1
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
2
CONTENTS
Page
1
•
SCOPE OF THE REPORT
•
METHODOLOGY
PRESENT STATUS OF TECHNOLOGY
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
1 - 22
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.
4
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
Mr. K. N. Kansara
Nadella - France
KANSARA ENGINEERS PVT.
NSK- Japan
LTD. (A Unit of Sewaram Kansara NTN - Japan
Group), E-36,M.I.A. Phase II,
Basni, Jodhpur - 342005 (INDIA)
Phone : +91-291-2745500,
2745501, Fax : +91-2912435187, 2745502
Email :
[email protected]
Web : www.skbearings.com
Mr. Rohit Saboo, President &
( a. ) BRENCO
CEO
Incorporated , U.S.A.
Email : [email protected]
Since 1982-For
Mr. Devendra Mishra Vice
Cartridge Tapered
President Manufacturing
Roller Bearings for
[email protected] Railway wagons and
NAIONAL ENGINEERING
Locomotives.
INDUSTRIES Ltd.
www.brencoqbs.com
Khatipura Road,Jaipur -302 006
(b) NTN Corporation ,
Phone : 2223221
Japan
Fax : 0141-2221926.2222259
Since 1985-For Ball
E-mail : [email protected] 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 remanufacturing,
retrofitting and
overhauling of grinding
and super finishing
machines for bearing
races.
http://www7.ocn.ne.jp/~
izk.co
Products
Rollers
(CYLINDERICAL,
SPHERICAL,
NEEDLE, TAPER)
Ball Bearing ,
Steel Ball,
Tapered Roller
Bearing, Railway
Bearing (Roller
Bearing in Axle
Box, Spherical
Roller Bearing,
Cartridge Tapered
Roller Bearing),
Large Diameter
Bearing
5
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]
. 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 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
Hatebur
Umformmaschinen
AG
Postfach 916
General GuisanStrasse 21
CH-4153 Reinach
Switzerland
Tel.: +41 61 716 21 11
Fax: +41 61 716 21 31
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
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
Ball Bearing Cage
production line
(Transfer Press) in
Technical Collaboration
with M/s Toho
Industrial Co. Ltd.,
Japan was set up in
2000.
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
Email:[email protected]
om.tw
URL:www.chinfong.co
m.tw
Ball Bearing
Cages, Sheet
Metal Components
and Dust Shields
Mr. Anil Agrawal , MD
Conventional Lathes,
Low cost automated
hydraulic lathes,
Auto lathes (Ace
Machines) Perma line
Bearing Race
Turning
M/s Supersonic Turners Pvt.
Ltd.
Works 1 & H.O. ,F-393(A), Road
Forged & Turned
Bearing Race
Hatebur Hotmatic
hotformers ,a fullyautomated Forging
&Hatebur
Coldmatic
coldformers
produce precision
and complex parts
formed directly
from wire.
Dust shield
(Z-shield,)
6
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
KNK Bearing
Conventional Set-Up
Suitable for Batch Type
Production
7
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
8
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 aligning ball bearings
Radial Ball Bearings
Ball and Roller Bearings
Ball Bearings
Thrust Ball Bearings
Roller Bearings
Radial " Roller Bearings
Thrust Roller Bearings
9
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 roller bearings
Single row tapered roller bearings
Double row tapered roller bearings
Spherical roller bearings
Cylindrical roller 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,
10
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
11
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
12
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
13
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
Market share of Big Bearing manufacturer companies in India
30.00
26.00
Market share in %
25.00
21.40
20.00
15.70
15.00
8.45
10.00
7.04
3.16
5.00
1.19 0.96 0.93 0.77
0.73 0.63 0.55
Bimtel bearings
Asian
2.90 2.60
1.60 1.50
1.34 1.30 1.25
0.00
Imports
Others
Texspin
SBL
Mipco Seamless Rings
Austin
ARB Bearings
Kirloskar Oil Engines
Sujana Industries
ABC Bearings Ltd.
Harsha
HMT Bearings
Tata bearings
NRB Bearings
Timken India
National Engineering industries
FAG Bearings India
SKF Bearings India
Name of Companies
14
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
15
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)
5.
