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Technology Study Report on

Bearing Industry

- : Prepared By : -

MSME - Development Institute, Government of India

Ministry of Micro Small and Medium Enterprises

Bais Godam, Jaipur – 302 006 (Raj.)

Ph. 0141-2212098, 2213099, Fax. 2210553

e mail- [email protected]

web- dcmsme.gov.in

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CONTENTS

Page

• SCOPE OF THE REPORT

• METHODOLOGY

1 PRESENT STATUS OF TECHNOLOGY 1 - 22

1.1 Introduction

1.2 Industry Overview

1.3 Global Collaboration

1.4 Status of Bearing and Bearing Component Cluster at Jaipur

1.5 Raw Material

1.6 Plant and Machinery in SME Sector

1.7 Manufacturing Process

2 IDENTIFYING TECHNOLOGY GAP 23 - 27

3 THRUST AREAS FOR TECHNOLOGY & TECHNOLOGY GAPS 28 - 32

4 PROPOSED ADVANCE TECHNOLOGY & ITS BENEFITS 33 - 39

5 PROJECT PROFILE 40 - 49

Annexures

a. Technology Providers

b. Quality Standards (BIS)

c. Chemical Composition of Through-Hardening Bearing Steels Composition

(%)

3

SCOPE OF THE REPORT

This Technology Study Report on Indian bearings industry covers overview

of the industry, Present status of Technology being used by the MSME sector in

manufacturing the product, Technological Gap, Modernisation & technological Up

gradation aspect of bearing Industry & highlighting benefit of proposed technology

over the existing technology and its viability in keeping view of the competitive

markets as well as international competitiveness. The report is useful for bearings

and component manufacturers, end user industries like automobile, machine tools,

steel and equipment manufacturers ring, bearing component manufacturers, raw

materials suppliers like steel industry, commercial and investment banks,

investors, business analysts, consultants and students.

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METHODOLOGY

Technology Study Report is prepared as per guide line given by DC(MSME). The interaction with following prominent Bearing & Bearing component Manufacturers were carried out to know more about present status as well as latest proven technology has been adopted by MSME & Large Bearing Manufacturers. Some advance plant & machinery suppliers were also contacted over phone or through internet. Contact Person Collaborations/

Advance Technology Products

Mr. K. N. Kansara KANSARA ENGINEERS PVT. LTD. (A Unit of Sewaram Kansara Group), E-36,M.I.A. Phase II, Basni, Jodhpur - 342005 (INDIA) Phone : +91-291-2745500, 2745501, Fax : +91-291-2435187, 2745502 Email : [email protected] Web : www.skbearings.com

Nadella - France NSK- Japan NTN - Japan

Rollers (CYLINDERICAL, SPHERICAL, NEEDLE, TAPER)

Mr. Rohit Saboo, President & CEO Email : [email protected] Mr. Devendra Mishra Vice President Manufacturing [email protected] NAIONAL ENGINEERING INDUSTRIES Ltd. Khatipura Road,Jaipur -302 006 Phone : 2223221 Fax : 0141-2221926.2222259 E-mail : [email protected]

( a. ) BRENCO Incorporated , U.S.A. Since 1982-For Cartridge Tapered Roller Bearings for Railway wagons and Locomotives. www.brencoqbs.com (b) NTN Corporation , Japan Since 1985-For Ball Bearings, Cylindrical & Spherical Roller Bearings. Since 1997-For Tapered Roller Bearings. http://www.ntn.co.jp (c) Izumi Kinzoku Kogyo Co. Ltd., Japan Since 1996 - For re-manufacturing, retrofitting and overhauling of grinding and super finishing machines for bearing races. http://www7.ocn.ne.jp/~izk.co

Ball Bearing , Steel Ball, Tapered Roller Bearing, Railway Bearing (Roller Bearing in Axle Box, Spherical Roller Bearing, Cartridge Tapered Roller Bearing), Large Diameter Bearing

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Mr. Vinod Agarwal, M.D. Mr Namit Agarwal ,Director Agrasen Engineering Industries Limited F-198/199, Road No, 9F Vishwakarma Industrial Area, Phone +91-141- 2330614 E-mail : [email protected] , [email protected]

Hatebur Hotmatic hotformers (AMP 30 S) & Hatebur Coldmatic coldformers Installation of Auto Turning Lines for Small DGBB from Tubes - Production capcity 120,000 per day, SOP

Forged & Turned Bearing Race

. Mr. M.R.I. SHAIKH ( Indian Representative of M/S Hatebur Umformmaschinen AG) CHRYSTEC MACHINE TOOLS PVT LTD, 103 Winner's Court, Lulla Nagar Pune 411040 Maharastra, India 00912030527484 Mobile: +91 (0) 9892249582 WEB SITE www.chrystec.com

Hatebur Umformmaschinen AG Postfach 916 General Guisan-Strasse 21 CH-4153 Reinach Switzerland Tel.: +41 61 716 21 11 Fax: +41 61 716 21 31

Hatebur Hotmatic hotformers ,a fully-automated Forging &Hatebur Coldmatic coldformers produce precision and complex parts formed directly from wire.

Mr. M.K. Banthia, Director MANU YANTRALAYA G-1/800, Sitapura Industrial Area, Jaipur - 302 022, India TEL : +91-141-277 1412 FAX : +91-141-277 1410 E-mail : [email protected] www.manuyantralaya.com

Ball Bearing Cage production line (Transfer Press) in Technical Collaboration with M/s Toho Industrial Co. Ltd., Japan was set up in 2000.

Ball Bearing Cages, Sheet Metal Components and Dust Shields

Mr. :- Pramod Mathur, Director M/S CHANDRA INDUSTRIES A-1, Industrial Estate, Bais Godam, Jaipur-302006(INDIA) Phone:- +91-141- 2214246, 2213017, Fax:- =91-141-2211288 E-mail:- [email protected] http:www.chandrashields.com

Transfer Press Form M/S CHIN FONG MACHINE INDUSTRIAL CO., LTD. 186 Chang Shui Road, Chang Hua, Taiwan 500 R.O.C. TEL:+886-4-7524131 FAX:+886-4-7611920 E-mail:[email protected] URL:www.chinfong.com.tw

Dust shield (Z-shield,)

Mr. Anil Agrawal , MD

M/s Supersonic Turners Pvt. Ltd. Works 1 & H.O. ,F-393(A), Road

Conventional Lathes, Low cost automated hydraulic lathes, Auto lathes (Ace Machines) Perma line

Bearing Race Turning

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No. : 9F2,VKI Area, Jaipur-302 013 (Raj.) India

Works 2 : G-846, Road No. : 14, VKI Area, Jaipur – 302 013 (Raj.) India [email protected] www. supersonicjaipur.com Mr. Suryakant Gadia M/S K.N.K.Bearings Pvt.Ltd., 114-115,Jhotwara Industrial Area Jaipur, ( Raj.) 0141-2341952/2340638, Fax:0141-2344133 [email protected] www.knkearing.com

Conventional Set-Up Suitable for Batch Type Production

KNK Bearing

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Chapter - 1

PRESENT STATUS OF TECHNOLOGY

1.1 INTRODUCTION

The technology used is conventional type in unorganized sector. But the

organized sector players are using state of the Art Technology to manufacture the

bearings as per the global standards. The unorganized sector players are also

gradually switching over to technology up gradation.

The cluster units at Jaipur for bearing and Bearing component

manufacturing units are employing conventional technology, but with the cluster

level intervention the units have initiated technology. upgradation by employing

CNC Machine for turning, grinding, finishing, testing, etc.

The machining operation involved in manufacture of antifriction bearings

include forging of the rings, turning, heat-treatment, face and outer dia -grinding,

Bore and track grinding, finish and super finishing grinding , Demagnetizing,

cleaning, inspection assembly and packaging, etc.

The Product

The Bearing is a machine element used in rotating parts of virtually every

machine. Bearing permit smooth low friction rotary or linear movement between

two surfaces. It employs either a sliding or a rolling action. If we could reduce

friction by only 10% in all the rolling bearing in use today, it would mean an energy

saving equivalent to the combined out put of Not less than 25 large Nuclear Power

Stations. Bearing can be broadly classified into two segments:-

• Bimetal

• Antifriction – Bearings

Bimetal bearings (also known as engine bearings) are primarily used in engines

of automobiles or machines. The bearings are meant to reduce the friction

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between the moving parts of the engine crankshaft or crank shaft or associated

support surfaces.

Antifriction Bearings include Ball Bearings and Roller Bearings. Roller bearings

can further be subdivided into tapered roller. Cylindrical roller, Needle roller, thrust

bearings and other special application bearings. The main components of an

antifriction bearing are the inner race (ring), the other race (ring) the rolling

elements, cages (retainers) and seals. The following are the major types of

bearing.

a. Ball bearing

b. Cylindrical roller bearing

c. Taper roller bearing

d. Needle roller bearing

Further classification of these major categories is given below:

� Single row deep groove ball bearings

� Maximum capacity type ball bearings

� Single row angular contact ball bearings

� Duplex angular contact ball bearings

� Double row angular contact ball bearings

� Four point contact ball bearings

� Self al igning ball bearings

� Radial Ball Bearings

� Ball and Roller Bearings

� Ball Bearings

� Thrust Ball Bearings

� Roller Bearings

� Radial " Roller Bearings

� Thrust Roller Bearings

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� Single direction thrust ball bearings with flat back face

� Single direction thrust ball bearings with seating ring

� Double direction thrust ball bearings with flat back face

� Double direction thrust ball bearings with seating ring

� Double direction angular contact thrust ball bearings

� Single row cylindrical roller bearings

� Double row cylindrical rol ler bearings

� Single row tapered roller bearings

� Double row tapered roller bearings

� Spherical roller bearings

� Cylindrical rol ler thrust bearings

� Needle roller thrust bearings

� Tapered roller thrust bearings

� Spherical roller thrust bearings

1.2 INDUSTRY OVERVIEW:

The bearing Industry in India can be divided into three segments; the

organized sector, comprising 12 leading manufacturers, located at Rajasthan,

Gujarat, Maharastra, Andhra Pradesh, Karnataka, Tamil Nadu, West Bengal and

Jharkhand primarily cater to the OEM Segment which are predominantly

automotive, Railway and other Industrial users. The unorganized sector includes

the small scale manufacturers and manufacturers of spurious bearings. The

unorganized sector contributes to about 18% of the total Industry turn over. The

unorganized sector players have a strong regional presence and mainly cater to

the needs of the replacement markets. The Indian bearing Industry is estimated at

Rs. 100 billion. The domestic Industry caters to the 74 % of total demand for

common varieties & sizes. The organized sector units contribute around 53% of

the Industry sales. The imports are about 26% of the total demand of the industry,

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while about 18% import comes through official channels. There is also estimated

8% illegal imports. Legal imports generally represent the specialized / super

precision bearings not manufactured in India. Illegal imports generally represent

the entry of spurious imports of bearings. The legal imports are about Rs.1 8.00

billion while the spurious imports is about Rs. 8.00 billion.

The small scale units manufacturing bearing are mainly concentrated in

Rajasthan and Gujarat having 15 and 50 units respectively. The bearing

manufacturing units are also present in Delhi, Punjab, and Maharastra. The state

of Rajasthan has major concentration of about 100 bearing components

manufacturing units with 1000 to 1200 Vendors carrying out turning job work.

There are substantial No. of component manufacturing units in Gujarat,

Maharastra, West Bengal and Punjab also. The bearing component manufacturing

units are the vendors of organized sector, and unorganized sector bearing

manufacturing units for supply of inner & outer races, balls, rollers, cages, seals,

retainers & rivets. These components are also exported to Europe, United States

of America and other global customers.

