practical training report on ball bearing

7/31/2019 Practical Training Report on Ball Bearing

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PRACTICAL TRAINING REPORTTAKEN AT

NATIONAL ENGINEERING INDUSTRIES LTD JAIPUR(KEEPING THE NATION ON THE MOVE)

Prepared By

Prem Prakash KhatriB.Tech. IV Yr. (Mech. Engg.)

Vivekanand Institute

of Technology-East ,jaipur


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COMPANY PROFILE

Founded in 1946 by B. M. Birla.

Renew name in 1958 from NBCL to NEIL.

Producing 1.9m bearing from 20mm to 1350 mm in 500different sizes

Spread 118 acres in jaipur & 56 acres in newai Production of Ball Bearing , Cylindrical roller Bearing ,

Tapered Roller Bearing , Cartridge Tapered Roller , steel balls.

Largest bearing given to Rourkela Steel Plant .

Raw material from tisco,west germany,japan &Holland.


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The NEI Office Network

Head office-9/1

R.N. Mukherjee

road in Kolkata.


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NEI PLANT AT JAIPUR

PLANT INFORMATION:situated at khatipura road from 1 km of westrailway station

PLANT INFORMATION (NEWAI):establised in 1980-81.

SHIFTS:

Production goes in three shifts and one General Shift. 1st shift from 06.0014.30 Hours

2nd shift from 14.3023.00 Hours

3rd shift from 23.00

06.00 Hours General shift from 08.0017.00 Hours


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COLLBORATORS OF N.E.I. Ltd.

The Hoffman Manufacturing Co. Chelmsford, U.K.

(Now RHP)

Withelm Stahtecker GMBH, West Germany

Federal Mogul Corporation, U.S.A.

SRO Switzerland

Heald Incorp. Ltd, Boston U.S.A.

NTN, Japan

Brenco U.S.A.


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DEPARTMENTS IN NEI LTD., JAIPUR

BALL BEARING DIVISION

TAPER BEARING DIVISION

AXLE BOX DIVISION

TOOL ROOM ELECTRICAL AND MAINTENANCE

MACHINE BUILDING

LARGE DIA BEARING

STEEL FOUNDRY RESEARCH n DEVELOPMENT HRD


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Four major parts-balls,inner and outer race,cage.

HEADING

FLASHING

SOFT GRINDING

HEAT TREATMENT

WORK HARDENING

HARD GRINDING


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FINISH GRINDING

LAPPING

SUPER FINISHING

ULTRA SONIC WASHING

VISUAL INSPECTION

ANTIRUST OILING, COUNTING, PACKING


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The Manufacturing Process

OPERATIONS: -

1) HEADING:- This is the foremost operation to manufacturethe balls. This machine cuts the wire with the help of cutter andthen the cutes piece is drawn into the spherical shape by theapplication of the punch &die arrangement. This process mainlyconsists of three main steps: -a) Wire feeding

b) Cutting of the wire.c) Turn into spherical shape.


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Ball Machine

2) FLASHING : - The balls

obtained by the above

operation are not perfectly

spherical but it consists of

collar or flash in the centralperiphery. So, to achieve a

spherical shape some

material is removed from its

surface with the help offlashing machine. In this

machine there are two plane

plates. Balls are made to roll

between these plates again

and again until the proper

shape of the balls is achieved.

To make it cool some coolant

is also provided.Rill plates for ball machine


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3)SOFT GRINDING- In this operation grinding wheels used is

made of soft material and have grooves on its surface. Balls

are made to rotate in these groves. It removes extra material

and makes the ball spherical.


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4)HEAT TREATMENT:- The heat treatment operation can be accomplished

by Chugai Ro furnace. During this process the balls are first of all washed

by water at 60c and are then supplied to the hardening furnace in which

there are total of four zones consisting of different temperatures.

Temperature of the zone depends upon the type of job. After that these

are passed through quenching oil tank so that the job get cool. In tank

there is a agitator to maintain the temperature of oil uniform. Then these

are further cooled with dry air and proper washing. At this time five balls

are taken from sample box and are checked against their hardness testing

m/c. Stresses are developed during the hardening and quenching process

these stresses are relieved by tempering operation. So after checking

hardness they are further sent into a tempering furnace by which the

temperature is to be supplied to the job or material (ball). The

temperature of tempering furnace is about is about 170C for somespecified time limit. These balls are again checked for their hardness by

hardness tester m/c.