20mm to 75 mm
Axle Box Bearing Races for Railway
passenger coaches and wagon
100mm to 200mm
16
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
• Carbon
• Chromium
% Composition
0.95 to 1.1
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
17
The plant and machinery in Different Category of Units are as
follows
Activity
Plant & Machines presently in use
Manufacturing Bearing
Races By Bar Route &
Seamless tube Method
(Drilling and trepanning
Operation are not
required )
Bar turning Machine
Centre Lathe
Lathe Addahs
Low cost automated hydraulic lathes
Tools cutter Grinder
CNC Machine for
Races Turning/Machining.
Auto lathes (Ace Machines) Perma
line
Forging Bearing Race
Shearing
Heating
Forging,Trimming
Rolling
Tempering
Die Making
Inspection
Gas cutting and hacksaw machines
and modern shearing machines for
raw material cutting
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
Screw press having capacity : 350
tone
Hydraulic ring rolling machine
capacity to roll up to 300 mm.
diameter
With the help of oil fired furnace /
electrically heated furnace forgings is
treated with sperodise anealing to
remove residual stresses
Special die sinking machine ,EDM
Hardness testing machine
equipments
Laboratory for testing of final
products of forging with chemical
composition and micro examination
Heat Treatment : Hardening & Tempering
Approx.
Cost ( Rs. In
Lakh )
12-15
8-10
0.50
8-10
12
15-20
6-8x4
10-13
15-2-0
12-15
20-25
15-20
10-15
7-10
22-25
25-30
6-10
6-10
0.50
2-5
18
1 - Heating 850 °C
Natural salt bath Pit type furnace
(Austenitizing) to alter the with pre-heating Furnace
structure of the material
2 - Quenching 40 °C
Rapid cooling to fix the
structure of the material
and thus increase
hardness.
3 - Tempering 170 °C"
Reheating" to reduce the
effects of thermal shock
(quenching) inside the
structure and stabilise the
material.
Washing Races
Blackening of Races
Mar quenching processes
Electric Furnace
Tumbling Barrel
Quenching oil Tank with Cooling
System
Grinding Followed by
The Machinery being used for
Honing of Outer & Inner Grinding & honing by the
Races
SSI Bearing Manufacturing Units are
Imported & Second Hand
Machinery.
Face Grinding
Face Grinder ( Rowland ,USA)-1No
Centreless Ginding
Centreless Grinder ( WMW, USA) 1No
Centreless Grinder ( ,Lidkoping USA)
1-No
Bore Grinding
Bore Grinder (Jung Germany)1 -No
Bore Grinder (UVA, USA)1 -No
Outer Track Grinding
Outer Track Grinder ( Heald, USA)-1
N0
Outer Track Grinder
( Bryant,USA,1No
Inner Track Grinding
Inner track Grinder( Norton) 1 -No
Inner track Grinder( Newall,USA) 1 No
Duplex Machine
Honing of Track
Honing Machine 5Nos
Washing of Races
Washing Machine (Self Fabricated)
Lapping Machine
Lapping M/c
Cages & Shields
Manufacturing Unit
Blanking, Bending,
Drawing, Piercing,
Cleaning, Inspection
Pinning ( Pinning in
cages)
0.65-2
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
Pinning Press (Electro Magnetic
Process ,20 Ton -1 No
3-4
0.1-.0.15
0.1-0.12
8-10
5.3 -8
3.45- 6
0.5-3
3.48-5
5.22-7
1- 3
1.5-2
1.40-4
1-1.4
12-15
15-20
0.1-0.2
19
Riveting Press ,Hydraulic 20 ton,1Riveting cages in
No1
Bearing
Ball Manufacturing Unit
0.2-0.3
Cold Heading
Flashing
Heat Treatment
Cold Header Machine
Ball Flash removing M/c.
Hardening followed by Tempering on
Rotary type furnace
Tumbler
Ball Grading M/c.
Lapping M/c.