There are about 450 to 500 number of spurious bearing assembling units situated in the

State of Punjab, Delhi and Gujarat, eating the market of organized & unorganized sector

players.

A number of global bearing manufacturers have established their units in

India through joint ventures or 100% ownership and more are expected to follow

suit.The Big player of bearing sector are present in U.S.A, Russia, Japan, China

and eastern Europe. Some of leading bearing manufacturer are : -

- NSK Japan

- NTN Japan

- KOYA Seiko Japan

- FAG Germany

- SKF Sweden

- NRB France

- Timken USA

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International Bearing Market

1.3 GLOBAL COLLABORATION

All the manufacturers in the organised sector have entered into collaboration

agreements for supply of complete process know how as well as supply of major

manufacturing machinery. The collaboration agreements are still valid and the industry

gets all assistance for process, know-how product development,customer development,

tool design, production control techniques etc from them. Most of the big player are

having either technical or financial Collaboration with leading Auto Manufacturer.

International Collaboration gives Access to best technology in the world.

GLOBAL COLLABORATION

COMPANY COLLABORATION

SKF India SKF Sweden

FAG Bearing India FAG, Germany

NEI NTN

NRB Nadella, France

ABC Bearing Ltd. NSK Japan

TIMKEN India TIMKEN USA

Bimetal Bearing Ltd. Clevite Corporation USA

Gabriel India Suspension Italy

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The Indian Bearing Industry, especially the companies having technical and

financial collaboration with Global player are expected to garner higher price in

export market

In view of the growing industrial and automobile sector, the growth in this

industry is going to be substantial . The requirement of bearings increasing day by

day in India in both the OEM and replacement market and increasing number of

small manufacturing industries developing in Jaipur (Rajasthan) Rajkot and

Surrender Nagar (Gujarat) and Punjab have come up in unorganized sector.

These industries are manufacturing from complete bearings to components and

supplying to leading players.

The following are the major manufacturers of bearings in India:

1. Associated Bearing Company Ltd., Pune (Maharashtra)

2. Asian Bearings Company Ltd., Hosur (Tamil Nadu)

3. Karnataka Ball Bearing Corporation Ltd., Mysore (Karnataka)

4. HMT Ltd., Hyderabad (Andhra Pradesh)

5. Tata Iron and Steel Company Ltd., (Bearings Division) Kharagpur

(West Bengal)

6. Shriram Bearings Ltd., Ranchi (Bihar)

7. National Engineering Industries Ltd., Jaipur (Rajasthan)

8. FAG Precision Bearings Ltd., Vadodara (Gujarat)

9. Antifriction Bearing Company Ltd. Bharuch (Gujarat) Lonavala

(Maharashtra)

10. Union Bearings Manufacturing Co., Porbunder (Gujarat)

11. Needle Roller Bearing Co. Ltd., Thana/Jalna (Maharashtra)

12. Shriram Needle Industries Ltd., Ranchi (Bihar)

13. Deepak Insulated Cables Ltd., Mysore (Karnataka) (Needle Bearings

Division)

14. Austin Engg Company Limited Junagadh , Gujarat

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Market share of Big Bearing manufacturer companies in India

15.70

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15. Karnataka Ball Bearing Co Ltd., Mysore

16. Mysore Kirloskar Ltd, Harihar (Karnataka)

17. Needle Roller Bearings Ltd, Thane

18. Needle Roller Bearings Ltd., Waluj

19. SKF India Limited, Chinchwad , Pune

20. SKF India Limited, Bommasandra, Bangalore

21. Timken India Limited, Jamshedpur

22. ZKL Bearings India Pvt. Ltd.,

23. NTN (India) Limited

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The Government of India has set up bearings cluster for development of

unorganized segment in Small and Medium sector and understand the market and

quality linkage and make them competitive and prepare them with the best benchmarking

practices in the sector.

1.4 STATUS OF BEARING AND BEARING COMPONENT CLUSTER AT JAIPUR

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 Ist 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. with

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, ABC are also procuring the Bearing races from

Jaipur. In addition to above , the Small Scale Units manufacturing Bearing in the

state of Rajasthan, Delhi, Gujrat and Punjab also purchasing Bearing Races and

components from Jaipur. Apart from Bearing Races there are Bearing

manufacturing SSI Units, Ball manufacturing Unit, and cage manufacturing unit

present in Cluster.

In the Jaipur Cluster, There are Approx 11 No. of SSI Bearing Manufacturing

Unit, about 90 No. of Outer & Inner Soft Races Manufacturing SSI Units and about

2000 No. of outer /Inner Races turning Tiny/Artisan units. Apart from above there

is one large scale bearing manufacturing unit at JAIPUR namely M/s. NEI Ltd.

owned by Birla Group.

The Bearing Manufacturing SSI Units of Cluster are producing 36 Lacs of

Bearing worth of Rs. 8 Crore and The Bearing Races 50 Lacs Quantity and other

Bearing components having the Approx worth of Rs. 100 Crore are produced In

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the Cluster. The Bearing and Bearing components units at Jaipur Cluster are

engaged in manufacturing of outer & Inner Races, Cages Dust shield, Balls, & Ball

Bearing.

The Detail of type and size of Bearing Races are as under:-

S.No. Type of Bearing Races Inner Dia Range

1. Ball Bearing Races 10mm to 80mm

2. Taper Roller Bearing Races 17mm to 100 mm

3. Cylindrical Roller Bearing Races 20mm to 75 mm

4. Special type of Bearing Races

for Transport Vehicles (Thrust Bearing) 20mm to 75 mm

5. Axle Box Bearing Races for Railway

passenger coaches and wagon 100mm to 200mm

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1.5 Raw Material

. The raw material used in the Manufacturing of bearing Races is SAE 52100 high

Carbon Chrome bearing steel, which has composition similar to EN-31 (100 CR 6

As per BIS specification). The raw material for Bearing Races is in the form of

Rods & Seamless Hollow Tubes. This is a Spherodised Annealed Steel. Alloy

Steel wire rods are used for the manufacture of rollers & balls. The cages and

retainers are made out of plain carbon steel of 1008 & 1015 grade.Other materials

like stainless steels are also used as per the customers requirements .

Approximate required composition for BEARING RACEs are:-

• Constitute % Composition

• Carbon 0.95 to 1.1

• Chromium 1.4 to 1.6

• Manganese 0.50 max.

• Silicon 0.15 to 0.35

• Sulphur 0.025 (Max.)

• Phosphorous 0.05

• Oxygen Content Note more than 15 ppm

CAGE'S

• The Material for manufacturing cages is CRCA Strips of

• C2015 Bearing grade steel having carbon percentage at

• 0.08% max. and Magnesium ranging from 0.25% to 0.45%

BALL'S

• Steel Balls of grade 20, 16 &10 with close tolerance,

• smooth surface made by using SAE 52100 High Carbon

• Chrome Bearing Steel.

1.6 PLANT AND MACHINERY IN MSME SECTOR

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The plant and machinery in Different Category of Units are as follows

Activity Plant & Machines presently in use

Approx. Cost ( Rs. In Lakh )

Bar turning Machine 12-15 Centre Lathe 8-10 Lathe Addahs 0.50 Low cost automated hydraulic lathes 8-10 Tools cutter Grinder 12 CNC Machine for Races Turning/Machining.

15-20

Manufacturing Bearing Races By Bar Route & Seamless tube Method (Drilling and trepanning Operation are not required )

Auto lathes (Ace Machines) Perma line

6-8x4

Forging Bearing Race Shearing Gas cutting and hacksaw machines

and modern shearing machines for raw material cutting

10-13

Induction Heating Furnace for Forging 300 kw, 3 KHz - For all Lines.

15-2-0 Heating

Oil Fired furnace 12-15 300 tone power press 20-25 200 tone power press 15-20 100 tone power press 10-15 50 tone power press 7-10

Forging,Trimming

Screw press having capacity : 350 tone

22-25

Rolling Hydraulic ring rolling machine capacity to roll up to 300 mm. diameter

25-30

Tempering With the help of oil fired furnace / electrically heated furnace forgings is treated with sperodise anealing to remove residual stresses

6-10

Die Making Special die sinking machine ,EDM 6-10

Hardness testing machine equipments

0.50 Inspection

Laboratory for testing of final products of forging with chemical composition and micro examination

2-5

Heat Treatment : Hardening & Tempering

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1 - Heating 850 °C (Austenitizing) to alter the structure of the material

Natural salt bath Pit type furnace with pre-heating Furnace

0.65-2

2 - Quenching 40 °C Rapid cooling to fix the structure of the material and thus increase hardness.

Mar quenching processes

3 - Tempering 170 °C" Reheating" to reduce the effects of thermal shock (quenching) inside the structure and stabilise the material.

Electric Furnace

3-4

Washing Races Tumbling Barrel 0.1-.0.15 Blackening of Races Quenching oil Tank with Cooling

System 0.1-0.12

Grinding Followed by Honing of Outer & Inner Races

The Machinery being used for Grinding & honing by the SSI Bearing Manufacturing Units are Imported & Second Hand Machinery.

Face Grinding Face Grinder ( Rowland ,USA)-1No 8-10 Centreless Grinder ( WMW, USA) 1-No

5.3 -8 Centreless Ginding

Centreless Grinder ( ,Lidkoping USA) 1-No

3.45- 6

Bore Grinder (Jung Germany)1 -No Bore Grinding Bore Grinder (UVA, USA)1 -No

0.5-3

Outer Track Grinder ( Heald, USA)-1 N0

3.48-5 Outer Track Grinding

Outer Track Grinder ( Bryant,USA,1No

5.22-7

Inner track Grinder( Norton) 1 -No Inner Track Grinding Inner track Grinder( Newall,USA) 1 -No

1- 3

Duplex Machine 1.5-2 Honing of Track Honing Machine 5Nos 1.40-4 Washing of Races Washing Machine (Self Fabricated) 1-1.4 Lapping Machine Lapping M/c 12-15

Cages & Shields Manufacturing Unit Blanking, Bending, Drawing, Piercing, Cleaning, Inspection

Steel Cages are manufactured by using Bearing Grade Steel Sheet. These sheets are stamped with the help of Hydraulic Presses and various dies to provide the desired form and size of Steel Cage

15-20

Pinning ( Pinning in cages)

Pinning Press (Electro Magnetic Process ,20 Ton -1 No

0.1-0.2

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Riveting cages in Bearing

Riveting Press ,Hydraulic 20 ton,1-No1

0.2-0.3

Ball Manufacturing Unit Cold Heading Cold Header Machine 10-12 Flashing Ball Flash removing M/c. 4-6 Heat Treatment Hardening followed by Tempering on

Rotary type furnace 20-25

Tumbling Tumbler 2-3 Ball Grading Ball Grading M/c. 3-5 Rough Lapping Lapping M/c. 4-6 Abrasive Lapping Abrasive Lapping M/c. 2-3

with the help of H.S. Diesel oil and Chromium Oxide Caustic Soda Washing Inspection

Grading Greasing

Oil Lapping

Packing

3-6

Assembly of Outer & Inner Races with Balls / Roller & Cage duly suited and locked by power press

Marking Machine and Comparator

3-4

Cleaning, Checking & Final Inspection Measuring & Inspection Tools and Gauge, Comparators, Dial

Gauges, Demagnetisers, Micrometer, Slip gauge, Surface Plate,Telescope Gauge, Cylindrical Gauges etc

7-10

Testing Laboratory Equipment 2-3 Load ,RPM, Noise, Temperature etc Checking For final inspection

Load ,RPM, Noise, Temperature etc Checking For final inspection Set-up

1-2

Packing Sleeve packaging machine/Shrink Packing

0.7-1

Surface Grinder/Duplex Grinder

7

Bench Drilling machine

0.1

Pedestal Grinder

0.15

Tool post Grinder 0.1 Electric Arc Welding M/c 0.5

Work Shop M/c Tools

Fitter Bench & Measuring Instruments, Gauges, Fixtures etc.

