.

is presented to

VIKAS YADAV

for successfully completing the Elearning program on

Bearings

Date : 23-04-2020
INTERNSHIP REPORT ON BEARINGS AT TATA STEEL

By

VIKAS YADAV-18119903

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
RAIPUR
MAY-JUNE 2020
 ACKNOWLEDGEMENT

Words fail me to express my sincerest gratitude to this esteemed organization, which has
conferred on us the privilege to pragmatically convert our theoretical knowledge into
practical viable experience. During the course of my training at TATA STEEL so many
people have guided me and I will remain indebted to them throughout my life for making my
training at TATA STEEL, a wonderful learning experience.

Thanks to all those operators, Diploma Engineer Trainees and my trainee colleagues with
whom I had developed a special bond.

5
 CONTENTS

Chapter No. Topic Page No.

1. DEFINITION OF INDUSTRY 7
2. INTRODUCTION OF NEI 8
3. INTRODUCTION OF BEARING 8
4. INTRODUCTION OF BALL BEARING 11

5. MANUFACTURING PROCESS OF BALL BEARING

a. Inner track wheel

b. Outer track wheel
c. Cage
d. Balls
e. Rivets

6. TROUBLE SHOOTING 31
7. CONCLUSION 33

6
DEFINITION OF INDUSTRY

Industry can be defined as:

‘’Any type of Economic Activity producing GOODs or SERVICES‛’

‘‘It is part of a chain – from raw materials to finished product, finished product to
service sector, and service sector to research and development.‛’

‘‘It includes AGRICULTURE, MANUFACTURING and SERVICES‛’

‘‘Industry varies over time and between different countries‛’

Industrial linkage:

‘‘When one Industry depends on the output of another‛’

This can cause problems if one industry has production problems or closes down

The CAR INDUSTRY is a good example – each component (engine parts, lights, body etc.)
may be produced by a different company before it goes to the ASSEMBLY PLANT.

BEARING INDUSTRY GLOBAL SCENERIO :

The world Market of quality Bearing is very vast. The Big players of bearing sector are
present in U.S.A, Russia, Japan, China and Eastern Europe. Some of leading bearing
Manufacturers are: -
- NSK Japan
- NTN Japan
- KOYA Seiko Japan
- FAG Germany
- SKF Sweden
- NRB France
- Timken USA

There are few of leading bearing manufacturer present in India. Most of the big player is
having either technical or financial Collaboration with leading Auto Manufacturer.
International Collaboration gives Access to best technology in the world.
7
BEARING INDUSTRY INDIAN SCENERIO:

The Indian Bearing Industry is estimated at Rs. 30 Billion Approximately. The Industry has
established a highly diversified product range of around 1000 type of Bearing having High
Volume Demand. As much as 70% of the total

Demand for common varieties and size of bearing is met by the domestic Industry, and the
remaining demand to the tune of 30% is imported essentially for Industrial Application and
special purpose.

The Indian bearing Industry can be divided in to the organized sector and un-organized
sector. The organized sector primarily caters to the original equipment Manufacturer (OEM)
Segment, which predominantly comprises automotive industries and other mechanical
Industrial users. The replacement market is dominated by unorganized Sector.

ABOUT NEI:
Bearing in India started with the setting up of manufacturing unit in JAIPUR by the Birla
Group in 1946 under the name of "National Bearing Company Ltd."
The 1st Bearing was manufactured in 1950 with a modest start of 30 thousand bearing in 19
Sizes. The Bearing Races (Soft) was Manufactured by the Tiny Unit in the Small Scale
Sector at Jaipur during 1970 on Job Work basis.

It is a view to utilize the end piece of the Stainless steel tube which could not be fed to the
Multi operation of National Engineering Industries Jaipur.

There after there is a continuous growth of this Industry and now it has grown to a level that
Almost All the Leading Manufacturer of the country are procuring Soft Bearing Races from
JAIPUR. The National Engineering Industries procure lakhs of Ring every month from these
Bearing Race Manufacturing Unit.