Abrasive Lapping M/c.
with the help of H.S. Diesel oil and
Chromium Oxide
Caustic Soda Washing
Inspection
Grading
Greasing
Packing
10-12
4-6
20-25
Marking Machine and
Comparator
3-4
Tumbling
Ball Grading
Rough Lapping
Abrasive Lapping
Oil Lapping
2-3
3-5
4-6
2-3
3-6
Assembly of Outer &
Inner Races with Balls /
Roller & Cage
duly suited and locked by
power press
Cleaning, Checking & Final Inspection
Measuring & Inspection
Testing
Load ,RPM, Noise,
Temperature etc
Checking For final
inspection
Packing
Work Shop M/c Tools
Tools and Gauge, Comparators, Dial 7-10
Gauges, Demagnetisers, Micrometer,
Slip gauge, Surface Plate,Telescope
Gauge, Cylindrical Gauges etc
Laboratory Equipment
2-3
Load ,RPM, Noise, Temperature etc
1-2
Checking For final inspection Set-up
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
Electric Arc Welding M/c
Fitter Bench & Measuring
Instruments, Gauges, Fixtures etc.
0.1
0.5
8-10
20
Material Handling
Electric
Air Pipe line
Centralised Cooling
Tank with filtration
System
Chain Pulley & Hoist
D.G.Set 20 KVA
Compressor
Centralised Cooling Tank with
filtration System ( Superior )
0.5-.7
3-4
1-1.2
0.6-0.8
21
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:-
22
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.
23
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
Manufacturing Bearing
Races By Bar Route &
Seamless tube Method
(Drilling and trepanning
Operation are not
required )
Bar turning Machine
. Installation of Auto
Turning Lines for Small
DGBB from Tubes Production
capcity
120,000 per day,
Centre Lathe
Lathe Addahs
Low cost automated
hydraulic lathes
Tools cutter Grinder
CNC Machine for
Races Turning
/Machining.
Investment Range
Auto lathes (Ace
Machines) Perma line
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:
•
•
•
•
•
•
•
Investment Range
With the help of oil fired
furnace / electrically
heated furnace forgings
is treated with sperodise
anealing to remove
residual stresses
Investment Range :
Rs. 200-250 Lakh
Heat Treatment :
Hardening & Tempering
1 - Heating 850 °C
Natural salt bath Pit
(Austenitizing) to alter the type furnace with prestructure of the material.
heating Furnace
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.
Investment Range :
Rs. 1400-1700 Lakh
Temperature Controlled
Energy Efficient Heating
Funace
• Liquid carburising
processes
• Gas carburising
processes
• Continue
hardening
processes
36
2 - Quenching 40 °C
Mar quenching
Rapid cooling to fix the
processes
structure of the material
and thus increase
hardness.
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
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.
Investment Range
Cages & Shields
Manufacturing Unit:
Blanking, Bending,
Drawing, Piercing,
Cleaning, Inspection
Investment Range
Ball
Manufacturing
Unit
The Machinery being
used for Grinding &
honing by the
SSI Bearing
Manufacturing Units are
Imported & Second Hand
Machinery.
Rs.20-30 Lakh
Automatic Lines,
Bore Grinding Machine
Track Grinding Machine
(Internal Grinding
Machine)
Center less Grinder
(External Grinding
Machine )
Honing Machine
100-200 Lakh
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
800-1000 Lakh
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.
50—100 Lakh
100-200 Lakh
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
Inspection
Grading
Automatic Lines M/S
Kansara Engineers Pvt.
Ltd. (A Unit of Sewaram
Kansara Group), E36,M.I.A. Phase II, Basni,
Jodhpur - 342005
(INDIA) has adopted
automatic line and have
good market share in
SME manufacturers in
India
Grading Machine
Greasing
Packing
Assembly of Outer &
Inner Races with Balls /
Roller & Cage
duly suited and locked by
power press
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
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.
•
Testing
Load ,RPM, Noise,
Temperature etc
Checking For final
inspection
Nominal Laboratory
Equipment
Load ,RPM, Noise,
Temperature etc
Checking For final
inspection Set-up
Packing
Sleeve packaging
machine/Shrink Packing
Packing
Sleeve packaging
machine
Work Shop M/c Tools
Surface Grinder/Duplex
Grinder
Bench Drilling machine
Pedestal Grinder
Tool post Grinder
Electric Arc Welding M/c
Fitter Bench & Measuring
Instruments, Gauges,
Fixtures etc.