8-10

20

Material Handling Chain Pulley & Hoist 0.5-.7 Electric D.G.Set 20 KVA 3-4 Air Pipe line Compressor 1-1.2

Centralised Cooling Tank with filtration System

Centralised Cooling Tank with filtration System ( Superior )

0.6-0.8

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1.7 Manufacturing Process

These are following three methods which are being used by units manufacturing

bearing races (Soft Turned).

BAR ROUTE :-

Bar route method is considered to be most economical method

manufacturing of soft turned Bearing Races. The following steps are involved in

this method. For the Inner Diameter upto 25mm , this method is more economical

as compared to the other method. That is why this method is more popular and it's

estimated that 70% of Bearing Races soft turning upto 25 mm I.D. size and 50%

Races of the total quantity of soft races manufactured by using this manufacturing

technology. Beyond 25mm I.D. this method is not much cost effective

Bar Turning

Drilling, Parting & Trepanning

(Trepanning is the operation in which the outer race & inner race is parted off from

a single piece of Bar).

Inner Diameter Machining & Facing

Outer Diameter Machining & Facing

Radius Formation

Track Formation

Ready for Dispatch for further operation.

Seamless Tube Method:-

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In the Seamless Tube Method the Drilling and trepanning operation are not

required , the remaining operations are as follows :-

Parting

I.D. Machining & Width Machining

Outer Dia Machining & Facing

Track and Radius Formation

Ready for dispatch for further operation

This process technology is preferably being used for the outer Dia of 25mm or

higher size. Apart 40% of the total volume of Soft Races turning is being produced

by using above mentioned method in the cluster.

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Forging Method:-

Bearing Races are manufactured by Hot Forging Method. The operation of Drilling,

parting, and trepanning are not required while using Forging Method. The Metallic

closed Dies are used in Hot Forging Method. This method is more suitable and

economical for outer Dia of 30 mm and above size. In the cluster Approx. 10% of

Bearing Races are produced by using Forging Method. The Forged Bearing Races

are machined/finished as Indicated in the earlier method.

Further Operation for Bearing Manufacturing

The Bearing Outer & Inner Races manufactured by using any one of the

method mentioned above are then supplied to large scale and small scale Bearing

manufacturing Unit. The further sequence of operation for manufacturing of

Bearing are as under

Hardening & Tempering of Outer & Inner Races.

Grinding Followed by Honing of Outer & Inner Races

Assembly of Outer & Inner Races with Balls / Roller & Cage duly suited and

locked by power press.

Cleaning, Checking & Final Inspection

Packing

Ready for dispatch

24

Heat Treatment Heat Treatment increases material hardness. At each of the three steps, different processes are available, depending on the product.

Heating 850 °C- Austenitizing) to alter the structure of the material.

Quenching 40 °C- Rapid cooling to fix the structure of the material

and thus increase hardness

Tempering 170 °C "Reheating" to reduce the effects of thermal shock (quenching)

inside the structure and stabilise the material.

Grinding Various Machines are used to perform Grinding operations:

• Surface grinding

• Outer ring outer diameter grinding

• Inner ring inner diameter grinding

• Inner ring outer diameter grinding (raceway)

• Outer ring inner diameter grinding (raceway)

• Super-finishing : Improves the condition of raceway surfaces by polishing with a grinding rod.

Manufacturing Process of Other Bearing Component

25

Steel Ball :-

Steel Ball with Close tolerance and desired surface finish are produced by using

SAE-52100 Steel Rod. The process flow diagram for

Ball Flashing Operation Deburring Machine Rill Filing Machine

Wire is fed from de-coilers into cold Header Machines when ere it cut into Blanks,

then pressed into balls between hemispherical dies.

26

Manufacturing of steel ball is as under:-

Flow chart

Cold Heading (on Cold Header Machine)

Flashing (on Ball Flash removing M/c.)

Heat Treatment (Hardening followed by Tempering on Rotary type furnace)

Tumbling (on tumbler)

Ball Grading (on Ball Grading M/c.)

Rough Lapping (on Lapping M/c.)

Abrasive Lapping (on Abrasive Lapping M/c.)

Oil Lapping (with the help of H.S. Diesel oil and Chromium Oxide)

Caustic Soda Washing

Inspection

Grading

Greasing

Packing

27

Steel Cage's:-

Steel Cages are manufactured by using Bearing Grade Steel Sheet. These sheets

are stamped with the help of Hydraulic Presses and various dies to provide the

desired form and size of Steel Cage.

The Process flow diagram for manufacturing of Bearing Cages is as under:

Blanking

Bending

Drawing

Piercing

Cleaning

Inspection

Ready for dispatch

Cage’s Manufacturing Process

28

Metal Shields - Bearing Metal Shields is protective closures which retains lubricants and assist in preventing contaminants from reaching internal surfaces.

Dust

Shields - The aperture usually found in the top cover housing is sealed to form a barrier to assist prevention of airborne contamination into the contact area Shielded Bearings - A shielded bearing has a metallic shield on the backside and Shielded bearings are not sealed bearings. With the shielded type of bearing, grease may enter the bearing readily, but dirt is restricted by the close fitting shields. If there is no shield on the backside of this bearing, the excess grease can escape into the inner bearing cap of the equipment bearing housing.

Assembly : Assembly of various items, performing additional functions (greasing, marking, etc.) During each of these steps, the bearing manufacturing process layout is carried out in compliance with total quality (self-inspection, SPC and TPM).

Chapter-2

IDENTIFYING TECHNOLOGY GAP

29

The following section present on Analysis of Business operation for the Bearing

and Bearing Component Cluster Jaipur. The following factors have been taken into

consideration in the Analysis.

• Raw Material

• Technology (Machinery & Production)

• Quality Standard

• Product & Marketing

• Entrepreneur & their Enterprises.

• Finance & working capital.

• Man Power Requirement

• Infrastructural Facilities.

• Business Development Service.

The raw material SAE 52100 Spherodised bearing steel only available from few Indian

Supplier.

• Indian Seamless Metal Tube, PUNE

• Indian Seamless Steel & Alloy, PUNE

• Mahindra Ugine Steel Company Khapoli.

Internationally, the accent is on achieving higher and higher quality levels of bearings.

Higher precision, minimum handling damages and maximum cleanliness are the thrust

areas for development. Individual units have their own grading of quality. SKF, for

example, designates t, as Q77, Q66, Q55, where Q66 is reported as the prevalent level

and Q55 as the level aimed at International manufacturers are moving towards special

bearings, and sub assemblies involving bearings, where production of small batch

quantities becomes more attractive.

High rates and consistency of productivity have been achieved by the manufacturers

abroad by line manufacture. The market demands there, permit mass production

techniques and thereby bring in economies in production.

30

- As regards materials, closer grade and specification ratings are emphasised.

- Upgrading of technology has generally come not from within or from market forces

but usually from the collaborator's insistence, if the latter has stakes, either financial or

through its name.

The following testing facilities are not available in most of the cluster units.

• Chemical examination of steel.

• Non Destructive Testing of Material.

• Metallographic

The Machinery and equipment used by majority of SSI units for manufacturing of Bearing

Races are of sub standard and obsolete. Even the SSI Bearing manufacturing units are

using the second Hand Imported Grinding & Honing Machine which are having Lesser

Tolerance Accuracy so the bearing manufactured by these units are not preferred by

International Industrial Buyer.

The Product require high degree of precision the manufacturer are unable to

maintain Accuracy with in 2 microns. In accordance with the standard of International

Market. The existing plant & machinery can give accuracy with 4 microns.

The profile cutting operation of Bearing Races is not properly done due to Non

Availability of optical profile grinder.

Therefore lot of technological intervention need to be done in the area of

Machinery and Production in order to make final product as per International Standard.

The following observation need technological Intervention:-

(1). Use of Kerosene for Splash Cleaning for Assembled Bearing and Swab Cleaning

of Individual Parts.

(2). Inspection of Contamination level of the Bearing not inspected.

(3). Dust free Room/Assembly shop of Bearing not maintained.

(4) Erroneous measurement of parallelism, concentricity, flatness, taper, straightness,

radial and Axial clearance.

(5) Non Uniform Temp. in Shaker Hearth Furnace

(6) Mar Quenching Oil is being used for Quenching, but Mar Quenching Salt is not the

practice.

31

(7) Blackening Salt is full of Contamination.

(8) Sampling System is Erroneous.

(9) Roundness Testing is used for setting parameter of M/c.

(10) Micro Structure Like Type of Martensite, Retained Austenite, Benetic Structure , is

not being inspected.

(11) Sub-Zero Treatment is not being done in the cluster

(12) Micro Hardness measurement is not practice .

(13) Speed, Feed and Depth of cut for Turning and grinding are not optimum .

(14) Precision Measuring Instrument are all shop made.

(15) Fatigue Testing of Bearing not being carried out.

(16) No phosphating of Inner and outer ring .

(17) Go-No-Go gauges practice is not existed.

(18) Forging Dies are made of H 11 & H13 Hot Die Steel and Hot H21 & H 23 material.

The Quality of Bearing Races is concerned SSI Units have to follow the relevant

specification, drawing and other instruction provided by the purchaser. The system of

100% inspection is being followed without any process wastage. However some of the

Bearing manufacturer permit 1% process wastage. In the event of rejection the unit has

to make payment for loss of the raw material the Bearing Manufacturer.

The main defects of Ball Bearing Races are Track Centre out (for which Unit is 100

Micron) eccentricity in outer Dia and Track Dia or Base and Track Dia. The Radius form

on Outer Dia and base of race is not proper which Account for major rejection.

The gauge calibration facility are not available as the gauge are required to be calibrated

periodically in order to ensure the quality of product. The most of SSI/Artisan Unit of

Cluster do not have the well organized marketing channel and Demand forecasting

system and are facing marketing problem due to lack of availability of sufficient fund and

other resources required for Advertisement & Publicity, Credit required by the buyers,

Branding, Market Assessment etc.

Most of Artisan Units are having defective Product pricing system. The units are cutting

prices due to cut throat competition.

32

The Bearing Manufacturing SSI Units are only supplying to replacement market.

There is very vast scope to supply OEM & Other sector if they produce standard quality of

Bearing.

The Problem of duplicating and Reconditioning of old Bearing are another

Constraint in the Industry.

SSI Bearing Manufacturing Units are also facing challenge from Indian Large

Scale Bearing Manufacturer like SKF, NEI, TATA Bearing etc. as large scale unit have

made Huge Investment for Product Technologies, Collaboration from world leader of

Bearing Industry. Large Scale units have employed the professionally qualified work force

and producing at higher volume as compared to SSI Units, and hence taken a lead in all

the functional Area of Manufacturing, R & D, Marketing etc. More over these units are

using latest and Innovative technique to have their higher productivity, quality and

profitability. The SSI Units are far away and yet to adopt these technique tool for their

betterment 25 % of total demand for bearing industry is met by imports. While a part of

the imports come through official channels, there is also a huge volume of illegal imports.

legal Imports generally represent the specialized bearings not manufactured in India.

There are a large variants of imported bearings, each holding a small market share in

India. Though, the quality of bearings manufactured by large players in India is

comparable to world standards, domestic manufacture is not viable due to the small size

of the market segment.

It becomes uneconomical to manufacture such type of bearings as it includes huge

capital expenditure. Illegal imports generally represent the entry of spurious imports of

bearings. In the past, the Indian bearings industry was highly protected on account of

very high import duties ranging from 150% to 240% ad valorem. As a result, illegal

imports via smuggling and under invoicing of imports was the order of the day, accounting

for a high 45-50% of total imports. While duty rates have come down over the last few

years, a few countries like China, Russia, Eastern Europe dump their excess production

at a very low rate. This leads to a huge price differential between domestic and imported

bearings (almost 40-50%), encouraging imports.