The other leading manufacturer like S.K.F., FAG, TATA Bearing, NBC are also procuring
the Bearing races from Jaipur. In addition to above, the Small Scale Units manufacturing
Bearing in the state of Rajasthan, Delhi, Gujarat and Punjab also purchasing Bearing Races
and components from Jaipur.

BEARING:-

A bearing is a device to allow constrained relative motion between two or more parts,
typically rotation or linear movement.

8
Bearings may be classified broadly according to the motions they allow and according to
their principle of operation as well as by the directions of applied loads they can handle.

TYPES:-

There are many different types of bearings.

Stiffness
Type Description Friction † Speed Life Notes
Widely used,
relatively
high friction,
Rubbing Depends on suffers from
surfaces, materials and Good, stiction in
usually with construction, provided some
lubricant; some PTFE has wear is Low to very applications.
Low to
Plain bearings use coefficient of low, but high - depends Depending
very
bearing pumped friction some upon application upon the
high
lubrication and ~0.05-0.35, slack is and lubrication application,
behave depending normally lifetime can
similarly to upon fillers present be higher or
fluid bearings. added lower than
rolling
element
bearings.
Rolling Ball or rollers Rolling Good, Moderat Moderate to Used for
element are used to coefficient of but some e to high high (depends higher
bearing prevent or friction with slack is (often on lubrication, moment

9
 minimize steel can be usually requires often requires loads than
rubbing ~0.005 present cooling) maintenance) plain
(adding bearings with
resistance lower friction
due to seals,
packed
grease,
preload and
misalignmen
t can
increase
friction to as
much as
0.125)
Mainly used
in low-load,
high
Off-center Adequate precision
Jewel Low due
bearing rolls in Low Low (requires work such as
bearing to flexing
seating maintenance) clocks. Jewel
bearings may
be very
small.
Can fail
quickly due
Very to grit or dust
high Virtually infinite or other
(usually in some contaminants
Fluid is forced limited applications, .
Zero friction
Fluid between two Very to a few may wear at Maintenance
at zero
bearing faces and held high hundred startup/shutdow free in
speed, low
in by edge seal feet per n in some cases. continuous
second Often negligible use. Can
at/by maintenance. handle very
seal) large loads
with low
friction.
Zero friction Active
at zero magnetic
speed, but bearings
Faces of
constant (AMB) need
bearing are
power for Indefinite. considerable
Magneti kept separate No
levitation, Maintenance power.
c by magnets Low practical
eddy free. (with Electro
bearings (electromagnet limit
currents are electromagnets) dynamic
s or eddy
often bearings
currents)
induced (EDB) do not
when require
movement external

10
 occurs, but power.
may be
negligible if
magnetic
field is quasi-
static
Very high or
Limited
low depending
range of
Material flexes on materials and
movement,
Flexure to give and Very strain in
Very low Low no backlash,
bearing constrain high. application.
extremely
movement Usually
smooth
maintenance
motion
free.
†Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct
from the friction of the bearing.
Table 1: Types of bearing

INTRODUCTION OF BALL BEARING

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races.
The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads.
It achieves this by using at least two races to contain the balls and transmit the loads through
the balls. In most applications, one race is stationary and the other is attached to the rotating
assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate
as well. Because the balls are rolling they have a much lower coefficient of friction than if two
flat surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other kinds of rolling-element
bearings due to the smaller contact area between the balls and races. However, they can
tolerate some misalignment of the inner and outer races.

COMMON DESIGNS
There are several common designs of ball bearing, each offering various trade-offs. They can
be made from many different materials, including: stainless steel, chrome steel,

11
and ceramic(silicon nitride (Si3N4)). A hybrid ball bearing is a bearing with ceramic balls and
races of metal.

