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INDUSTRIAL TRAINING
[Document subtitle]
 VENDOR(RAW
MATERIAL)

VENDOR
RECEIVING FAIL
DEPARTMENT

PA
SS

HEAT
TREATMENT

FACE AND OUTER

DIAMETER
GRINDING
RECEIVING UNIT

FIRST THE LOT OF MATERIAL IS RECEIVED FROM THE VENDOR IS STORED INSIDE
GRINDING
THE STORAGE UNIT AND THEN A UNIQUE GRN NUMBER IS GENERATED BY
OPERATOR AND SAMPLE FROM THE LOT IS TAKEN. THE NUMBER OF SAMPLE IS
BASED ON NUMBER OF THE RAW MATERIAL FROM VENDOR.

SAMPLE PLAN:-

RAW MATERIAL SAMPLE SIZE

ASSEMBLY
2-20 100%
21-280 20
281-1200 47
1201-3200 53
3201-10000 68
10001-35000 STORAGE
77
35000-150000 96
150001-500000 119
>500001 143

AFTER SAMPLE (BOTH INNER AND OUTTER) IS OBTAINED THEN THE SAMPLE IS
FIRST CHECKED USING COMPARATORS FOR THE DIMENSSIONS OF OUTTER
DIAMETER , TRACK DIAMETER , WIDTH , AND BORE DIAMETER WITH THE
MASTER PIECE . IF SAMPLE PASS THIS PRIMARY INSPECTION THEN IT IS SENT FOR
FURTHER INSPECTION TO CONTRACER MACHINE WHERE IT IS INSPECTED WITH
HIGH DEGREE OF ACCURACY. USING CONTRACER MACHINE THE SAMPLE IS
FURTHER CHECKED FOR GROOVE SIZE, GROOVE DIAMETER , CHAMFER , AND
ANGLES INCLUDED . THEY ARE COMPARED FROM THE PRESTORED DATA FROM
R&D SECTION IF THE VALUE LIES WITHIN THE GIVEN RANGE OF THEN THE
SAMPLE HAS PASS THE INSPECTION OTHERWISE IT IS REJECTED AND THEN SENT
BACK TO VENDOR. THE RAW MATERIAL WHICH PASS THE INSPECTION ARE NOW
SENT FOR HEAT TREATMENT INORDER TO INCREASE ITS HARDNESS.

HEAT TREATMENT

OVALITY AND CRACKHARDENIN

PRE HARDNESS QUENCHI HARDNES TEMPERING
AIR WASHING
CHECKING
WASHING G FURNACE
TESTING NG
COOLING UNIT S FURNACE
AND DRYING
TESTING
STEP 1: PRE WASHING

IN THIS PROCESS WATER WITH SULPHA CLEAN IS HEATED UPTO 60 C FOR 8 10

MINUTES .

THIS IS DONE IN ORDER TO REMOVE OIL , DIRT , DUST etc FROM THE JOB.

STEP2: HARDENING FURNACE

THIS INVOLVES HEATING OF JOB AT APPROPRIATE TEMPRATURE (850 C) FOR

SUITABLE TIME. IT IS DIVIDED 4 ZONES EACH ZONE CONSIST OF TUNGSTEN
CHROMIUM HEATER WHERE EACH JOB IS HEATED 10 -15 MINUTES IN EACH
ZONE.

IN ORDER TO AVOID OXIDATION AN INERT ATMOSPHERE IS MAINTAINED INSIDE

IT.
STEP3: QUENCHING OIL TANK

THE JOB FROM THE FURNANCE IS DIPPED IN OIL WHICH IS MAINTAINED AT

CONSTANT TEMPRATURE (150 C).

AGITATOR IS USED INSIDE TANK TO MAINTAIN UNIFORM TEMPRATURE OF OIL.

HARDNESS OF JOB IS CHECKED BY TAKING FEW SAMPLE THE HARDNESS

SHOULD BE IN THE RANGE OF 62.5 65.5

STEP4: WASHING AND DRYING UNIT

IN THIS PROCESS AFTER QUENCHING THE JOB IS HEATED IN A MIXTURE OF

WATER WITH SULPHA CLEAN UPTO (22.57.5 C ) FOR 8 10 MINUTES .

THIS IS DONE IN ORDER TO REMOVE OIL , DIRT , DUST etc. FROM THE JOB.

AFTER WASHING IS DONE THE JOB IS DRIED USING AIR SO THAT NO TRACE OF
WATER IS LEFT IN THE JOB.