• Most of the unit, the enterprise structure is proprietary or partnership type. The

proprietor/ partner himself look after the Management Aspect and Keep over all control of

the functioning of the unit and in most of the cases they do not posses the required

technical/Managerial back ground.

33

• Technological Awareness of Entrepreneur are not upto the level. It need to be improved

so they can successfully compete the era of liberalization and globalization.

Finance is the most critical problem of the Industry in term of shortage of finance,

delayed payments, difficulties in getting bank finance and additional requirement of credit.

• Units require to maintain large inventory and it's the experience of manufacturer that the

working capital need are not fully realized by the bank & financial institution and it directly

affect their market.

• The SSI Units faces common problem regarding availability of skilled man power, A

worker After working for a period of few year in this Industry leave the Job to start his own

turning unit or to get higher wages from another unit.

• There is no regular training facilities available where the manufacturer and worker

undergo need based training.

• The SSI Units also faces problem about less availability of trained man power such as

turner, tool maker etc.

- The Tiny/Artisan Units are scattered in Different Area. They are functioning under

rented shop and due to availability of lack of space, the placement of machinery &

handling of material with in the unit is not proper.

- Due to frequent power cuts production is hampered.

- There is dearth of quality BDS in the Area of technology, Marketing, Export, Health

& Safety etc.

• Networking among R & D Centre, Technical Training Centre, Testing Centre are not

present in cluster.

34

Chapter 3

THRUST AREAS FOR TECHNOLOGY & TECHNOLOGY GAPS

The reflections of technological achievement are seen in the quality of the product.

The bearings manufactured by the Indian industry have to improve considerably to meet

international standards. If the roots of the problem are to be identified, one comes to the

following conclusions:

Machine Tools - precision, productivity

Materials - quality, consistency

Operations - process mastery, assembly, quality control Skill

These broad areas can be identified as "Technology Gaps" in bearing manufacture.

Although considerable efforts have been made in these directions, the gaps have not yet

been bridged.

Technology Gaps: Activity Plant & Machines

presently in use

Proposed plant and Machinery

Bar turning Machine Centre Lathe Lathe Addahs Low cost automated hydraulic lathes Tools cutter Grinder CNC Machine for Races Turning /Machining.

Manufacturing Bearing Races By Bar Route & Seamless tube Method (Drilling and trepanning Operation are not required )

Auto lathes (Ace Machines) Perma line

. Installation of Auto Turning Lines for Small DGBB from Tubes - Production capcity 120,000 per day,

Investment Range Investment Range : Rs. 10-20 Lakh

Investment Range : Rs. 100-200 Lakh

Forging Bearing Race Gas cutting and hacksaw

machines and modern shearing machines for raw material cutting

Automatic Hot & Cold Forming machines

35

Induction Heating Furnace for Forging 300 kw, 3 KHz - For all Lines. Oil Fired furnace 300 tone power press 200 tone power press 100 tone power press 50 tone power press Hydraulic ring rolling machine capacity to roll up to 300 mm. diameter Screw press having capacity : 350 tone Special die sinking machine Bar shearing machine Hardness testing machine equipments

Laboratory for testing of final products of forging with chemical composition and micro examination

The outstanding features of the forging shop include:

• Automatic bar loading

• Induction heating • Laser sensor

assisted ESA technology for precise bar feed control and auto Bar End Ejection

• On line control & monitoring of forging temperature

• Highly sensitive press load monitoring system

• High speed forging process eliminating risk of cracks due to temperature drop.

• Auto monitoring system for yield & tool life.

With the help of oil fired furnace / electrically heated furnace forgings is treated with sperodise anealing to remove residual stresses

Investment Range Investment Range : Rs. 200-250 Lakh

Investment Range : Rs. 1400-1700 Lakh

Heat Treatment : Hardening & Tempering

1 - Heating 850 °C (Austenitizing) to alter the structure of the material.

Natural salt bath Pit type furnace with pre-heating Furnace

Temperature Controlled Energy Efficient Heating Funace

• Liquid carburising processes

• Gas carburising processes

• Continue hardening processes

36

2 - Quenching 40 °C Rapid cooling to fix the structure of the material and thus increase hardness.

Mar quenching processes

3 - Tempering 170 °C "Reheating" to reduce the effects of thermal shock (quenching) inside the structure and stabilise the material.

Investment Range

Rs. 0.6-2 Lakh Rs.20-30 Lakh

The Machinery being used for Grinding & honing by the SSI Bearing Manufacturing Units are Imported & Second Hand Machinery.

Automatic Lines,

Bore Grinding Machine

Track Grinding Machine (Internal Grinding Machine)

Center less Grinder (External Grinding Machine )

Grinding Followed by Honing of Outer & Inner Races (Surface grinding, Outer ring outer diameter grinding, Inner ring inner diameter grinding, Inner ring outer diameter grinding (raceway), Outer ring inner diameter grinding (raceway), Superfinishing Improves the condition of raceway surfaces by polishing with a grinding rod.

Honing Machine

Investment Range 100-200 Lakh 800-1000 Lakh

Cages & Shields Manufacturing Unit:

Blanking, Bending, Drawing, Piercing, Cleaning, Inspection

Steel Cages are manufactured by using Bearing Grade Steel Sheet. These sheets are stamped with the help of Hydraulic Presses and various dies to provide the desired form and size of Steel Cage

Press Section (Blanking Transfer Press M/S Chandra Industries &M/S Manu Yantralaya have adopted transfer Presses and have good market share in SME manufacturers in India.

Investment Range 50—100 Lakh 100-200 Lakh

Ball Manufacturing Unit

37

Cold Heading (on Cold Header Machine) Flashing (on Ball Flash removing M/c.) Heat Treatment (Hardening followed by Tempering on Rotary type furnace) Tumbling (on tumbler)

Ball Grading (on Ball Grading M/c.) Rough Lapping (on Lapping M/c.) Abrasive Lapping ( on Abrasive Lapping M/c.) Oil Lapping (with the help of H.S. Diesel oil and Chromium Oxide) Caustic Soda Washing

Automatic Lines M/S Kansara Engineers Pvt. Ltd. (A Unit of Sewaram Kansara Group), E-36,M.I.A. Phase II, Basni, Jodhpur - 342005 (INDIA) has adopted automatic line and have good market share in SME manufacturers in India

Inspection Grading

Grading Machine

Greasing

Packing

Hydraulic power press AUTO INNER & OUTER DIAMETER INSPECTION, AUTO IR & OR ULTRASONIC

WASHING MACHINE, AUTO CONSERVATION OIL SPRAYING MACHINE Automatic Lines(AUTO COMBINING & CAGE ASSEMBLY MACHINE), AUTO GREASING & SHIELDING MACHINE, AUTO DEMAGNETIZING MACHINE, , AUTO BALL

BEARING ASSEMBLY

MACHINE ,

Pinning Press

Assembly of Outer & Inner Races with Balls / Roller & Cage duly suited and locked by power press

Marking Machine

Laser Marking M/C

38

Cleaning, Checking & Final Inspection

Tools and Gauge, Comparators, Dial Gauges, Demagnetisers, Micrometer, Slip gauge, Surface Plate,Telescope Gauge, Cylindrical Gauges etc

• Chemical

composition of raw

material Including

Microscopic

examination

• Ultrasonic Testing

• Oxygen contain

Checking

• R.A. Value

measurement for

Rough

measurement.

• Calibration Testing equipment

Testing Nominal Laboratory Equipment

Load ,RPM, Noise, Temperature etc Checking For final inspection

Load ,RPM, Noise, Temperature etc Checking For final inspection Set-up

AUTO DOUBLE SIDE VIBRATION & NOISE

INSPECTION MACHINE, AUTO

DOUBLE SIDE SENSITIVITY

INSPECTION MACHINE, AUTO

RADIAL INTERNAL CLEARANCE & SENSITIVITY

INSPECTION MACHINE , Packing Sleeve packaging

machine/Shrink Packing

Packing Sleeve packaging

machine

Work Shop M/c Tools Surface Grinder/Duplex

Grinder CNC M/ C Tools

Bench Drilling machine Pedestal Grinder Tool post Grinder Electric Arc Welding M/c Fitter Bench & Measuring

Instruments, Gauges, Fixtures etc.

Chapter 4

PROPOSED ADVANCE TECHNOLOGY & ITS BENEFITS

39

Bearing Steel :

The most common material used in the manufacture of bearing rings, balls and rollers is Alloy steel conforming to specifications SAE 52100. This material has become standard material for the industry all over the world. While the basic material remains the same, the steel manufacturers all over the world have been improving this material in order to improve the life span and quality of the bearing. The Indian steel manufacturers although manufacturing steel to specifications SAE 52100, are not able to meet the requirement of the bearing manufacturers in so far as purity and oxygen content is concerned. Therefore, bearing Steel Manufacturers should be equipped with Vacuum Degassing & Vacuum Oxygen De-Carburising Equipment (LEYBOLD HERAEUS, Germany.) In order to maintain Oxygen content < 15ppm . The tubes are tested to ensure that the steel is free from injurious imperfections such as piping, cracks, porosity, segregation or injurious inclusions as referred to in ASTM-381.The inclusion rating is evaluated in accordance with Plate III of ASTM E-45,The tubes are spheroidized and annealed to ensure that the microstructure consists of spheroidized commentate in a ferrite matrix with carbide size conforming to Plates 2 to 4 as per IS 4398-1972 and CG 2.1 - 2.3 as per SEP 1520-78.Spherodise annealing and normalising improves the machinability of the annealed hypereutectoid steel and improves its microstructure. To accomplish spherodise annealing and ormalising,temperature controlled energy efficient electrically heated furnace with a capacity of 6,000kg and oil fired furnaces with capacities of 3,500kg to 4,000kg are being proposed for SME sector . The spherodise annealing and normalising process provides improved ductility, removal of residual stresses, improved machinability and grain refinement.

Race Turning :

Auto lathes (Ace Machines) /CNC Machines/ SLC-100G/Machines for Ring Turning CNC Turing centers of HMT, GD Weiler and other reputed makes, capable of components upto 100mm diameter are being proposed for SME sector. Though some units in MSME sector have already installed f Auto Turning Lines for Small DGBB from Tubes - Production capacity 120,000 per day, One of them M/s Supersonic Turners Pvt. Ltd , Jaipur is performing well in this sector. Benefits : These machines are built on the Modular concept for Productive, trouble free Running with minimal operator Intervention. They are ideally suited & developed for small to medium sized disk type components that are made in large volumes like bearing rings, water pump rings, sleeves, brake pistons etc. These machine offers many high productive features that enhances productivity significantly

1.High rate of production

2. Cost effective

3. Less wastage

40

4. Better and consistent quality

5.Less power consumption

The CNC, SPM and convectional turning machines for centreless, cylindrical and round operations. SPM type convectional turning machines for proof turning and some other special operations. PLC and hydraulic type convectional machining centres for various operations are being used in SME sector as advance technology .

HEAT TREATMENT : Following Plant & equipment for Heat Treatment are being proposed in SME Sector

• Liquid carburising processes • Gas carburising processes • Continue hardening processes • Natural salt bath processes • Mar quenching processes • quenching ( Cryogenic or Nitrogen Mathanol system ): To eliminate retained

Austenite,the quench temperature has to be lowered

Forging : Manufacturers of closed die Forgins for Bearing Race equipped with Following Equipments in SME Sector.

• Induction Heating Furnace for Forging 300 kw, 3 KHz - For all Lines.