ANGULAR CONTACT

An angular contact ball bearing uses axially asymmetric races. An axial load passes in a
straight line through the bearing, whereas a radial load takes an oblique path that tends to
want to separate the races axially. So the angle of contact on the inner race is the same as that
on the outer race. Angular contact bearings better support "combined loads" (loading in both
the radial and axial directions) and the contact angle of the bearing should be matched to the
relative proportions of each. The larger the contact angle (typically in the range 10 to 45
degrees), the higher the axial load supported, but the lower the radial load. In high speed
applications, such as turbines, jet engines, and dentistry equipment, the centrifugal forces
generated by the balls changes the contact angle at the inner and outer race. Ceramics such
as silicon nitride are now regularly used in such applications due to their low density (40% of
steel). These materials significantly reduce centrifugal force and function well in high
temperature environments. They also tend to wear in a similar way to bearing steel—rather
than cracking or shattering like glass or porcelain.
Most bicycles use angular-contact bearings in the headsets because the forces on these
bearings are in both the radial and axial direction.

AXIAL

12
An axial ball bearing uses side-by-side races. An axial load is transmitted directly through the
bearing, while a radial load is poorly supported and tends to separate the races,so that a larger
radial load is likely to damage the bearing.

DEEP-GROOVE
In a deep-groove radial bearing, the race dimensions are close to the dimensions of the balls
that run in it. Deep-groove bearings can support higher loads.

CONSTRUCTION TYPES

CONARD
The Conrad-style ball bearing is named after its inventor, Robert Conrad, who was awarded
British patent 12,206 in 1903 and U.S. patent 822,723 in 1906. These bearings are assembled
by placing the inner race into an eccentric position relative to the outer race, with the two
races in contact at one point, resulting in a large gap opposite the point of contact. The balls
are inserted through the gap and then evenly distributed around the bearing assembly, causing
the races to become concentric. Assembly is completed by fitting a cage to the balls to
maintain their positions relative to each other. Without the cage, the balls would eventually
drift out of position during operation, causing the bearing to fail. The cage carries no load and
serves only to maintain ball position.
Conrad bearings have the advantage that they are able to withstand both radial and axial
loads, but have the disadvantage of lower load capacity due to the limited number of balls
that can be loaded into the bearing assembly. Probably the most familiar industrial ball
bearing is the deep-groove Conrad style. The bearing is used in most of the mechanical
industries.

SLOT-FILL

In a slot-fill radial bearing, also referred to as a full complement design, the inner and outer
races are notched on one face so that when the notches are aligned, balls can be slipped in the
resulting slot to assemble the bearing. A slot-fill bearing has the advantage that the entire
groove is filled with balls, called a full complement, resulting in a higher radial load capacity
than a Conrad bearing of the same dimensions and material type. However, a slot-fill bearing
cannot carry a significant axial load on the loading slot side. Also, the slots cause a
discontinuity in the races that has a small but adverse effect on strength.

ROWS

13
There are two row designs: single-row bearings and double-row bearings. Most ball bearings
are a single-row design, which means there is one row of bearing balls. This design works
with radial and thrust loads. A double-row design has two rows of bearing balls. Their
disadvantage is they need better alignment than single-row bearings.

FLANGED

Bearings with a flange on the outer ring simplify axial location. The housing for such
bearings can consist of a through-hole of uniform diameter, but the entry face of the housing
(which may be either the outer or inner face) must be machined truly normal to the hole axis.
However such flanges are very expensive to manufacture. A more cost effective arrangement
of the bearing outer ring, with similar benefits, is a snap ring groove at either or both ends of
the outside diameter. The snap ring assumes the function of a flange.

CAGED

Cages are typically used to secure the balls in a Conrad-style ball bearing. In other
construction types they may decrease the number of balls depending on the specific cage
shape, and thus reduce the load capacity. Without cages the tangential position is stabilized
by sliding of two convex surfaces on each other. With a cage the tangential position is
stabilized by a sliding of a convex surface in a matched concave surface, which avoids dents
in the balls and has lower friction. Caged roller bearings were invented by John Harrison in
the mid-18th century as part of his work on chronographs. Caged bearings were used more
frequently during wartime steel shortages for bicycle wheel bearings married to replaceable
cups.