Calibration Testing
equipment
AUTO DOUBLE SIDE
VIBRATION & NOISE
INSPECTION MACHINE, AUTO
DOUBLE SIDE SENSITIVITY
INSPECTION MACHINE, AUTO
RADIAL INTERNAL
CLEARANCE & SENSITIVITY
INSPECTION MACHINE ,
CNC M/ C Tools
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
• 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- 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
Value per annum
:
10533.6 MT ( Two Shift )
:
Rs, 79,10,73,360/-
9.0 UTILITY REQUIREMENTS
:
1500 KW
Hot Forming Plant
Electrical:
- Power supply
(start and production)
Compressed air:
- Pressure
- Consumption
(non compressed state)
Cooling water:
- Pressure
- Max. flow rate
(depending on part)
10
120 kVA
5,5-10 bar
3 Nm3/h
4 bar
30 m3/h
IMPLEMENTATION SCHEDULE :
S.No.
Activities
Period in
Months
1
Preparation of project report and selection of site
1
2
3
4
6
7
8
Registration
Application for Electricity Connection
Availability of finance& Procurement of machinery
Electrification & installation
Recruitment of staff
Trial run
Total
1
1
6
2
1
1
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
2 Noise abatement cabin.
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.
CNC Lathe 200 mm
1
Cylindrical Grinder
1
Internal Grinder
1
Vertical milling Machine
1
Spare Parts
1
Changeover Aids
1
Other Conventional M/c Tools like
1
drill, weld bench vice , portable
grinder etc
Accessories
1
Total
vat, Taxes, Installation & Electrification @ 10%
TOTAL
Office Equipment, Dies & Tools
LS
Total Investment In Plant &
machinery
Pre operation Charges i.e. for Getting
Electricity Connection etc.
4
5
6
7
8
9
10
9
1
133879000
133879000
1
1
7964550
653,400
7964550
2000000
400000
300000
450000
5440050
2393820
200000
2000000
400000
300000
450000
5440050
2393820
200000
10032660
10032660
163786480
16378648
180165128
7614585
187779713
7614585
653400
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
4
5
Skilled Worker
Semi skilled worker/ Helper
Peon / Watchman
8
4
3
8000
4500
3000
64000
18000
9000
Total
18
Additional Perquisites @ 15%
Total Expenditure in Salary & Wages
123400
18510
141910
52
ii
S.No.
1
2
3
Raw Material
Particular (Indigenous)
Bearing steel Sheets
Die Blocks & Consumables
others
Qty
924
200000
Rate
60000
1
L.S.
TOTAL
Value (Rs.)
55440000
200000
10000
55650000
iii
1
2
Utilities
Power ( 8000 unit per day)
Water & Compressed Air
iv
Other Contingent Expenses
1
2
3
4
5
6
7
8
9
Postage and stationary
Office Consumable stores
Transport charges
Telephone charges
Publicity Expenses
Traveling expenses
Repair & Maint.
Miscellaneous expenses
Insurance
TOTAL
3500
3500
10000
5500
5000
1500
10000
2500
15648.30942
57148.30942
Total Recurring Expenditure :
Description
Personnel
Raw material
Utilities
Other Contingent Expenses
TOTAL
Total working capital for 1.5months :
Cost
141910
55650000
1105000
57148.30942
56954058.31
85431088
v
S.No.
1
2
3
4
vi
e
i
ii
1100000
LS
TOTAL
Rs.
Total Capital Investment :
Fixed Capital
Working Capital for 1.5 Months
Total Capital Investment :
Total Capital Investment
Value (Rs.)