• Well equipped furnace

• 300 tone power press




• Hydraulic ring rolling machine capacity to roll up to 300 mm. diameter

• Screw press having capacity : 350 tone

• Special die sinking machine- EDM

• Bar shearing machine

• Hardness testing machine equipments

• Full equipped laboratory for testing of final products of forging with chemical composition and micro examination

41

Hot & Cold Automatic Forming plant operates at an average speed of 110 ppm providing the utmost production efficiency when compared to the conventional forging process. The Hotmatic AMP 30 S/AMP-50S three-station hotformer is ideally suited to the production of parts for the automotive, fittings and bearing industries are being suggested for large scale units . Benefits : • Simple operation and conversion • High production output (up to 140 parts/minute) • Accurate transfer • Broad range of parts (e.g. cams for passenger vehicles) • Fully developed and proven machine design

Note : M/s Agrasen Engineering Industries Limited is equipped with HotmaticAMP-30S, propelling towards future with an outstanding growth rate.

The outstanding features of the forging shop include:

• Automatic bar loading • Induction heating • Laser sensor assisted ESA technology for precise bar feed control and auto

Bar End Ejection • On line control & monitoring of forging temperature • Highly sensitive press load monitoring system • High speed forging process eliminating risk of cracks due to temperature

drop. • Auto monitoring system for yield & tool life.

Ring Rolling Process :. The raw material is heated in an induction bar heater and in precisely temperature-controlled furnaces, which provide scale free heating. The plant is equipped with gas cutting and hacksaw machines and modern shearing machines for raw material cutting. The plant uses pneumatic, mechanical and hydraulic power presses for forging. Sun Forge C-1/285, G.I.D.C.,Phase II, Aji Ind. Estate,Rajkot - 360 003, Gujarat have equipped with such technology .

Cold Rolling Plant : Ring Rolling Machin- D51A, D51B, D52 and D53K series , D51A & D51B series of vertical type Ring Rolling (Zhucheng Shengyang Machinery Co., Ltd ) and Hatebur Coldmatic coldformers (AKP 3-5 | AKP 4-5 | AKP 4-6 S | AKP 5-5 ) produce precision and complex parts formed directly from

42

wire. The parts produced this way are characterized by precision tolerances, quality surface finish and overall strength, are being also used in Bearing sector. Benefits : Machine have advantages of small volume and compact structure and saving material and power and so on, which also widely used for hot rolling of ring like blank in bearing forging and auto gear and flange manufacture industry. D52 & D53K series of CNC horizontal type Ring Rolling Machine have the following advantages: advanced structure, numerical programme control, high automation degree and productivity and saving material and power and so on. Especially D53K CNC Ring Rolling Machine, it can roll rings simultaneously in radial and axial direction and is the ideal equipment of processing large scale seamless rings, which has been widely used in spaceflight, aviation, ship, petrochemical industry and power industry and so on. Manufacturing of Bearing Cage & Shields : The following plant & Machineries are being suggested for SME Sector

• AIDA Transmax TMX Transfer Press or Straight Side 2-point Transfer

Presses

• software’s provided by Forming Technologies (I) Pvt. Ltd

• Transfer Press – 50 (Aida, Asahi Seiko, Kyori, Chin Fong Machine

Industrial Co., Ltd.186 Chang Shui Road, Chang Hua, Taiwan

other)15Ton~150Ton

• Rivet Insertion Machines – 43 (Toa Seiko, Shimizu Seiko)

Press Section (Blanking Transfer Press The main process in the production of a bearing cage. At first stage, in a process called blanking, a round ring is being cut out of a steel coil. Then, in a process called transfer pressing, a proper cage is formed by pressing out from a blank.

BLANK Pre-forming Forming Piercing

43

Rivet insertion Rivet, which is a part of bearing-cage, is manufactured from a steel wire. . The process of rivet insertion is implemented by specialized machines. The cage set is made of two identical cages joined by a rivet.

Rivet Insertion Machines – 43 (Toa Seiko, Shimizu Seiko)

44

Advanced Flow Chart to manufacturer Bearing Cages

Benefits :

Convenient to integrate with the 2D/3D transfer unit to increase production

Minimal overall clearance derived from high-precision components

Low noise and low vibration which contribute to extended die life

Note: Manu Yantralaya has adopted transfer presses & consistently marching ahead to furnish the needs of customers belonging to ball bearing industry..

Assembly Section : Automatic Line from R& S Machine China are being proposed for large scale

Quality control : Some advance Machine & equipments are being used as mentioned under:

• TALYROND - Roundness , squarness, concentricity and coaxiality of

bearing and components ,Testing instrument, FORM TALYSURF

• Profile and surface finish testing instrument etc. from - Taylor Hobson,

U.K.

• Bearing Eccentricity stand, Dial Calibration Instrument and Gauss Meter

(Residual Magnetism Tester) etc.

45

• Form and surface finish measuring instrument is being used for checking the micro

geometry, it evaluate parameters like Form geometry and surface finish of components

• Roller Sorting Machine

• Bearing Noise Level & Vibration Tester

.

ADVANCE TESTING EQUIPMENTS : The following testing equipment s are being used by M/S KANSARA ENGINEERS PVT. LTD.Jodhpur .

• Carl ZEISS Microscope model No. AXIOVERT 100 A – Germany

• Taper Roller Head Radius Measuring Instrument

• Talyrond 262- U.K.

• Dial Calibrator

• Talysurf FTS- U.K. Intra 2 System with Ultra Comprising

• Profile Projector

• Surface Roughness Tester

• ATC Calibrator

Chapter – 5 PROJECT PROFILE

Product : Forged Bearing Races NIC Product Code : 356601005 Product Code ( ASICC ) : 71243

46

Plant Capacity per annum : 7200MT ( Two Shift ) Job work per annum : Rs, 9,36,00,000 Month & Year of Preparation : March, 2011

: Prepared By : -

Micro Small and Medium Enterprises Development Institute, Government of India

Ministry of Micro Small and Medium Enterprises Bais Godam, Jaipur – 302 006 (Raj.)

Ph. 0141-2212098, 2213099, Fax. 2210553 e mail- [email protected]

web- dcmsme.gov.in

Forged Bearing Races

1.0 INTRODUCTION : The profile envisage to set up Automatic Hot & Cold Forming Forging Plant to manufacturer Bearing Races .The operation of Drilling, parting, and trepanning are not required while using Forging Method. The Metallic closed Dies are used in Hot Forging Method. This method is more suitable and economical for outer Dia of 30 mm and above size.. The Forged Bearing Races are turned /finished on turning Lines.

2.0 MARKET & DEMAND ASPECT : The demand for bearing industry is

derived from demand in two key user segments - automobile and industrial sector growth. The automobile industry is the largest growth

47

driver for OEM market as it accounts for almost 45% of total bearing market. Engineering sector, which accounts for 28% of total share, holds the second growth driver. Considering the high reliance of bearing industry on automobile sector, the fate of bearing industry is largely dependent on production of vehicles. The demand of bearing is also linked to heavy-duty industrial application in rolling stock, rolling mills, heavy earth moving equipments and other heavy machinery, accounting for 21% of total bearing market. However demand in the latter category is met through imports and therefore does not have significant impact on domestic growth . Up Swing in Automobile Sector ,The Indian Automobile sector has grown 16.5% in FY03 contributed by export growth of 65.3% and domestic growth of 14.8%. The automobile industry comprising of commercial vehicles, passenger cars, multi-utility vehicles, two/three wheelers and tractors has performed extremely well in FY03. The sharp growth of this sector has been partly driven by the impact of lower interest rate on demand, intermediated by a competitive financial sector, which has steadily cut prices of automobile loans as interest rates went down. Infrastructure has received a fillip in last 2 years through N-S-E-W corridor and Golden Quadrilateral projects. The transformation of road transport industry through these initiatives will lead to higher demand for commercial vehicle industry. Passenger cars continue to grow in double digit driven by rising aspiration levels and easy availability of cheap finance. Within two wheelers, we expect motorcycle industry growth to continue on its growth path. After two bad years, the tractor industry is also likely to witness a revival with completion of inventory correction phase and good monsoons likely to drive demand. The positive outlook for auto sector augur well for bearings demand and we expect all segment of automobile industry to report strong growth in the coming year. Export Potential Exports of bearings companies has increased at a CAGR of 13% in last seven years from 1995-96 to 2001-02 at Rs2.5bn.Big players in Indian ball and roller bearing have been already exporting a part of their production to developed countries like US, Europe etc. Domestic players are already sensing the outsourcing opportunity and have initiated the process of manufacturing a range of bearings for meeting the requirements of global customers. The Indian bearing industry, especially the companies having technical/ financial collaboration with global players like SKF Bearings,

48

FAG Bearings, Timken India, ABC Bearings and NRB Bearings are expected to garner higher price in export market. The OEM and replacement market control the market dynamics of Bearing. The OEM and replacement market both account for 40% of total demand of Bearing Industry individually. The Bearing Manufacturer are only supplying to replacement market. There is vast market of OEM Sector The SSI Bearing Manufacturing units of cluster are mainly supplying to the replacement market of Bearing. On the other hand a number of SSI Races Manufacturing Units are supplying the Soft turned Bearing Races to the following large scale units. In the Bearing & Bearing component manufacturers cluster Jaipur Approx. 10% of Bearing Races are produced by using Forging Method.

Name of Large Scale Unit : No. of Vendor in Jaipur Cluster (i) NBC : 30 No. (ii) SKF : 05 No. (iii) ABC : 02 No. (iv) FAG : 04 No. (v) TATA :02 No. (vi) TIMKEN : 01 No. The Bearing Manufacturing SSI Units are only supplying to replacement market. There is very vast scope to supply OEM & Other sector if they produce standard quality of Bearing.

3.0 RAW MATERIALS : The raw material used in the Manufacturing of

bearing Races is SAE 52100 high Carbon Chrome bearing steel, which has composition similar to EN-31 (100 CR 6 As per BIS specification). The raw material for Bearing Races is in the form of Rods The Project profile envisage to perform job work of large scale Bearing manufacturers.

4.0 MANUFACTURING PROCESS & SOURCE OF TECHNOLOGY :

Manufacturing process begins by sending hot rolled bar material through Induction Heaters to achieve the proper temperature needed for forming the part. The material then proceeds into Hatebur 3 station or 4 station hot former. Depending on the job specifications, these machines pancake the part, then form and punch the inside diameter through the product. Both machines possess the added feature of combination forging, which produces two parts at the same time thus reducing material waste.

At this point, depending on the application, the product can go through forge normalizing or spheroidize annealing furnaces, cold ring rolling process, shot blasting or visual inspection areas prior to the shipping area.

49

4.1 Quality System :

The tests are conducted as per I.S. & A.S.T.M. standards. In the Laboratory, tests such as Chemical Composition, Including rating, carbide Bending, Grain Size and other tests are conducted. Once the material s approves after spherodized Annealing, it is send for turning process where Inspection of pre-turned races is done, continuous dimension inspection during turning process,100% Crack Detection testing,100% Visual Inspection for dent, forging spots, rust & Burr of turned races is done. After getting approval material is transferred for dispatch.

5.0 BASIS OF PROJECT SELECTION : The spurt in prices of the import raw material-steel tubes, has compelled the industry to look for an alternative form of material, which has been seen in forged/formed rings.The proposed . Hatebur machines are impressive not only for their precision and flexibility, but also because of their ability to produce large volumes of parts at a high production rate which in turn yields good production efficiency. In anticipating future demand & keeping view of global trend only such a plant may be a approved vendor of large scale bearing manufacturers.The proposed proven technology has already adopted by M/S Agrasen Engineering Industries Limited , Jaipur this technology , running very well , Hence it justified the project selection.