CERAMIC HYBRID BALL BEARINGS USING CERAMIC BALLS

Ceramic bearing balls can weigh up to 40% less than steel ones, depending on size and
material. This reduces centrifugal loading and skidding, so hybrid ceramic bearings can
operate 20% to 40% faster than conventional bearings. This means that the outer race groove
exerts less force inward against the ball as the bearing spins. This reduction in force reduces
the friction and rolling resistance. The lighter balls allows the bearing to spin faster, and uses
less energy to maintain its speed. While ceramic hybrid bearings use ceramic balls in place of
steel ones, they are constructed with steel inner and outer rings; hence the hybrid designation.

14
SELF-ALIGNING

Self-aligning ball bearings, such as the Wingquist bearing, are constructed with the inner ring
and ball assembly contained within an outer ring that has a spherical raceway. This
construction allows the bearing to tolerate a small angular misalignment resulting from
deflection or improper mounting.

OPERATING CONDITION

LIFESPAN

The calculated life for a bearing is based on the load it carries and its operating speed. The
industry standard usable bearing lifespan is inversely proportional to the bearing load cubed.
Nominal maximum load of a bearing (as specified for example in SKF datasheets), is for a
lifespan of 1 million rotations, which at 50 Hz (i.e., 3000 RPM) is a lifespan of 5.5 working
hours. 90% of bearings of that type have at least that lifespan, and 50% of bearings have a
lifespan at least 5 times as long.
The industry standard life calculation is based upon the work of Lundberg and Palmgren
performed in 1947. The formula assumes the life to be limited by metal fatigue and that the
life distribution can be described by a Weibull distribution. Many variations of the formula
exist that include factors for material properties, lubrication, and loading. Factoring for
loading may be viewed as a tacit admission that modern materials demonstrate a different
relationship between load and life than Lundberg and Palmgren determined.

FAILURE MODES

If a bearing is not rotating, maximum load is determined by force that causes plastic
deformation of elements or raceways. The identations caused by the elements can concentrate
stresses and generate cracks at the components. Maximum load for not or very slowly
rotating bearings is called "static" maximum load. For a rotating bearing, the dynamic load
capacity indicates the load to which the bearing endures 1.000.000 cycles.
If a bearing is rotating, but experiences heavy load that lasts shorter than one revolution,
static max load must be used in computations, since the bearing does not rotate during the
maximum load.

15
Maximum load
In general, maximum load on a ball bearing is proportional to outer diameter of the bearing
times width of bearing (where width is measured in direction of axle).

Lubrication

For a bearing to operate properly, it needs to be lubricated. In most cases the lubricant is
based on elastohydrodynamic effect (by oil or grease) but working at extreme temperatures dry
lubricated bearings are also available.
For a bearing to have its nominal lifespan at its nominal maximum load, it must be lubricated
with a lubricant (oil or grease) that has at least the minimum dynamic viscosity (usually
denoted with the Greek letter ) recommended for that bearing. The recommended dynamic
viscosity is inversely proportional to diameter of bearing. The recommended dynamic
viscosity decreases with rotating frequency. As a rough indication: for less than 3000 RPM,
recommended viscosity increases with factor 6 for a factor 10 decrease in speed, and for more
than 3000 RPM, recommended viscosity decreases with factor 3 for a factor 10 increase in
speed.
For a bearing where average of outer diameter of bearing and diameter of axle hole is 50 mm,
and that is rotating at 3000 RPM, recommended dynamic viscosity is 12 mm²/s. Note that
dynamic viscosity of oil varies strongly with temperature: a temperature increase of 50–70
°C causes the viscosity to decrease by factor 10.
If the viscosity of lubricant is higher than recommended, lifespan of bearing increases,
roughly proportional to square root of viscosity. If the viscosity of the lubricant is lower than
recommended, the lifespan of the bearing decreases , and by how much depends on which
type of oil being used. For oils with EP ('extreme pressure') additives, the lifespan is
proportional to the square root of dynamic viscosity, just as it was for too high viscosity,
while for ordinary oil's lifespan is proportional to the square of the viscosity if a lower-than-
recommended viscosity is used.
Lubrication can be done with a grease, which has advantages that grease is normally held
within the bearing releasing the lubricant oil as it is compressed by the balls. It provides a
protective barrier for the bearing metal from the environment, but has disadvantages that this
grease must be replaced periodically, and maximum load of bearing decreases (because if
bearing gets too warm, grease melts and runs out of bearing). Time between grease
replacements decreases very strongly with diameter of bearing: for a 40 mm bearing, grease
should be replaced every 5000 working hours, while for a 100 mm bearing it should be
replaced every 500 working hours. Lubrication can also be done with an oil, which has
advantage of higher maximum load, but needs some way to keep oil in bearing, as it normally
tends to run out of it. oil quality; therefore, the oil is usually changed less frequently than the
oil in bearings.