STEP5: TEMPERING FURNANCE

TEMPERING IS DONE IN ORDER TO REDUCE THE STRESS PRODUCED AFTER

HARDENING.

JOB IS HEATED AT 170 C FOR 110 MINUTES.

AFTER THAT JOB IS ALLOWED TO COOL.

HARDNESS OF JOB IS CHECKED BY TAKING FEW SAMPLE THE HARDNESS

SHOULD BE IN THE RANGE OF 60.5 63.5

STEP 6: OVALITY AND CRACK CHECKING

AFTER TEMPERING IS DONE ALL OF THE LOT IS NOW CHECKED FOR CRACK AND
OVALITY FOR THE MATERIAL TO BE ACCEPTED THE DEFLECTION SHOULD BE OF
200 MICRONS .

AFTER THE HEAT TREATMENT BOTH (INNER AND OUTTER ) ARE SEND FOR FACE
AND OUTTER DIAMETER GRINDING.

FACE AND OUTTER DIAMETER GRINDING

FACE GRINDING

AFTER PROPER HEAT TREATMENT THE JOB IS BROUGHT FOR FACE GRINDING FOR
MACHINE LIKE NISSEI MACHINE. THE JOB IS PLACED AND IT IS CARRIED
TOWARDS THE GRINDING WHEELS FOR FACE GRINDING HERE MATERIAL
REMOVED IS ABOUT 150-200 MICRONS.

FOR THE ABOVE MACHINE THE SPEED OF THE GRINDING WHEELS IS ABOUT 900
RPM AND SPEED CAN BE REDUCED OR ADJUSTED AS PER THE REQUIRED
THICKNESS OF THE JOB IF THE THICKNESS ON BOTH THE SIDES ARE SAME THEN
THE SPEED OF THE GRINDING WHEELS ARE SAME. AFTER EVERY 3 HOUR
INTERVAL DRESSING OF THE WHEEL IS DONE.

OUTTER DIAMETER GRINDING

AFTER FACE GRINDING THE JOB IS BROUGHT FOR OUTTER DIAMETER GRINDING
TO CENTERLESS GRINDER LIKE MICRON CENTERLESS GRINDING MACHINE THE
IS PLACED ON GUIDE TO GUIDE IT THROUGH BETWEEN REGULATING WHEEL AND
GRINDING WHEEL.

SPEED OF THE GRINDING WHEEL IS 1270 rpm.

SPEED OF REGULATING WHEEL IS 60 rpm.

THE JOB IS GRINDED IN THREE STAGES :

1.ABOUT 100 MICRONS OF MATERIAL IS REMOVED.

2.ABOUT 25 MICRONS OF MATERIAL IS REMOVED .

3. AFTER REMOVAL OF 25 MICRONS FIRST IT IS COMPARED WITH THE MATER

PIECE OF REQUIRED DIMENSSION AND THEN THE FEED IS DETERMINED.

PROCESSING CONDITION:

OUTTER TOLEREANCE SUFACE TAPER JUMP

DIAMETER FINISH(MICRONS
SIZE )
52 -.002/-.011 .32 .006 .002
58 -.002/-.011 .32 .006 .002
61.836 -.002/-.011 .32 .006 .002
68 -.002/-.011 .32 .006 .002
72 +.038/+.029 .32 .006 .002

GRINDING

OUTER GRINDING:

TRACK WASHING TRACK ASSEMB

GRINDING AND TRACK HONNIN LY
UNIT CHECKING G
UNIT MACHINE

IN THIS ONLY OUTER OF BEARING IS GRINDED HERE FIRST TRACK IS GRINDED

AND THEN IT IS WASHED WITH OIL AND THEN THE WIDTH AND THE RADIUS OF
THE TRACK IS CHECKED . THEN THE HONNING PROCESS (ALSO KNOWN AS
TRACK SUPERFINISHING) IS PERFORMED .
AFTER THESE ABOVE STEPS ARE COMPLETED THE OUTER IS SEND FORWARD FOR
THE ASSEMBLY.

INNER GRINDING :

TRACK BORE DEMAGNETIZING

GRINDIN GRINDING UNIT
G UNIT UNIT

ASSEMBL TRACK WASHING AND

Y HONNING TRACK AND BORE
MACHINE CHECKING UINT

AFTER FACE AND OUTER DIAMETER GRINDING INNER OF THE BEARING IS

BROUGHT HERE. FIRST THE TRACK OF THE INNER IS GRINDED AND THEN BORE
OF THE INNER IS GRINDED.

