Practical Training Report

PRACTICAL TRAINING REPORT TAKEN AT

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

Prepared By Rakesh Kumar Singh B.Tech. IV Yr. (Mech. Engg.) Swami Keshvanand Institute of Technology ,jaipur

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 500 different 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.

The NEI Office Network • Head office9/1 R.N. Mukherjee road in Kolkata.

NEI PLANT AT JAIPUR • PLANT INFORMATION:situated at khatipura road from 1 km of west railway station • PLANT INFORMATION (NEWAI):establised in 1980-81. • SHIFTS: • Production goes in three shifts and one General Shift. 1st shift from 06.00 –14.30 Hours • 2nd shift from 14.30 – 23.00 Hours • 3rd shift from 23.00 – 06.00 Hours • General shift from 08.00 – 17.00 Hours

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.

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

BALL BEARING DIVISION • Four major parts-balls,inner and outer race,cage. HEADING ↓ FLASHING ↓ SOFT GRINDING ↓ HEAT TREATMENT ↓ WORK HARDENING ↓ HARD GRINDING

BALL BEARING DIVISION ↓ GRINDING

FINISHING

FINISH ↓ LAPPING ↓ SUPER

↓ VISUAL ULTRAINSPECTION SONIC ↓ WASHING ANTIRUST OILING,↓ COUNTING, PACKING

The Manufacturing Process

OPERATIONS: -

1) HEADING :- This is the foremost operation to manufacture the balls. This machine cuts the wire with the help of cutter and then the cutes piece is drawn into the spherical shape by the application of the punch &die arrangement. This process mainly consists of three main steps: a) Wire feeding b) Cutting of the wire. c) Turn into spherical shape.

• 2) FLASHING : - The balls obtained by the above operation are not perfectly spherical but it consists of collar or flash in the central periphery. So, to achieve a spherical shape some material is removed from its surface with the help of flashing 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

Ball Machine

Rill plates for ball machine

• 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.

• 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 170°C for some specified time limit. These balls are again checked for their hardness by hardness tester m/c.

• 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 100µ to 30µ. • 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 7µ. • 8) LAPPING (L1): - Here balls are passed through a paste containing (cr2o3 + 2lt honilo oil +1/2lt olic acid). Function of cr2o3 is

• 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.

TAPER DIVISION • Parts:-cone,cup,roller&retainer. • Working sectionRoller section ↓

Heat treatment ↓

Grinding section ↓

Retainer section ↓

Assembly section

AXLE BOX DIVISION •

The axle box division mainly consists of the three sections as: 1. AXLE BOX HARDENING 2. RACE GRINDING 3. ASSEMBLY

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

LDB (LARGE DIAMETER BEARING DIVISION) Stages of making LDB• raw material from the steel foundry is taken , passed over different rotary furnaces at different temp , then it is sent to 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

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

•

SPARK EROSION MACHINE

•

CNC LATHE MACHINE

JIG BORING MACHINE

LABORATORY/METALLURGY SECTION • HONSFIELD TENSOMETER • UTM-40 TESTIMNG M/C • CLEMEX IMAGE ANALYSIS SYSTEM • CLEMEX CAT (MICRO HARDNESS TESTER) • ROCKWELL HARDNESS TESTER M/C

RESEARCH AND DEVLOPMENT • Technical collaboration agreement with NTN Corporation, Japan and Brenco. Incorporated of USA.

• design is done on CAD

MAINTENANCES • Electrical maintenances-winding, wiring etc. • PREVENTIVE MAINTENANCE • RUNNING BREAKDOWN MAINTENANCE • Mechanical maintenances-used different machines like lathe ,shaper,boring etc.

INDUSTRIAL SAFETY • Preventive measures • Use of safety guards for reciprocating machine component e.g. drop hammer paper cutter etc. • Fencing of dangerous and rotating parts like revolving shafts. • Rigid construction of heave items like hoists, cranes etc. • Proper insulation of electric wire & earthlings of electric appliances. • Wearing appropriate safety shoe and other necessary items for body products. • Maintenance clearness of shop floor. • Avoiding fire hazard.

Thanks