16
DIRECTION OF LOAD

Most bearings are meant for supporting loads perpendicular to axle ("radial loads").
Whether they can also bear axial loads, and if so, how much, depends on the type of
bearing. Thrust bearings (commonly found on lazy susans) are specifically designed for axial
loads.
For single-row deep-groove ball bearings, SKF's documentation says that maximum axial
load is circa 50% of maximum radial load, but it also says that "light" and/or "small" bearings
can take axial loads that are 25% of maximum radial load.
For single-row edge-contact ball bearings, axial load can be circa 2 times max radial load,
and for cone-bearings maximum axial load is between 1 and 2 times maximum radial load.
If both axial and radial loads are present, they can be added vectorially, to result in total load
on bearing, which in combination with nominal maximum load can be used to predict
lifespan. However, in order to correctly predict the rating life of ball bearings the ISO/TS
16281 should be used with the help of a calculation software.

AVOIDING UNDESIRABLE AXIAL LOAD

The part of a bearing that rotates (either axle hole or outer circumference) must be fixed,
while for a part that does not rotate this is not necessary (so it can be allowed to slide). If a
bearing is loaded axially, both sides must be fixed.
If an axle has two bearings, and temperature varies, axle shrinks or expands, therefore it is
not admissible for both bearings to be fixed on both their sides, since expansion of axle
would exert axial forces that would destroy these bearings. Therefore, at least one of bearings
must be able to slide.
A 'freely sliding fit' is one where there is at least a 4 µm clearance, presumably because surface-
roughness of a surface made on a lathe is normally between 1.6 and 3.2 µm.

FIT
Bearings can withstand their maximum load only if the mating parts are properly sized.
Bearing manufacturers supply tolerances for the fit of the shaft and the housing so that this
can be achieved. The material and hardness may also be specified.
Fittings that are not allowed to slip are made to diameters that prevent slipping and
consequently the mating surfaces cannot be brought into position without force. For a bearing
to have its nominal lifespan at its nominal maximum load, it must be lubricated with a
lubricant (oil or grease) that has at least the minimum dynamic viscosity (usually denoted
with the Greek letter ) recommended for that bearing.

17
MANUFACTURING OF BALLBEARING
Ball bearings are at the heart of almost every product with a rotating shaft .Most bearing
specifications and manufacturing tolerances are quantified in one-ten thousandths of an
inch (1/10,000) by ABMA; every manufacturing process is 100% checked and feedback
provided to ensure the integrity of the process and product.

Note: A micron (an abbreviation for micrometers) is one-millionth of a meter, or,

25,400 microns equals one (1) inch.

REPEATABILITY IN THE MANUFACTURING PROCESS

Predictable uniformity, or repeatability, in the manufacturing process is crucial to ensuring
consistent bearing performance. If variations occur in the manufacturing process from part
to part, the production line may make bearings that fall within the complete spectrum of
the allowable tolerance standards. That inconsistency-- producing parts that go from one
end of the range to the other--can lead in turn to variations in the performance of each
bearing, either individually or from lot to lot. The narrower the variation in each step of
the manufacturing process, the greater the consistency of each

18
 Manufacturing Flow Chart

Forged Rings (De-scaled) as Raw Material.