1100000
5000
1105000
204035307.3
85431088
289466395.3
Say
289.8 Cr
Finance Detail
% Contribution
i
Self Contribution
25
72366599
iii
Banks Contribution
75
217099796.3
FINANCIAL ANALYSIS
11
1
i
ii
iii
iv
v
Cost of Production (Per year) :
Total recurring cost :
Depreciation of machinery and equipment @ 10%
Interest on total Capital investment @ 12%
Depreciation of tools and office equipment / furniture @ 20%
Depreciation of Building @ 5%
Total :
683448699.7
18016512.8
34735968
1522917
625000
738349097.5
53
2
Total Sales (Per annum)
Products
Bearing Races
Sale of Scrap (5%)
3
4
5
6
Qty.
10533.6
527
TOTAL
Net Profit (Per yr.) (Before tax)
Total turnover per yr. -cost of production per yr.
(in Rs.) =
791073360
Net profit ratio :
Net profit × 100
Turn Over
Rate of return :
Net profit × 100
Total Investment
=
=
Rate
74000
Value (Rs.)
779486400
22000
11586960
791073360
:
Rs.
738349097.5
52724262.49
791073360
x100 =
7%
52724262.49
289466395.3
x100 =
18%
BREAK-EVEN POINT;
FIXED COST
1 40% salary & wages
2 Depreciation on machinery &
Equipments @ 10%
3 Depreciation of tools and office
equipment @ 15%
Depreciation of Building @ 5%
4
5 Interest on capital investment @ 12%
6 40% of other contingent expenses
7 Insurance
TOTAL
Net Profit (Per yr.) (Before tax)
BEP :
Fixed Cost × 100
=
Fixed Cost + Profit
12
52724262.49
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
681168
18016512.8
1522917
625000
34735968
199200
187779.713
55968545.51
52724262.49
51%
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 Sweden
SKF India
FAG Bearing India
NEI
FAG, Germany
NTN
NRB
Nadella, France
ABC Bearing Ltd.
NSK Japan
TIMKEN India
TIMKEN USA
Bimetal Bearing Ltd
Clevite Corporation USA
Kansara Engineering Pvt. Ltd.,
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.
For re-manufacturing, retrofitting
and overhauling of grinding and
super finishing machines for
bearing races.
Izumi Kinzoku Kogyo Co. Ltd., Japan
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, 9393524Toyama
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
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
Zhucheng Shengyang Machinery Co., Ltd
Sales :+86-536-6510558
Fax：+86-536-6519018
Purchasing：+86-536-6330266
Production：+86-536-6511668
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 )
Transfer Presses
: M/S CHANDRA INDUSTRIES ,
Jaipur , Installed Transfer
Presses for manufacturing Dust
shield (Z-shield,) .
Automatic Lines
(NEI has placed order for
Automatic lines from
R & S Machinery Equipment Ltd. )
Ring Rolling Machine
Vertical Ring Rolling Machine &f
Radial Ring Rolling Machine
Forging Manipulator
Charging-discharging Machine,
Hydraulic press machine
Finance：+86-536-6516178
Product
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]
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
Riveting machine, eyeleting
machine, snap fastening
machine, cutting machine, gluing
machine, press, eyelets, rivets,
aluminum tube forming machine
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
Stamping Presses
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]
Machine Tools Division, Beavar Road, Ajmer 305 003
Grinding M/C, & Machine Tools
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
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
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]
• Hardening & Tempering
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 Delhi110 020, INDIA
TEL: (91) 11-26372090 FAX: (91) 11-26372636
http://www.mitutoyo.co.jp
WMW Machinery Company using:
Profile projecter, Roundness Tester,
& other Measuring Instruments
Tooll Room Precision Mmachines
with latest grinding technology.
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]
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
Meccanica Nova S.p.A.
internationally into four independent
sectors:
Envirotec
(Environmental
Technology)
Protec (Engineered
Felts)
Feltec (Woolfelt)
Profiles
(Thermoplastic
Materials)
Internal and external grinding
systems.
Via Roma, 54/A
40069 - Zola Predosa - Bologna - Italy
Tel. +39 0512980211
Fax +39 0512980293
[email protected]
MARPOSS – Italy
MARPOSS ITALIA S.p.A.
Inprocess gagues of for better size
control.
