

MANUALS OF BB DIVISION
In the project given to me, under the supervision of Mr. Jayant, I have
made the list of questionair of technical topics and then prepared
manuals of the topics. These manuals are displayed on soft boards in
various departments .These manuals are helpful for the workers and also
ensure their own safety while operating on the machines.

List of Manuals BB division


S.NO.
1
2
3
4
5

MANUALS
A/C plant operation and maintenance
Cooling tower maintenance
Window A/C and split A/C maintenance
Panel A/C and oil cooler maintenance
Water cooler maintenance
R.O. water operation and maintenance

displayed
6
7
8
9
10

Pumps and cooling tower operation and maintenance


Knowledge of pumps
MTO filtration system
FES maintenance

5-S PLAN

37

I have been given the opportunity to train workers about 5-S rules
under the supervision of Mrs. Meenal.
WHAT IS 5-S Many people think house keeping should be done by house wives at home and cleaners at
the workplace. They do not realize that they too play an important role in keeping their
houses/workplaces clean. More importantly, they do not know how much they can gain
themselves by just practicing, good house keeping. The 5-S extra the virtues of tidiness
orderliness and cleanliness at all times and at every place. These account for the clinically
clean shop floors and also in their personal habits. It is the practice of good house
keeping.
The term 5S represents 5 Japanese words

1. Seiri
2. Seition
3. Seiso
4. Seiketsu
5. Shitsuke
Let us look at each word, understand what it means, and how it can apply to us.

SEIRI
SEITON

Take out unnecessary items and throw them away.


Arrange necessary items in a proper order so that they can be

SEISO

easily picked up for use.


Clean your work place completely so that there is no dust

SEIKETSU

anywhere.
Maintain a high standard of house keeping and work place

SHITSUKE

organization at all times


Train people to follow good house keeping disciplines
independently.
38

The factory is very much planned. All sections can work independently by with the
unmark able mutual co-operation.

39

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