(SAE 52100 steel)

Turning Operation

Center Less Grinding

Heat Treatment

Hardness testing

Rough Grinding

Finish Grinding

Honing & Super Finishing

Washing

Application of rust preventive

Ready for dispatch to assembly

19
Ball Bearing Materials
Ball bearings are generally made of high carbon steels, such as AISI 52100(fifty-two,
one hundred). One of the factors that determine the life of the bearing steel (thus the
bearing itself) is the purity or cleanliness of the steel. The 52100 steel are subjected to a
rigorous purification process with stringent controls in order to meet the ever-increasing
standards for cleanliness–eliminating nonmetallic inclusions or impurities. These
impurities are removed through various processes such as vacuum degassing and consumable-
electrode vacuum melting (CEVM), to name just two of the processes referred to when
discussing the merits and cleanliness of bearing steel.

The hardening of the steel is achieved by a heat treating process in which the steel
microstructure is manipulated by cycles of heating and quick cooling to obtain the
optimum hardness range for the steel–usually on the order of 60to 64 on the
Rockwell C Hardness scale. Penetration hardness tests (such as Rockwell or Brinell )
provide the means to estimate the actual hardness of metals.

Raw Material for bearings Races:

For Outer and inners the suggested raw material is SAE 52100 conforming to following
chemical

compositions Element C Si Mn S P Cr.

Minimum .98 .15 .25 ---------------------- 1.30

Maximum 1.10 .35 .45 0.025 0.025 1.60

Oxygen content; Not More than 15 ppm

Micro Inclusions

Inclusion type Series

Thin Thick

(A) Sulphides 2.5 1.5

(B) Alumina 2.0 1.0

(C) Silicate 0.5 0.5

(D) Globular Oxide 1.0 1.0

20
TURNING SECTION

Both the inner and outer rings are usually machined from the outer and Inner races are
manufactured from SAE 52100 steel, the raw material used in the section has been
considered as forged rings.

The turning operations are divided into various lathe operations, viz. O.D., face, track
and Bore. All these operations are done on production lathe machines. These lathe
machines offered in the project are production machines wherein individual job/
process sequence has to be set before every new batch is taken up.

HEAT TREATMENT
Hardness is a function of and brittle structure. When slowly quenched it would form
Austenite and Pearlite which is a partly hard and partly soft structure. When the
cooling rate is the Carbon content of the steel. Hardening of steel requires a change
in structure from the body-centered cubic structure found at room temperature to the face-
centered cubic structure found in the Austenitic region. The steel is heated to Austenitic
region. When suddenly quenched, the Martensite is formed. This is a verystrong extremely
slow then it would be mostly Pearlite, which is extremely soft.

The soft machined material is feed in the furnace and washed at 600 C, then send to a
chamber where the material heated in four chambers the first chamber has the temperature
8400 C and further chamber contains the 8500 C temperature.

Then it dipped into an oil tank at temperature 250C where the material get quenched then it
washed and then it tempered in water about 90 min. at temperature 1050 C .

21
QUENCHING MEDIA

Quenching is the act of rapidly cooling the hot steel to harden the steel.

Oil:

Oil is used when a slower cooling rate is desired. Since oil has a very high boiling
point, the transition from start of Martensite formation to the finish is slow and this
reduces the likelihood of cracking. Oil quenching results in fumes, spills and sometimes
a fire hazard Austenite at room temperature.

Different alloys. The reason to alloy steels is not to

increase their strength, but increase their harden ability – the ease with which full
hardness can be achieved throughout the material. Usually when hot steel is quenched, most
of the cooling happens at the surface, as does the hardening. The propagates into the depth of
the material. Alloying helps in the hardening and by determining the right alloys one can
achieve the desired properties for the particular application. Such alloying also helps in
reducing the need for a rapid quench cooling – thereby eliminate distortions and potential
cracking. In addition, thick sections can be hardened fully.