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
THIELINHAUS- German
Supfina-Germany ,.
wuper finishing machines(for
improving the surface finish of
raceways )
Super finishing machines for
super finishing rollers & along
with cambered profile - a unique
61
Kudale
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
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
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]
feature with supfina machines
Dial Calibrator
SLC-100G
Machines for Ring Turning
CNC Turing & Milling
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 +91-1812296786
[email protected]
http://www.smithsongrinders.com
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]
Bearing Race Grinding Machine
Forming Technologies (I) Pvt. Ltd.
107, Supreme Icon, Baner Road,
Pune -(Maharashtra) 411007 India
Phone(s) : 20 25663201
www.forming.com/
Zhucheng Shengyang Machinery Co., Ltd
Workshop machine
Sheet Metal Forming Software
and Training solution
D51A, D51B, D52 and D53K
63
Sales：+86-536-6510558
Fax：+86-536-6519018
Purchasing：+86-536-6330266
series of Ring Rolling Machine
which include more than 40
specifications. D51A & D51B
series of vertical type Ring Rolling
Production：+86-536-6511668
Finance：+86-536-6516178
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
IS 25
1979
Specification for antifriction bearing alloys
IS 719
1990
IS 1409
1959
4
IS 2398
1967
Identification Code for Rolling Bearings
5
IS 2399
1988
Rolling bearings - Vocabulary
IS 2513
1963
IS 2720 : Part
31
1990
IS 2849
1983
IS 2898
1976
IS 3090
1965
IS 3590
1966
IS 3630
1992
13 IS 3697
1966
Boundary dimensions for taper roller bearings
14 IS 3823
1988
Rolling bearings - Static load ratings
1
2
3
6
7
8
9
10
11
12
15
16
17
18
IS 3824
2002
IS 3824 : Part 1
1983
IS 3824 : Part 2
1983
IS 3824 : Part 3
1983
Specification for antifriction bearing grease
(superseding IS : 1276 : 1958)
Methods of chemical analysis of antifriction bearing
alloys
Boundary dimensions for rolling bearings for general
engineering purposes
Methods of test for soils: Part 31 Field determination of
California Bearing Ratio
Specification for non-load bearing gypsum partition
blocks (solid and hollow types)
Specification for Steel Balls for Rolling Bearings
Code of practice for installation and maintenance of
rolling bearings
Specification for load bearing lightweight concrete
blocks
Construction of Non-load Bearing Gypsum Block
Partitions - Code of Practice
Rolling Bearings - Dynamic Load Ratings and Rating
Life
Methods of evaluating dynamic load ratings of rolling
bearings Part 1 Radial ball bearings
Methods of evaluating dynamic load ratings of rolling
bearings Part 2 Radial roller bearings
Methods of evaluating dynamic load ratings of rolling
bearings Part 3 Thrust ball bearings
65
19
Methods of evaluating dynamic load ratings of rolling
bearings Part 4 Thrust roller bearings
Specification for Porous Metal Powder Oil-Impregnated
Bearings
IS 3824 : Part 4
1983
IS 3980
1982
21 IS 4025
2006
Rolling bearings -Gauging practice
22 IS 4215
1983
Specification for Ring Type Needle Bearings
20
23
Cold-rolled Carbon Steel Strips for Ball and Roller
Bearing Cages/Retainers - Specification
Carbon-chromium Steel for the Manufacture of Balls,
Rollers and Bearing Races - Specification
Rolling Bearings -- Plummer Blocks Housings -Boundary Dimensions
Specification for Thin-walled Half Bearing - Part I :
Plain Bearing
Specification for Thin-walled Half Bearings - Part II :
Flanged Bearing
Specification for Low Carbon Steel Wire for Rivets for
Use in Bearing Industry
IS 4397
1999
IS 4398
1994