6.0 PRESUMPTIONS: - (1) To improve the energy efficiency of the plant, it has to run continuously. The scheme is based on two shift of 75% efficiency 25 days/month and 300 days per annum (ii) Labour wages has been taken as per market rate. It is likely to vary depending upon the location of the project . (iii) Rate of interest has been taken 12% on an average on fixed and working capital. It is likely to vary due to financial outlay and the location of the unit. (iv) The operative period of the project is estimated to be about 8 years considering technology obsolescence. (v) Value of machinery & equipment is estimated on the basis Quotations received & prevailing cost of the local mkt. (vi) As the cost of raw Material is major part of working Capital and is very high and as per the mrket trend the working capital is being taken for 1.5 months only.

7.0 PRODUCTION CAPACITY :

50

The proposed ATEBUR-HOTMATIC® AMP 30 S work with one shearing and three forming stations for the production of forging parts up to 67 mm diameter and 0.7 kg input weight & 84- 140 strokes per minute. In keeping view plant capacity and presumptions made over capacity calculated as under :

8.0 Plant Capacity per annum : 10533.6 MT ( Two Shift )

Value per annum : Rs, 79,10,73,360/-

9.0 UTILITY REQUIREMENTS : 1500 KW

Hot Forming Plant

Electrical: - Power supply (start and production) 120 kVA Compressed air: - Pressure 5,5-10 bar - Consumption (non compressed state) 3 Nm3/h Cooling water: - Pressure 4 bar - Max. flow rate (depending on part) 30 m3/h

10 IMPLEMENTATION SCHEDULE :

S.No. Activities Period in Months

1 Preparation of project report and selection of site 1

2 Registration 1

3 Application for Electricity Connection 1

4 Availability of finance& Procurement of machinery 6

6 Electrification & installation 2

7 Recruitment of staff 1

8 Trial run 1

Total 13

11 FINANCIAL ASPECTS:

i) Land : The requirement of land for the proposed unit would be 3000 Sq. Mtr.

purchased @ 2500 3000 2500 7500000

Shed & Building Constriction 1000 5000 5000000

TOTAL 12500000

b PLANT & MACHINERY

S.No. Description of machine Qty. Price Amount

51

1 HATEBUR HOTMATIC® AMP 30 S with one shearing and three forming stations for the production of forging parts up to 67 mm diameter and 0.7 kg input weight. With 6 inline Induction heater and cold ring rolling machine & Shot Blasting

1 133879000 133879000

2 Noise abatement cabin. 1 7964550 7964550

3 Adaptation to tropical conditions. For ambient temperature higher than 40° C and for relative humidity higher than 90 %, it is necessary to install a larger cooler and a heater to keep condensation from forming inside the cubicle during machine standstill. The heater is controlled by temperature controller and hygrostat and allows a temperature difference of max. 15° C.

1 653,400 653400

4 CNC Lathe 200 mm 1 2000000 2000000

5 Cylindrical Grinder 1 400000 400000

6 Internal Grinder 1 300000 300000

7 Vertical milling Machine 1 450000 450000

8 Spare Parts 1 5440050 5440050

9 Changeover Aids 1 2393820 2393820

Other Conventional M/c Tools like drill, weld bench vice , portable grinder etc

1 200000 200000

10 Accessories 1 10032660 10032660

Total 163786480

vat, Taxes, Installation & Electrification @ 10% 16378648

TOTAL 180165128

9 Office Equipment, Dies & Tools LS 7614585 7614585

Total Investment In Plant & machinery

187779713

Pre operation Charges i.e. for Getting Electricity Connection etc.

3755594.26

c Total Investment In fixed assets 204035307.3

D. WORKING CAPITAL

i Personnel

S.NO. DESIGNATION No. Salary Total (Rs.)

1 Workshop in charge 1 30000 30000

2 Supervisor cum clerk 2 1200 2400

3 Skilled Worker 8 8000 64000

4 Semi skilled worker/ Helper 4 4500 18000

5 Peon / Watchman 3 3000 9000

Total 18 123400

Additional Perquisites @ 15% 18510

Total Expenditure in Salary & Wages 141910

52

ii Raw Material

S.No. Particular (Indigenous) Qty Rate Value (Rs.)

1 Bearing steel Sheets 924 60000 55440000

2 Die Blocks & Consumables 200000 1 200000

3 others L.S. 10000

TOTAL 55650000

iii Utilities Value (Rs.)

1 Power ( 8000 unit per day) 1100000 1100000

2 Water & Compressed Air LS 5000

TOTAL 1105000

iv Other Contingent Expenses

1 Postage and stationary 3500

2 Office Consumable stores 3500

3 Transport charges 10000

4 Telephone charges 5500

5 Publicity Expenses 5000

6 Traveling expenses 1500

7 Repair & Maint. 10000

8 Miscellaneous expenses 2500

9 Insurance 15648.30942

TOTAL 57148.30942

v Total Recurring Expenditure :

S.No. Description Cost

1 Personnel 141910

2 Raw material 55650000

3 Utilities 1105000

4 Other Contingent Expenses 57148.30942

TOTAL 56954058.31

vi Total working capital for 1.5months : Rs. 85431088

e Total Capital Investment :

i Fixed Capital 204035307.3

ii Working Capital for 1.5 Months 85431088

Total Capital Investment : 289466395.3

Total Capital Investment Say 289.8 Cr

Finance Detail % Contribution

i Self Contribution 25 72366599

iii Banks Contribution 75 217099796.3

11

FINANCIAL ANALYSIS

1 Cost of Production (Per year) :

i Total recurring cost : 683448699.7

ii Depreciation of machinery and equipment @ 10% 18016512.8

iii Interest on total Capital investment @ 12% 34735968

iv Depreciation of tools and office equipment / furniture @ 20% 1522917

v Depreciation of Building @ 5% 625000

Total : 738349097.5

53

2 Total Sales (Per annum)

Products Qty. Rate Value (Rs.)

Bearing Races 10533.6 74000 779486400

Sale of Scrap (5%) 527 22000 11586960

TOTAL : Rs.

791073360

3 Net Profit (Per yr.) (Before tax)

Total turnover per yr. -cost of production per yr.

(in Rs.) = 791073360 -738349097.5

52724262.49

4 Net profit ratio :

Net profit × 100 = 52724262.49 x100 = 7%

Turn Over 791073360

5 Rate of return :

Net profit × 100 = 52724262.49 x100 = 18%

Total Investment 289466395.3

6 BREAK-EVEN POINT;

FIXED COST

1 40% salary & wages 681168

2 Depreciation on machinery & Equipments @ 10%

18016512.8

3 Depreciation of tools and office equipment @ 15%

1522917

4 Depreciation of Building @ 5% 625000

5 Interest on capital investment @ 12% 34735968

6 40% of other contingent expenses 199200

7 Insurance 187779.713

TOTAL 55968545.51

Net Profit (Per yr.) (Before tax) 52724262.49

BEP :

Fixed Cost × 100 = 51%

Fixed Cost + Profit

12 LIST OF SUPPLIER ADDRESS

12.1 Plant & Machinery : A Hatebur Umformmaschinen AG

Postfach 916 General Guisan-Strasse 21 CH-4153 Reinach Switzerland Tel.: +41 61 716 21 11 Fax: +41 61 716 21 31 India M.R.I. SHAIKH CHRYSTEC MACHINE TOOLS PVT LTD, 103 Winner's Court, Lulla Nagar

54

Pune 411040 Maharastra, India 00912030527484 Mobile: +91 (0) 9892249582

B Zhucheng Shengyang Machinery Co., Ltd

Sales：+86-536-6510558

Fax：+86-536-6519018

Purchasing：+86-536-6330266

Production：+86-536-6511668

Finance：+86-536-6516178

12.2 Raw Materials & Consumables

1. Local Market

2. ISTM Lunkad Towers, Viman Nagar, Pune - 411014, India. Tel: +9120 41434100/01 +9120 66024901/02 Fax: +9120 26630779 www.ismt.com

Contact: Mr. S Mallya Executive Vice President – Marketing Email: [email protected]

3. Mahindra Ugine Steel Co. Ltd Jagdish Nagar, Khopoli – 410216 District – Raigad Maharashtra State, INDIA Ph.:+91 02192 - 263318 / 263347 / 262487 / 262488 / 263589 Fax: 91 02192 - 263073 / 263076 / 268502 http://www.muscoindia.com/contactus.htm For Steel Procurement Contact Mr.Ramchandra Rane G.M.(Marketing) e-mail [email protected] Ph.: 91-2192-263781 Telefax - 91-2192-268502 PABX - 91-2192-262488 / 263070(ext)640.

13 Resource centre of Technology : Plant & Machine Suppliers

13.1 R & S Machinery Equipment Ltd. Xiaowu No. 2 Industrial Zone, Yuwotou, Dongchong Town, Panyu Dist., Guangzhou, Guangdong, China, 511475

55

TEL: +86 20 8490 5870(3 lines) FAX: +86 20 8490 5880 E-MAIL: [email protected]

13.2 Hatebur Umformmaschinen AG Postfach 916 General Guisan-Strasse 21, CH-4153 Reinach, Switzerland

Tel.: +41 61 716 21 11, Fax: +41 61 716 21 31 14 List of the units set up by using this project Profile :

A. Agrasen Engineering Industries Limited F-198/199, Road No, 9F Vishwakarma Industrial Area, Contact Person : Mr. Vinod Agarwal Phone :+91-141-2330614 E-mail [email protected] , [email protected]

.

56

Annexure -a

TECHNOLOGY PROVIDERS

Technology / Plant Providers All the manufacturers in the organised sector have entered into collaboration agreements for supply of complete process know how as well as supply of major manufacturing machinery tool design, production control techniques etc from them,

Company COLLABORATION

SKF India

FAG Bearing India NEI

NRB

ABC Bearing Ltd.

TIMKEN India

Bimetal Bearing Ltd

Kansara Engineering Pvt. Ltd.,

SKF Sweden

FAG, Germany

NTN

Nadella, France

NSK Japan

TIMKEN USA

Clevite Corporation USA

NTN Japan, Nadella France

Technology Providers/ Machine & equipment Providers

Area Concerned

BRENCO Incorporated , U.S.A. www.brencoqbs.com

Cartridge Tapered Roller Bearings for Railway wagons and Locomotives.

NTN Corporation , Japan http://www.ntn.co.jp (c)

For Ball Bearings, Cylindrical & Spherical Roller Bearings, Tapered Roller Bearings.

Izumi Kinzoku Kogyo Co. Ltd., Japan

For re-manufacturing, retrofitting and overhauling of grinding and super finishing machines for bearing races.

Hatebur Umformmaschinen AG) CHRYSTEC MACHINE TOOLS PVT LTD, 103 Winner's Court, Lulla Nagar Pune 411040 Maharastra, India 00912030527484 Mobile: +91 (0) 9892249582 WEB SITE www.chrystec.com

Hatebur Hotmatic hotformers ,a fully-automated Forging &Hatebur Coldmatic coldformers produce precision and complex parts formed directly from wire.

57

Hatebur Umformmaschinen AG Postfach 916 General Guisan-Strasse 21, CH-4153 Reinach Switzerland Tel.: +41 61 716 21 11 Fax: +41 61 716 21 31 Shimoumezawa 526, Namerikawa, 936-0852 Toyama Toyama plant: Mizuhashi-Iseya, Toyama-city, 939-3524Toyama

Bearing Cage (Manu Yantralaya, Jaipur Has set up Ball Bearing Cage production line(Transfer Press) in Technical Collaboration with M/s Toho Industrial Co. Ltd., Japan )

M/S CHIN FONG MACHINE INDUSTRIAL CO. LTD. 186 Chang Shui Road, Chang Hua, Taiwan 500 R.O.C. TEL:+886-4-7524131, FAX:+886-4-7611920 E- Mail:[email protected] URL:www.chinfong.com.tw

Transfer Presses : M/S CHANDRA INDUSTRIES , Jaipur , Installed Transfer Presses for manufacturing Dust shield (Z-shield,) .