Quenches are usually done to room temperature. Most medium carbon steels and low alloy
steels undergo transformation to 100% Martensite at room temperature. However, high
carbon and high alloy steels have retained To eliminate retained Austenite, the quench
temperature has to be lowered. This is the reason to use cryogenic quenching.

NITROGEN METHANOL SYSTEM

The above system comprise of Methanol Tank 200 liters SS 2.5 mm corrugated, Methanol
Flow Meter 0.50 to 5.2 per hour, Solenoid Valve, Needle Valves, all interconnected by
copper piping duly mounted on a stand with Nitrogen Pressure Regulator and Flow meter to
read 2 to 5 m3/hr.

GRINDING SECTION

The next stage is grinding, in order to give the rings the right form and dimensions.
The first operation on inner and outer rings is face grinding. Both faces are ground
simultaneously to give the final width.

22
Face is the surface at side of the inner and outer race , face should be finished indeed to get
the desire width of the bearing and since the bearing is a mating part and it has to be
assembled somewhere in the machine where it should be fit precisely.

Manufacturing Process of ball bearing

Input Wire Rod as Raw Material.
(SAE 52100 Steel)

Shearing & Heading operation

On Ball Header Machine

Deburring on Vibro Benz Machine

Flushing of excess material after the

Ball forged in cold header

Heat treatment of ball

Lapping in Ball Lapping machine

Inspection for checking

Hairline cracks

Lapping of balls in
Tumbling barrel

Magnetic Crack Testing and

Washing

Application of rust preventive and

Packing

23
The raw material used in the manufacture of balls is a specially formulated grade of
steel ring around the to remove this ring. wire. The raw material is supplied from either
wire or rod. It is then cut to length and the width is a small percentage larger than the
width of the finished ball. The wire or rod is then fed through a header. This cold
forged process produces "slugs" at an incredibly high speed. Wire is fed from decoilers
into cold heading machines where it is cut into blanks then pressed into between
hemispherical dies, The flash around the balls produced during pressing is removed
by filing plates in deburring machines.

Heat Treating Balls

Ball Flashing Operation

The balls are then machined in rill-filing machines, equipped with one fixed and one
rotating cast iron rill-plate. Concentric grooves in the plates ensure that the whole
ball surface is machined to the same extent and thus a spherical form is achieved.

24
Final inspection for size, form and surface finish is carried out on a samplebasis by
means of microscopes and other precision equipment. The balls are then cleaned and
packed ready for bearing assembly operations. The tiniest deviation in the roundness
of bearing elements can have an impact on bearing quality. Periodic form deviations
in the range of 1angstrom 10-10 m may influence bearing quality.

CAGE MANUFACTURING

Flow chart

Raw material
(narrow width CR sheet)

Blanking and punching

Forming (pocketing)

Inspection and batch checking

Shot blasting virbro

Assembly in assy. shop

The cages for various bearings sizes are manufactured from Cold Rolled narrow width
sheets IS 4397 cold rolled, cold annealed sheets, and The CR sheet is converted in the
cage in Press machines in successive press operations:

Blanking, Punching, forming (pocketing) rivet holes and visual inspection is carried for any
deformity. Cages are manufactured from cold rolled steel strip. Presses with progressiveor,
alternatively, transfer tools are used to produce cages halves from the strip. After surface
treatment and cleaning, the cage halves are coated with preservative and packed for
transport to the assembly plant.

25
 RIVET MANUFACTURING
Flow chart

Raw material

(wire EN 8)

Heading in ball header

Deburring in vibrobenz machine

Rust preventive oiling

Ready for assembly

The rivets are manufactured from wire rods, the wires is cut in required size in rivet
header machines, then in the vibro machines it is super finished. There is no grinding
operation involved.