IS 4773
2002
IS 4774 : Part 1
1982
IS 4774 : Part 2
1982
IS 4882
1979
29 IS 5489
1975
Carburizing steels for use in bearing industry
IS 5669
1987
General plan of boundary dimensions for radial rolling
bearings
31 IS 5692
1988
Tolerances for radial rolling bearings
IS 5932
1970
Boundary Dimensions for Thrust Ball Bearings with
Flat Seats
33 IS 5933
2002
Rolling Bearings - Thrust Bearings - Tolerances
24
25
26
27
28
30
32
34
Rolling Bearings - Chamfer Dimensions - Maximum
Values - Specification
Radial internal clearances in unloaded radial rolling
bearings
Code of practice for determination of bearing capacity
of shallow foundations
IS 5934
1999
IS 5935
1992
IS 6403
1981
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
35
36
42
IS 6458
1972
IS/ISO 6547
1981
43
44 IS 6548
1992
Specification for Double Row Cylindrical Roller
Bearings
Hydraulic Fluid Power - Cylinders - Piston Seal
Housings Incorporating Bearing Rings - Dimensions
and Tolerances
Rolling bearings - Instrument precision bearings
66
45
Specification for Locknuts, Narrow Series and
Lockwashers with Straight Inner Tab for Rolling
Bearings
Specification for Aluminium Alloy Castings and Strips
for Bearings
IS 6731
1977
IS 6751
1972
47 IS 6754
1972
Specification for Aluminium Alloy Ingots for Bearings
48 IS 6774
2004
Classification of essential oil-bearing aromatic plants
1994
Anaesthetic and respiratory equipment - Conical
connectors Part 2: Screw threaded weight bearing
connectors
1988
Tolerances for tapered roller bearings
46
49
IS 7409 : Part 2
50 IS 7460
51
IS 7461 : Part 1
1993
IS 7461 : Part 2
1992
IS 7461 : Part 3
1992
IS 8255
1976
IS 8475
1977
56 IS 8619
1977
52
53
54
55
57
IS 8656
1977
IS 8657
1977
59 IS 9193
1988
58
60
61
62
IS 9203 : Part 4
1979
IS 9247
1979
IS 9619
1980
IS 9764 : Part 1
1992
IS 9764 : Part 2
1994
IS 10203
1982
IS 10225
1982
63
64
65
66
General plan of boundary dimensions for tapered roller
bearings Part 1 Single row bearings
General plan of boundary dimensions for tapered roller
bearings Part 2 Double row bearings
General plan of boundary dimensions for tapered roller
bearings Part 3 Flanged cups
Specification for Flexible Load Bearing Polyurethane
Foam Components for Vehicles
Lead based antifriction bearing alloy for heavy duty
applications
Specification for Bearing Collars for Milling Arbors
Specification for Tapered Adapter Sleeves for Rolling
Bearings
Specification for Tapered Withdrawal Sleeves for
Rolling Bearings
Specification for Bearing Pullers
Specification for Friction Rollers for Mine Haulage
Tracks - Part IV : Rollers with Non-metallic Rope
Bearing Surfaces
Tolerances for radial rolling bearings with shields or
seals
Identification code for shell type needle bearings
(including sealed bearings)
Plain bearings - Washers for plain bearings and
wrapped bushes - Specification Part 1 Ring type thrust
washers
Plain bearings - Washers for plain bearings and
wrapped bushes -Specification Part 2 Half thrust
washers
Technical supply conditions for thin walled plain
bearings
Specification for Bearing Spools for Tractor-operated
Disc Harrows
67
67 IS 10260 : Part
1
68 IS 10260 : Part
2
69 IS 10260 : Part
3
70 IS 10285
1982
1982
1982
Terms, definitions and classification of plain bearings
Part I Construction
Terms, definitions and classification of plain bearings
Part II Friction and wear
Terms, definitions and classification of plain bearings
Part III Lubrication
1982
Guide for tannin bearing plants
IS 10385
1982
Method for determination of radial crushing strength of
sintered metal powder bearings
72 IS 10647
1985
Specification for Wheel Bearing Grease