R & S Industrial Automation Equipment (Shanghai) Ltd. 1F/BLG 6,No.67, LANE 1768,LIYUE RD.,MINHANG DIST. SHANGHAI,CHINA,201114, TEL: +86 21 5190 5246 +86 21 5190 5247 FAX: +86-21 5190 5248 E-MAIL: [email protected] http://www.rands.com.cn/english/contact.asp

Automatic Lines (NEI has placed order for Automatic lines from R & S Machinery Equipment Ltd. )

Zhucheng Shengyang Machinery Co., Ltd Sales :+86-536-6510558

Fax：+86-536-6519018

Purchasing：+86-536-6330266

Production：+86-536-6511668

Finance：+86-536-6516178

Product

Ring Rolling Machine Vertical Ring Rolling Machine &f Radial Ring Rolling Machine Forging Manipulator Charging-discharging Machine, Hydraulic press machine

Jinan King Rabbit Technology Development Co., Ltd., 23 East Huayuanzhuang Road, Jinan, Shandong, China , Postal Code: 250013 Telephone :: 86-531-86986670 Fax Number: 86-531-86970098 Contact Person: Mr. Guoqing Sun Showroom: http://rabbitlaser.en.made-in-china.com

Machine (Laser Engraving Rabbit

58

M/s GIANT RED-WOOD INTERNATION & CO., Ltd. CEO : Ming-Chang Chen .290,WAN SHOU RD,SEC1, KUEI SHANHSIANG,333,TAO YUAN HSIEN. TAIWAN,R. O. C. Phone : 886-2-82091151 Fax : 886-2-82003618 Url: http://www.giant-red-wood.com.tw Email : [email protected]

Riveting machine, eyeleting machine, snap fastening machine, cutting machine, gluing machine, press, eyelets, rivets, aluminum tube forming machine

WMW Machinery Company, 513 Acorn Street Unit B, Deer Park, New York 11729 USA Phone: 631-940-9121 - Fax: 631-940-9125 Email: [email protected] http://www.wmwmachinery.com

WMW machining capabilities include universal and heavy duty machining, heat treatment, material testing and quality control, dynamic balancing, metal sheet working, sand blasting, painting, packing

AIDA GREATER ASIA PTE LTD (SINGAPORE) – AGA

No.1 Bukit Batok Crescent #02-60 WCEGA PLAZA Singapore 658064 Tel (65) 6507 3555 Fax (65) 6507 3553 (Office) Email [email protected]

Stamping Presses

Machine Tools Division, Beavar Road, Ajmer 305 003

Ph.: 91-145-244 0620 / 2684 200,Fax: 91-145-244 0082

P.C. Verma, General Manager

91-145-2684 300/91-145-244 0240/(+91) 99280 16143

N.K. Gokhroo, Joint General Manager (Sales)

91-145-2684 330, (+91) 99280 16129

Grinding M/C, & Machine Tools

Olympus – Japan

Distributor India

I.R.Technology Services Pvt. Ltd.

B-8, Commerce Centre , 78, Tardeo Road,

Mumbai 400034 India

Tel :(91) 22-2495-1085

Fax :(91) 22-2495-0584

Metallurgical microscope Microscope from Olympus – Japan

or checking microstructure as..•

Spheroidize structure

• Amount of perlite

• Micro inclusions

• Carbide network

• Carbide streaks (bandings)

• Decarb

59

• Hardening & Tempering

Talysurf FTS (Taylor Hobson Limited - U.K.)

AMETEK INSTRUMENTS INDIA PRIVATE LIMITED Prestige Featherlite Tech Park, Plot No.148, 1st floor,EPIP 2nd Phase, Whitefield, BANGALORE 560066 INDIA ,

Tel: 1860 266 2468 FAX:+91 80 6782 3232

Sales :[email protected] Service:[email protected]

J.Gabriel Suresh Kumar Sales Manager [email protected]

S.R.Kiran Service Manager [email protected] Geetha Mohan [email protected]

Form and surface finish measuring

instrument for checking the

Crowning Profile & Surface Finish of

rollers.

Profile Projector (100X) :

Optics Range PGI

Taylor Hobson offers a wide range of

measuring instruments and software

solutions for high value applications

optics.

Bearing Range PGI to achieve extremely tight tolerances required for their demanding applications.

PGI Ultra Range Precision

Precision inductive range of products is the main market reference tool for surface finish, shape and measure 3D contour.

Hand Held Range Surtronic

Mitutoyo make (Japan,) Mitutoyo South Asia Pvt. Ltd. C-122, Okhla Industrial Area, Phase-I, New Delhi-110 020, INDIA TEL: (91) 11-26372090 FAX: (91) 11-26372636 http://www.mitutoyo.co.jp

Profile projecter, Roundness Tester,

& other Measuring Instruments

WMW Machinery Company using:

Postal Address: 513 Acorn Street, Unit B Deer Park, NY 11729 U.S.A.

Telephone: 1-631-940-9121

Fax: 1-631-940-9125

Email: [email protected]

Tooll Room Precision Mmachines

with latest grinding technology.

BWF Kunststoffe GmbH & Co. KG he BWF Group is subdivided

60

Bahnhofstraße 20

Postfach 1120

D-89362 Offingen

Telephone +49-82 24-71-0

Telefax +49-82 24-71-21 45

BWF-Profiles(at)bwf-group.de

www.bwf-group.de

internationally into four independent

sectors:

Envirotec

(Environmental

Technology)

Protec (Engineered

Felts)

Feltec (Woolfelt)

Profiles

(Thermoplastic

Materials) Meccanica Nova S.p.A. Via Roma, 54/A 40069 - Zola Predosa - Bologna - Italy Tel. +39 0512980211 Fax +39 0512980293 [email protected]

Internal and external grinding systems.

MARPOSS – Italy MARPOSS ITALIA S.p.A.

40010 BENTIVOGLIO (BO) Via Saliceto, 13 Tel. +39 051 899111 Fax +39 051 899870

P. IVA: 01510581208

Head Office:

MARPOSS INDIA Pvt. Ltd.

122 050 IMT MANESAR 147, Sector 7 Distt. Gurgaon Haryana Tel. +91 124 4735700 Fax +91 124 4735701

Inprocess gagues of for better size

control.

THIELINHAUS- German wuper finishing machines(for

improving the surface finish of

raceways )

Supfina-Germany ,. Super finishing machines for super finishing rollers & along with cambered profile - a unique

61

feature with supfina machines Kudale Dial Calibrator

M/S Micromatic Machine Tools Pvt. Ltd., Marketing office 301-302, Vikas Deep Building District Centre, Laxminagar, New Delhi-110 092 Tel: 011-22025846, Fax: 011-22026761 Contact: Mr. Amit Goel, Mobile: 9871091058 Email: [email protected] Plot No. 550-E, Sector - 37-II, Pace city, Gurgaon - 122 001 Tel: 0124-4745500, Fax: 0124-4030832 5D/8D, NIT, Railway Road, Faridabad-121050 Tel: 0129-4033050

SLC-100G Machines for Ring Turning

M/SJyoti CNC Automation PVt. Ltd. G-506, Lodhika, G.I.D.C., Vill. Metoda, Dist : Rajkot - 360 021 (INDIA) Phone+91-2827-287081, 287082, +91-2827-287412, Fax +91-2827-287480 E-mail :[email protected] http://www.jyoti.co.in Jyoti CNC Automation Pvt. Ltd. S - 24, Dwarika Tower, Central Spine, Vidhyadhar Nagar, Jaipur (Rajasthan)- 302023 E-mail : [email protected] Mr. Vikas Soni : 97833 07603

CNC Turing & Milling

GEDEE WEILER (P) LTD, Technical Centre, Vellalore Road, Podanur Post, Coimbatore - 641 023. Email : [email protected] Ph : +91-422-2413908 / 2413804 Fax : +91-422-2413528 http://www.gdweiler.com/sales-service.php SALES GEDEE WEILER (P) LTD, 871, Second Floor, Sector 10A, Gurgaon – 122 001 E-MAIL: [email protected] Contact Person : Mr. MANMOHAN SINGH - REGIONAL MANAGER Mob : 09312092204 SERVICE GEDEE WEILER (P) LTD, 871, Second Floor, Sector 10A, Gurgaon – 122 001 E-MAIL: [email protected]

CNC Turning & software

62

Contact Person : Mr.R.Mohankumar (Service Engineer) Mob : 093120 92205

ISTM, Corporate Office Lunkad Towers, Viman Nagar, Pune - 411014, India. Tel: +9120 41434100/01, +9120 66024901/02 Fax: +9120 26630779 www.ismt.com Contact: Mr. S Mallya Executive Vice President – Marketing Email: [email protected]

Bearing Steel ISMT supplies bearing tubes to the major bearing manufacturers throughout the world. Oxygen Content Oxygen content < 15ppm. On specific request oxygen content < 10 ppm can be offered

Mahindra Ugine Steel Co. Ltd Jagdish Nagar, Khopoli – 410216 District – Raigad Maharashtra State, INDIA Ph.:+91 02192 - 263318 / 263347 / 262487 / 262488 / 263589 Fax: 91 02192 - 263073 / 263076 / 268502 http://www.muscoindia.com/contactus.htm

Bearing Steel For Steel Procurement Contact Mr.Ramchandra Rane G.M.(Marketing) e-mail [email protected] Ph.: 91-2192-263781 Telefax - 91-2192-268502 PABX - 91-2192-262488 / 263070(ext)640.

Mr. Davinder Pal Singh Smithson Machine Tools, E-49, Industrial Area, Jalandhar, Punjab, India – 144004, Phone +91-181-2290218, Fax +91-181-2296786 [email protected] http://www.smithsongrinders.com

Bearing Race Grinding Machine

Bhavya Machine Tools Address : A-601, 6th Floor, Sapath-4, Opp. Karnavati Club, S.G. Highway Road, Ahmedabad-51. Gujarat. (India). Phone : +91-79-4024 2800, +91 - 79 - 3007 4560 FAX : +91-79-4024 2877 Mobile : +91 9428450980 , + 91 9375208872 E-mail :

[email protected]

Workshop machine

Forming Technologies (I) Pvt. Ltd.

107, Supreme Icon, Baner Road, Pune -(Maharashtra) 411007 India Phone(s) : 20 25663201 www.forming.com/

Sheet Metal Forming Software and Training solution

Zhucheng Shengyang Machinery Co., Ltd D51A, D51B, D52 and D53K

63

Sales：+86-536-6510558

Fax：+86-536-6519018

Purchasing：+86-536-6330266

Production：+86-536-6511668

Finance：+86-536-6516178

series of Ring Rolling Machine which include more than 40 specifications. D51A & D51B series of vertical type Ring Rolling

Schuler India Private Limited 401–403 Keshava , Bandra-Kurla Complex, Bandra (East), Mumbai 400 051 India Tel.: +91 (22) 66 80 03 00 Fax.: +91 (22) 66 80 03 99 www.schulergroup.com

Metal Forming.

64

Annexure - b

Quality Standards (BIS)

The quality is of paramount importance for bearing. The organized sector units are

following global standards and use front line technology for inspection & quality control.

The unit in unorganized sector have substantial level of awareness and learning to start

defining the processes for measurement of efficiency and effectiveness.