PROCESS OF MAKING A BEARING

26
 FLOW CHART

Cage Rivet Outer Inner Balls

Put inner in outer

Insert balls

put under riveting machine

riveting

Washing of bearing

Demegnetizing

Clearance testing

Packaging of bearing in pillow wrapping machine

Ready to dispatch

27
Finally the rings, balls and cage - which have been manufactured in different locations -
come together for automatic assembly. Raceway diameters of inner and outer rings are
measured separately. By selecting suitable combinations of ring and ball sizes, the
required internal clearance is obtained. Balls are fed between the rings and spaced
equally before the two cage halves are fitted and then riveted together.

Prior to automatic assembly the rings are optically inspected. After washing, the final
inspection sequence starts. This consists of a number of automated stations, which check
running accuracy, vibration level, and outside and bore diameters, as well as radial
clearance of the bearings. The bearings are then automatically washed, coated with
preservative, greased and fitted with seals or shields, before being packed according to
customer requirements.

28
 Materials

Material comparison for common bearing balls]

Stainle
UNS ss REX- 440ND Hayne
Material M50 BG-42 Si3N4 BECU 455 C276
52100 steel 20 UR s 25
440C

Hardness
60 58 62 62 66 60 50 70 40 50 40
[HRC]

Temperat
ure limit 300 300 400 400 600 300 1200 1500 400 500 1000
[°F]

Corrosion
resistanc 1 3 1 2 1 4 5 5 1 4 5
e

Cost 1 1 1 2 3 1 5 5 3 2 4

Availabili
1 1 2 2 2 4 5 3 3 2 4
ty

Non- Non- Non-

Magne Magne Magne Magne Magne Magne Magne Magne
Magnetic magne magne magne
tic tic tic tic tic tic tic tic
tic tic tic

1.5 in No 5 in
Size limit None None None None None None (38 m Torqu None None (130 m
m) e Tube m)

Relative
3 2 4 4 5 3 1 5 1 1 1
load

29
Bearing Visual Defects:

Appearance Cause Action Photo

Small indentations Lack of Do not unpack Outer ring of a spherical

around the cleanliness bearing until just roller bearing with
raceways and before and before it is to be raceways that have been
rolling elements. during mounting mounted. Keep worn by abrasive
Dull, worn operation. workshop clean particles. It is easy to
surfaces. and use clean feel where the dividing
tools. line goes between worn
and unworn sections.

Grease discoloured Ineffective seals Check and

green. possibly improve
the sealing.

Lubricant Always use fresh,

contaminated by clean lubricant.
worn particles Wipe the grease
from brass cage nipples. Filter the
oil.

Appearance Cause Action Photo

Worn, frequently Lubrication has Check that the Outer ring of a

mirror-like, surfaces; gradually been lubricant reaches spherical roller bearing
at a later stage blue used up or has the bearing. that has not been
to brown lost its lubricating More frequent adequately lubricated.
discoloration. properties. relubrication. The raceways have a
mirror finish.

30
Appearance Cause Action Photo

Depressions in raceways. The bearing Secure the Outer ring of taper

These depressions are has been bearing during roller bearing
rectangular in roller bearings exposed to transport by damaged by
and circular in ball bearings. vibration while radial vibration during
The bottom of these stationary. preloading. operation.
depressions may be bright or Provide a
dull and oxidized. vibration-
damping base.
Where possible,
use ball
bearings
instead of roller
bearings.
Employ oil bath
lubrication,
where possible. Vibration damage to
the ring of a
cylindrical roller
bearing. The damage
has arisen while the
bearing was not
running.

Inner and outer ring

of a cylindrical roller
bearing exposed to
vibration. The inner
ring has changed
position.

31
 CONCLUSION

My training at TATA STEEL was very fruitful and I gained a lot of practical knowledge about
various manufacturing processes and techniques. I also got the opportunity to realize the
challenges faced and expertise required in manufacturing processes for mass production.

It was indeed a great experience undergoing training at the plant.

32