IS 10648
1983
Code for identification of ring type needle bearings
(including sealed bearings)
74 IS 11027
1984
Definitions of tolerances for rolling bearings
71
73
75
IS 11145
2002
IS 11159 : Part
3
1989
IS 11284
1985
IS 11430
1985
IS 11904
1999
80 IS 12102
1987
76
77
78
79
81
82
IS 12211
1987
IS 12375 : Part
2
1993
IS 12635
2000
IS 12778
2004
IS 12791
1989
IS 13405
1999
IS 13406
1992
IS 13544
1992
83
84
85
86
87
88
Plain Bearings -- Thin Walled Half-Bearings -Checking of Peripheral Length
General classification of lubricants, industrial oils and
related products (Part 3) Family F (Spindle bearings,
bearings and associated clutches)
Rotary tube test for iron bearing materials for the
manufacture of sponge iron/direct reduced iron(DRI )
Code of practice for the packaging of ball and roller
bearings
Rolling bearings with locating Radial bearings snap
ring - Dimensions and tolerances – Specification
Specification for Tapered Roller Bearings
Micrographic method for assessing the distribution of
carbides in tool steel and bearing steels using
photomicrographs
Implants for Surgery - Partial and Total Hip Joint
Prostheses - Part 2 : Bearing Surfaces Made of
Metallic and Plastic Materials
Water Well Drilling and Blast Hole Drilling - Rock Roller
Bit with Non-sealed Ball and Roller Bearing
Arrangement - Technical Supply Conditions
Hot Rolled Parallel Flange Steel Sections for Beams,
Columns and Bearing Piles - Dimensions and Section
Properties
High carbon chromium (bearing) steel tubes for the
manufacture of bearing races
Rolling Bearings - Cylindrical Roller Bearings,
Separate Thrust Collars - Boundary Dimensions Specification
Radial ball bearings with flanged outer ring - Flange
dimensions
Trailers - Mounting of ball bearing turn table Dimensions
68
89 IS 13637 : Part
1
90 IS 13637 : Part
2
91
IS 13962
1993
1999
1994
92
93
IS 14478
1997
IS 14691
1999
94 IS 14802 : Part
1
95 IS 14802 : Part
2
96 IS 14803 : Part
1
97
IS 14803 : Part
2
98
99
2000
2000
2000
2000
IS 15620
2005
IS 15624
2005
IS 15625
2005
100
Technical Drawings - Rolling Bearings - Part 1 :
General Simplified Representation
Technical Drawings - Rolling Bearings - Part 2 :
Detailed Simplified Representation
Rolling bearings - Metric tapered roller bearings Designation system
Plain Bearings - Thick-walled dushes, Plain and Flange
Type, Full Round (Without Any Joint or Slit) Specification
Rolling Bearings - Taper Rolling Bearings - Tapered
Roller - Metric Series - Specification
Plain Bearings - Hardness Testing of Bearing Metals Part 1 : Compound Materials
Plain Bearings - Hardness Testing of Bearing Metals Part 2 : Solid Materials
Plain Bearings - Part 1 : Fits
Plain Bearings - Part 2 : Tolerances on Form and
Position and Surface Roughness for Shafts, Flanges
and Thrust Collars
Plain bearings - multilayer materials for thin-walled
plain bearings
Thermoplastic polymers for plain bearings classification and designation
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.
max.
0.90
1.03
0.75
1.00
0.15
0.35
0.70
0.90
—
0.10
ASTM-A295 (K19526) min.
max.
0.89
1.01
0.50
0.80
0.15
0.35
0.40
0.60
—
0.10
ASTM-A295 (1570)
min.
max.
0.65
0.75
0.80
1.10
0.15
0.35
—
—
—
0.10
ASTM-A295 (1560)
min.
max.
0.56
0.64
0.75
1.00
0.15
0.35
0.70
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.
max.
0.85
1.00
1.40
1.70
0.50
0.80
1.40
1.80
—
0.10
ASTM-A485 grade 3
min.
max.
0.95
1.10
0.65
0.90
0.15
0.35
1.10
1.50
0.20
0.30
ASTM-A485 grade 4 min.
max.
0.95
1.10
1.05
1.35
0.15
0.35
1.10
1.50
0.45
0.60
DIN 100 CrMo6
0.92
0.25
0.25
1.65
0.30
1.02
0.40
0.40
1.95
0.40
min.
ISO Grade 4, 683/XVII max.
70