Bureau of Indian standards laid down following standards for Bearings:

S.No. Standard No. Year Title

1 IS 25 1979 Specification for antifriction bearing alloys

2 IS 719 1990

Specification for antifriction bearing grease (superseding IS : 1276 : 1958)

3 IS 1409 1959

Methods of chemical analysis of antifriction bearing alloys

4 IS 2398 1967 Identification Code for Rolling Bearings

5 IS 2399 1988 Rolling bearings - Vocabulary

6 IS 2513 1963

Boundary dimensions for rolling bearings for general engineering purposes

7 IS 2720 : Part 31

1990 Methods of test for soils: Part 31 Field determination of California Bearing Ratio

8 IS 2849 1983

Specification for non-load bearing gypsum partition blocks (solid and hollow types)

9 IS 2898 1976 Specification for Steel Balls for Rolling Bearings

10 IS 3090 1965

Code of practice for installation and maintenance of rolling bearings

11 IS 3590 1966

Specification for load bearing lightweight concrete blocks

12 IS 3630 1992

Construction of Non-load Bearing Gypsum Block Partitions - Code of Practice

13 IS 3697 1966 Boundary dimensions for taper roller bearings

14 IS 3823 1988 Rolling bearings - Static load ratings

15 IS 3824 2002

Rolling Bearings - Dynamic Load Ratings and Rating Life

16 IS 3824 : Part 1 1983

Methods of evaluating dynamic load ratings of rolling bearings Part 1 Radial ball bearings

17 IS 3824 : Part 2 1983

Methods of evaluating dynamic load ratings of rolling bearings Part 2 Radial roller bearings

18 IS 3824 : Part 3 1983

Methods of evaluating dynamic load ratings of rolling bearings Part 3 Thrust ball bearings

65

19 IS 3824 : Part 4 1983

Methods of evaluating dynamic load ratings of rolling bearings Part 4 Thrust roller bearings

20 IS 3980 1982

Specification for Porous Metal Powder Oil-Impregnated Bearings

21 IS 4025 2006 Rolling bearings -Gauging practice

22 IS 4215 1983 Specification for Ring Type Needle Bearings

23 IS 4397 1999

Cold-rolled Carbon Steel Strips for Ball and Roller Bearing Cages/Retainers - Specification

24 IS 4398 1994

Carbon-chromium Steel for the Manufacture of Balls, Rollers and Bearing Races - Specification

25 IS 4773 2002

Rolling Bearings -- Plummer Blocks Housings -- Boundary Dimensions

26 IS 4774 : Part 1 1982

Specification for Thin-walled Half Bearing - Part I : Plain Bearing

27 IS 4774 : Part 2 1982

Specification for Thin-walled Half Bearings - Part II : Flanged Bearing

28 IS 4882 1979

Specification for Low Carbon Steel Wire for Rivets for Use in Bearing Industry

29 IS 5489 1975 Carburizing steels for use in bearing industry

30 IS 5669 1987

General plan of boundary dimensions for radial rolling bearings

31 IS 5692 1988 Tolerances for radial rolling bearings

32 IS 5932 1970

Boundary Dimensions for Thrust Ball Bearings with Flat Seats

33 IS 5933 2002 Rolling Bearings - Thrust Bearings - Tolerances

34 IS 5934 1999

Rolling Bearings - Chamfer Dimensions - Maximum Values - Specification

35 IS 5935 1992

Radial internal clearances in unloaded radial rolling bearings

36 IS 6403 1981

Code of practice for determination of bearing capacity of shallow foundations

37 IS 6453 1984 Technical supply conditions for rolling bearings

38 IS 6454 1972 Specification for Self-Aligning Roller Bearings

39 IS 6455 1972 Specification for Single Row Radial Ball Bearings

40 IS 6456 1972 Specification for Double Row Radial Ball Bearings

41 IS 6457 1972 Specification for Single Row Cylindrical Roller Bearings

42 IS 6458 1972

Specification for Double Row Cylindrical Roller Bearings

43 IS/ISO 6547 1981

Hydraulic Fluid Power - Cylinders - Piston Seal Housings Incorporating Bearing Rings - Dimensions and Tolerances

44 IS 6548 1992 Rolling bearings - Instrument precision bearings

66

45 IS 6731 1977

Specification for Locknuts, Narrow Series and Lockwashers with Straight Inner Tab for Rolling Bearings

46 IS 6751 1972

Specification for Aluminium Alloy Castings and Strips for Bearings

47 IS 6754 1972 Specification for Aluminium Alloy Ingots for Bearings

48 IS 6774 2004 Classification of essential oil-bearing aromatic plants

49 IS 7409 : Part 2 1994

Anaesthetic and respiratory equipment - Conical connectors Part 2: Screw threaded weight bearing connectors

50 IS 7460 1988 Tolerances for tapered roller bearings

51 IS 7461 : Part 1 1993

General plan of boundary dimensions for tapered roller bearings Part 1 Single row bearings

52 IS 7461 : Part 2 1992

General plan of boundary dimensions for tapered roller bearings Part 2 Double row bearings

53 IS 7461 : Part 3 1992

General plan of boundary dimensions for tapered roller bearings Part 3 Flanged cups

54 IS 8255 1976

Specification for Flexible Load Bearing Polyurethane Foam Components for Vehicles

55 IS 8475 1977

Lead based antifriction bearing alloy for heavy duty applications

56 IS 8619 1977 Specification for Bearing Collars for Milling Arbors

57 IS 8656 1977

Specification for Tapered Adapter Sleeves for Rolling Bearings

58 IS 8657 1977

Specification for Tapered Withdrawal Sleeves for Rolling Bearings

59 IS 9193 1988 Specification for Bearing Pullers

60 IS 9203 : Part 4 1979

Specification for Friction Rollers for Mine Haulage Tracks - Part IV : Rollers with Non-metallic Rope Bearing Surfaces

61 IS 9247 1979

Tolerances for radial rolling bearings with shields or seals

62 IS 9619 1980

Identification code for shell type needle bearings (including sealed bearings)

63 IS 9764 : Part 1 1992

Plain bearings - Washers for plain bearings and wrapped bushes - Specification Part 1 Ring type thrust washers

64 IS 9764 : Part 2 1994

Plain bearings - Washers for plain bearings and wrapped bushes -Specification Part 2 Half thrust washers

65 IS 10203 1982

Technical supply conditions for thin walled plain bearings

66 IS 10225 1982

Specification for Bearing Spools for Tractor-operated Disc Harrows

67

67 IS 10260 : Part 1

1982 Terms, definitions and classification of plain bearings Part I Construction

68 IS 10260 : Part 2

1982 Terms, definitions and classification of plain bearings Part II Friction and wear

69 IS 10260 : Part 3

1982 Terms, definitions and classification of plain bearings Part III Lubrication

70 IS 10285 1982 Guide for tannin bearing plants

71 IS 10385 1982

Method for determination of radial crushing strength of sintered metal powder bearings

72 IS 10647 1985 Specification for Wheel Bearing Grease

73 IS 10648 1983

Code for identification of ring type needle bearings (including sealed bearings)

74 IS 11027 1984 Definitions of tolerances for rolling bearings

75 IS 11145 2002

Plain Bearings -- Thin Walled Half-Bearings -- Checking of Peripheral Length

76 IS 11159 : Part 3

1989 General classification of lubricants, industrial oils and related products (Part 3) Family F (Spindle bearings, bearings and associated clutches)

77 IS 11284 1985

Rotary tube test for iron bearing materials for the manufacture of sponge iron/direct reduced iron(DRI )

78 IS 11430 1985

Code of practice for the packaging of ball and roller bearings

79 IS 11904 1999

Rolling bearings with locating Radial bearings snap ring - Dimensions and tolerances – Specification

80 IS 12102 1987 Specification for Tapered Roller Bearings

81 IS 12211 1987

Micrographic method for assessing the distribution of carbides in tool steel and bearing steels using photomicrographs

82 IS 12375 : Part 2

1993 Implants for Surgery - Partial and Total Hip Joint Prostheses - Part 2 : Bearing Surfaces Made of Metallic and Plastic Materials

83 IS 12635 2000

Water Well Drilling and Blast Hole Drilling - Rock Roller Bit with Non-sealed Ball and Roller Bearing Arrangement - Technical Supply Conditions

84 IS 12778 2004

Hot Rolled Parallel Flange Steel Sections for Beams, Columns and Bearing Piles - Dimensions and Section Properties

85 IS 12791 1989

High carbon chromium (bearing) steel tubes for the manufacture of bearing races

86 IS 13405 1999

Rolling Bearings - Cylindrical Roller Bearings, Separate Thrust Collars - Boundary Dimensions - Specification

87 IS 13406 1992

Radial ball bearings with flanged outer ring - Flange dimensions

88 IS 13544 1992

Trailers - Mounting of ball bearing turn table - Dimensions

68

89 IS 13637 : Part 1

1993 Technical Drawings - Rolling Bearings - Part 1 : General Simplified Representation

90 IS 13637 : Part 2

1999 Technical Drawings - Rolling Bearings - Part 2 : Detailed Simplified Representation

91 IS 13962 1994

Rolling bearings - Metric tapered roller bearings - Designation system

92 IS 14478 1997

Plain Bearings - Thick-walled dushes, Plain and Flange Type, Full Round (Without Any Joint or Slit) - Specification

93 IS 14691 1999

Rolling Bearings - Taper Rolling Bearings - Tapered Roller - Metric Series - Specification

94 IS 14802 : Part 1

2000 Plain Bearings - Hardness Testing of Bearing Metals - Part 1 : Compound Materials

95 IS 14802 : Part 2

2000 Plain Bearings - Hardness Testing of Bearing Metals - Part 2 : Solid Materials

96 IS 14803 : Part 1

2000 Plain Bearings - Part 1 : Fits

97 IS 14803 : Part 2

2000 Plain Bearings - Part 2 : Tolerances on Form and Position and Surface Roughness for Shafts, Flanges and Thrust Collars

98 IS 15620 2005

Plain bearings - multilayer materials for thin-walled plain bearings

99 IS 15624 2005

Thermoplastic polymers for plain bearings - classification and designation

100 IS 15625 2005

Plain bearings - Lublication holes, grooves and pockets - Dimensions, types designation and their application to bearing bushes

69

Annexure - c

Chemical Composition of Through-Hardening Bearing Steels Composition (%) Grade C Mn Si Cr Mo ASTMb-A295 (52100) min. 0.98 0.25 0.15 1.30 — ISOc Grade 1, 683/XVII max. 1.10 0.45 0.35 1.60 0.10 ASTM-A295 (51100) min. 0.98 0.25 0.15 0.90 — DINd 105 Cr4 max. 1.10 0.45 0.35 1.15 0.10 ASTM-A295 (50100) min. 0.98 0.25 0.15 0.40 — DIN 105 Cr2 max. 1.10 0.45 0.35 0.60 0.10 ASTM-A295 (5195) min. 0.90 0.75 0.15 0.70 —

max. 1.03 1.00 0.35 0.90 0.10

ASTM-A295 (K19526) min. 0.89 0.50 0.15 0.40 — max. 1.01 0.80 0.35 0.60 0.10

ASTM-A295 (1570) min. 0.65 0.80 0.15 — — max. 0.75 1.10 0.35 — 0.10

ASTM-A295 (1560) min. 0.56 0.75 0.15 0.70 — max. 0.64 1.00 0.35 0.90 0.10

ASTM-A485 grade 1 min. 0.95 0.95 0.45 0.90 — ISO Grade 2, 683/XVII max. 1.05 1.25 0.75 1.20 0.10 ASTM-A485 grade 2 min. 0.85 1.40 0.50 1.40 —

max. 1.00 1.70 0.80 1.80 0.10

ASTM-A485 grade 3 min. 0.95 0.65 0.15 1.10 0.20 max. 1.10 0.90 0.35 1.50 0.30

ASTM-A485 grade 4 min. 0.95 1.05 0.15 1.10 0.45 max. 1.10 1.35 0.35 1.50 0.60

DIN 100 CrMo6 min. 0.92 0.25 0.25 1.65 0.30 ISO Grade 4, 683/XVII max. 1.02 0.40 0.40 1.95 0.40

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