AFTER THAT THE INNER IS PASSED THROUGH A DEMAGNETIZING UNIT WHERE

THE RESIDUAL MAGNETIZM OF THE INNER IS REMOVED .

THEN IT IS SENT FOR WASHING AND THEN SENT FOR INSPECTION OF TACK
RADIUS AND WIDTH AND BORE DIAMETER .

THEN IT IS SENT FOR TRACK HONNING.

AFTER ALL THESE PROCESS THE MATERIAL IS SENT FOR ASSEMBLY TO THE
ASSEMBLY UNIT.

ASSEMBLY:

OUTER

DEMAGNETIZI MATCHING
NG , MACHINE
WASHING
INNER AND DRYING
UNIT

INSPECTI
ASSEMBLY WASHING
ON UNIT
1

INSPECTIO
DEMANETIZ NOISE MARKING
ING N UNIT 2
AND CHECKIN UNIT
WASHING G
UNIT

IN ASSEMBLY FIRST THE INNER AND THE OUTTER OF THE BEARINGS ARE
BROUGHT TOGETHER AFTER THE COMPLETION OF GRINDING PROCESS.VISUAL
HERE
PACKING OILING
FIRST THE INNER AND OUTTER ARE DEMAGNETIZED
UNIT CHECKIN
G
AND THEN THEY ARE WASHED USING OIL AND DRIED USING AIR. THEN IT IS
PASSED TO THE MATCHING UNIT WHERE THE INNER AND OUTTER ARE MATCHED
ACCORDING TO THERE SIZE AND TRACK DIAMETER . AFTER MATCHING IS DONE
NOW THESE MATCHED PIECES ARE SEND FORWARD FOR ASSEMBLY UNIT INSIDE
WHICH THE BALLS ARE INSERTED IN BETWEEN THE OUTTER AND INNER OF
APPROPRIATE SIZE AND THEN THE CAGE IS INSERTED FROM BOTH SIDE AND
THEN THEY ARE RIVETED IT IS DONE IN ORDER TO KEEP THE BALLS PROPERLY
PLACED AT A PARTICULAR DISTANCE FROM EACH OTHER IN ORDER TO MAKE A
BEARING PROPERLY FUNCTIONING.

AFTER ASSEMBLY THE BEARING IS SENT TO WASHING UNIT WHERE IT IS WASHED

USING OIL PROPERLY.

NOW IT IS PASSED TO INSPECTION UNIT1 WHERE FIRST IT IS CHECKED FOR ITS

BORE DIAMETER , THEN IT IS CHECKED FOR OUTTER DIAMETER, THEN IT IS
CHECKED FOR THE STANDARD TORQUE FOR THAT SIZE AND FINALLY THEN IS
CHECKED FOR RADIAL CLEARANCE .

THEN IT IS PASSED THROUGH DEMAGNETING AND WASHING UNIT WHERE FIRST

THE RESIDUAL MAGNETISM IS REMOVED FIRST THEN IT IS WASHED USING OIL
AND THEN IT IS SENT FOR ULTRASONIC WASHING .

NOW IT IS PASSED THROUGH NOISE CHECKING UNIT WHERE IT IS CHECKED IF

THE BEARING IS MAKING NOISE DURING ITS OPERATION.

THEN IT IS PASSED THROUGH MARKING UNIT WHERE THE SIZE , BRAND NAME
ARE MARKED ON THE BEARING. IT CAN BE DONE EITHER BY ETCHING OR LASER
MARKING SYSTEM. THEN AFTER VISUAL INPECTION THE BEARING IS SENT TO
INSPECTION UNIT 2 . WHERE IT IS CHECKED FOR GROOVE AND WEIGHT . THEN
GREESE IS FILLED INSIDE IT . THEN WEIGHT IS AGAIN CHECKED SO AS TO CHECK
THE RIGHT AMOUNT OF GREESE . AND NOW THE SEALING IS PROVIDED OVER IT.

SEALINGS USED ARE OF THREE TYPES Z, RS ,ENCODER SEAL.

IT IS BASED ON THE REQUIREMENT OF THE CUSTOMER.

THEN IT IS AGAIN PASSED FOR VISUAL INSPECTION.

THEN IT IS OILED AND THEN IT IS SENT FOR PACKING WHERE IT IS PACKED

USING VCI PLASTIC SHEET. ITS BECAUSE OF ITS ANTI RUSTING PROPERTY.