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5)WORK HARDENING PROCESS: - This process takes place in WHT (work

hardening tumbler) machine. By this operation case hardening is done of

balls by dropping balls from a certain height. Also desiccating is done by

this operation.

6) HARD GRINDING (G2): -It is a process of grinding in which grinding

wheel is made of hard material and have groves on its surface where the

balls are ground to achieve or acquire a good & smooth surface finish by

removing the material from its surface. By this process we can grind the

balls so as to reduce the size from 100 to 30.

7) FINISH GRINDING (G3): -It is a grinding process in which some material

is again removed from the surface of balls to achieve a good or high

surface finish. By this process the size of material is further reduced is

about 7.

8) LAPPING (L1): - Here balls are passed through a paste containing

(cr2o3 + 2lt honilo oil +1/2lt olic acid). Function of cr2o3 is to remove

extra material and of olic acid is to provide brightness. So that it have a

good surface finish.


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9) SUPER FINISHING: - Now the balls are the in honilo oil. It also contains

cr2o3 and olic acid but in very small quantities. Here finished touch to the

balls is given.

10) ULTRA SONIC WASHING : - The balls are now washed with MTO(mineral terpentine oil). The balls are then further washed by MTO moving

with ultrasonic wave produced by generators situated below the machine.

11) VISUAL INSPECTION: - The balls are now inspected visually in the ball

inspection area. Inspection take places through instruments are: - a) Microscope- surfaces of the balls are inspected.

b) Militrone gauge- checks the size of the balls.

c) Vibration tester- Capacity to withstand with vibrations and noise is

tested

in terms of decible.

d) Tele roundness machine- checks the roundness and surface finishing.

12) ANTI RUST OILING, COUNTING, PACKING OPERATION: -

The balls are oiled to prevent rusting then counted and packed.


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TAPER DIVISION

Parts:-cone,cup,roller&retainer.

Working section-

Roller section

Heat treatment

Grinding section

Retainer section

Assembly section


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AXLE BOX DIVISION

The axle box division mainly consists of the three sections

as: -

1. AXLE BOX HARDENING

2. RACE GRINDING

3. ASSEMBLY


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MACHINE BUILDING

The following m/c are present in this department :-

LATHE M/C, MILLING M/C

SLOTTER M/C, SHAPER M/C

BEND SAW, POWER SAW

TOOL GRINDER, BORE GRINDER

DRILLING M/C, CNC MILLING

ANGULAR SURFACE GRINDER, BEARING LIFE

TESTING M/C


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LDB (LARGE DIAMETER BEARING

DIVISION)

Stages of making LDB-

raw material from the steel foundry is taken , passed overdifferent rotary furnaces at different temp , then it is sentto the grinding section

Grinding:-BORE GRINDING M/C (SL 400*500?)

OD GRINDING M/C BUA 63(T)

COPPER BORING

RUSSIAN BORING

ROLL CLEARANCE

BERTHIEZ GRINDING M/C ASSEMBLING


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TOOL ROOM

The tool room of NEI consists of following machine

LATHES

MILLING MACHINE ,SHAPER MACHINE

UNIVERSAL GRINDING MACHINE

HEALD MACHINE , SLOTTER MACHINE

SURFACE GRINDING MACHINE

JIG BORING MACHINE

SPARK EROSION MACHINE

CNC LATHE MACHINE


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LABORATORY/METALLURGY SECTION

HONSFIELD TENSOMETER

UTM-40 TESTIMNG M/C

CLEMEX IMAGE ANALYSIS SYSTEM

CLEMEX CAT (MICRO HARDNESS TESTER)

ROCKWELL HARDNESS TESTER M/C


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RESEARCH AND DEVLOPMENT

Technical collaboration agreement with NTN

Corporation, Japan and Brenco. Incorporated

of USA.

design is done on CAD


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MAINTENANCES

Electrical maintenances-winding, wiring etc.

PREVENTIVE MAINTENANCE

RUNNING BREAKDOWN MAINTENANCE

Mechanical maintenances-used different machines like lathe,shaper,boring etc.


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INDUSTRIAL SAFETY

Preventive measures

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

Fencing of dangerous and rotating parts like revolving shafts.

Rigid construction of heave items like hoists, cranes etc.

Proper insulation of electric wire & earthlings of electric appliances.

Wearing appropriate safety shoe and other necessary items for bodyproducts.

Maintenance clearness of shop floor.

Avoiding fire hazard.


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Thanks

practical training report on ball bearing

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