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    A Seminar Report On: Production of Ball Bearing

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    Parveen Kumar
    This document summarizes the production process of ball bearings. It discusses the key materials used, including various steels and brasses for different components. The main production steps are described, beginning with cold heading of steel wire to form balls. Other processes include flashing, grinding, heat treatment, tumbling, and finishing. Quality inspection includes dial gauge checks for accuracy. The grinding department finishes surfaces of inner and outer races. Final processes are honing and lapping for precise fits and surface finishes before assembly. Lubrication is also discussed as important for preventing wear between metal parts.

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    A Seminar Report On: Production of Ball Bearing

    Uploaded by

    Parveen Kumar
    24 views25 pages
    This document summarizes the production process of ball bearings. It discusses the key materials used, including various steels and brasses for different components. The main production steps are described, beginning with cold heading of steel wire to form balls. Other processes include flashing, grinding, heat treatment, tumbling, and finishing. Quality inspection includes dial gauge checks for accuracy. The grinding department finishes surfaces of inner and outer races. Final processes are honing and lapping for precise fits and surface finishes before assembly. Lubrication is also discussed as important for preventing wear between metal parts.

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    akanshu

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    This document summarizes the production process of ball bearings. It discusses the key materials used, including various steels and brasses for different components. The main production steps are described, beginning with cold heading of steel wire to form balls. Other processes include flashing, grinding, heat treatment, tumbling, and finishing. Quality inspection includes dial gauge checks for accuracy. The grinding department finishes surfaces of inner and outer races. Final processes are honing and lapping for precise fits and surface finishes before assembly. Lubrication is also discussed as important for preventing wear between metal parts.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    24 views25 pages

    A Seminar Report On: Production of Ball Bearing

    Uploaded by

    Parveen Kumar
    This document summarizes the production process of ball bearings. It discusses the key materials used, including various steels and brasses for different components. The main production steps are described, beginning with cold heading of steel wire to form balls. Other processes include flashing, grinding, heat treatment, tumbling, and finishing. Quality inspection includes dial gauge checks for accuracy. The grinding department finishes surfaces of inner and outer races. Final processes are honing and lapping for precise fits and surface finishes before assembly. Lubrication is also discussed as important for preventing wear between metal parts.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 25

    A seminar report

    on

    PRODUCTION OF
    BALL BEARING

    By,
    Akanshu Sharma
    (ME07003)
    Introduction to Bearings

    • Ball Bearings
    • Radial and Thrust loads
    • Roller Bearings
    • Radial and Thrust loads
    • Needle Bearings
    • Only radial load
    Ball Bearings

    • Terminology
    • Outer ring, which contains the outer raceway
    • Inner ring, which contains the inner raceway
    • Complement of balls
    • Two-piece separator (also called cage or
    • retainer
    BEARING MATERIAL

     
          Bearing contains varying amount of carbon, iron,
    chromium, manganese, phosphorus, sulphur, silicon
    etc. Each of these elements plays a role in making
    final steel suitable for bearings. 
    ELEMENT  AMOUNT 

      
      Manganese - 0.25 to 0.35
    Silicon - 0.025 to 0.35
      Sulphur - 0.025 max.
      Phosphorus - 0.025 max.
      Nickel - 0.025 max.
      Copper - 0.35 max.
    RAW MATERIAL

     
          A variety of steel and brasses are used for
    different components for bearings depending upon
    the properties required in the final product. 

    Balls - Ni-Cr Steel wire


    Rollers - High Carbon chrome steel rods
    Races - High carbon steel
    Cage - Brass and mild steel
    PARTS OF BEARINGS

     
          Basically every anti-friction bearing consist of 4
    basic parts:-

    •An outer ring


    •Inner ring
    •Rolling element
    •A cage
    BEARING DESIGNATION 

          There are various standards & specifications used for bearing


    designation, which helps to identify a bearing, by its number. 
          Generally bearing number represents its type, bore, outside
    diameter & sometimes-special design construction if any. In general, for
    bearing having more than 20mm bore, one can simply multiply last two
    digits by five. 

          For Example:-

                Bearing Number-6207
                07*5=35mm Bore
                2=thickness proportion & outside diameter
                6= single row, deep groove ball bearing.  
    PRODUCTION PROCESS

    BALL DEPARTMENT 

                            In this section, Balls of different diameters are


    manufactured by cold heading process. Raw material for Ball
    manufacturing is High Carbon Steel wires in the form of coils. 
          Two types of balls are manufactured, one for Antifriction Ball
    Bearings, which are used in the factory itself and other type for
    cycle industry called Bicycle Balls. 
         
     Following are various operations in which the raw material has to
    be passed. 

    TUMBLING
    COLD HEADING

    FINISHING PROCESS 
    FLASHING 

    SOFT GRINDING  HARD GRINDING 

    HEAT TREATMENT   FINISH GRINDING 


    COLD HEADING
     This is the first operation of the series. Raw material in the form of coils put on
    a revolving drum. One end of it is fed in heading machine in which a much die
    with shear mechanism allows to obtain piece (not exactly round), which are
    used for ball manufacturing. 

                A punch is fitted to the Ram except this a shear mechanism is also used. This is
    obtained by crank which gives reciprocating motion in a direction perpendicular to main
    shaft, while shear mechanism is obtained by converting the motion of main shaft to
    reciprocating motion of the cutter.

    The process consist mainly three steps:- 

    Wire feeding
    Cutting and transfer to the maximum displacement of the cutter.
    Heating and removal of balls.
    FLASHING

    After cold heading we do not get perfect spherical shape but it


    consists but it consists of collar or flash in the central periphery
    which is required to be removed. So in this operation, central extra
    material is removed and it comes in spherical shape, this process is
    done on flashing machine. Principal feature of the machine is that
    it consists two metal plates mounted vertically. 
                Both plates have annular groove cut all over its face
    according size of ball. The grooving position of ball size plates faces
    each other. 
    SOFT GRINDING 

    This operation is achieved for removing excess material


    from the balls. This operation is done on Lapping machine.
    The difference between Lapping and Flashing is that the
    Lapping machines have one metallic plate instead of two,
    and other one is made of abrasives. The metallic plate is
    fixed and abrasive plate is used for material removing. The
    process is performed before heat treatment process
    because of easy removing of material in soft stage. 
    HEAT TREATMENT

    After soft grinding, balls are sending for heat treatment.


    Bicycle Balls are treated in the same section but Bearing
    Balls are heat treated in separate section. Hardening is
    done by heating the balls at 850 Degrees Centigrade for
    three hours in electric arc furnace and then they are Oil
    quenched. Oil for quenching is known as ‘Fusion 40’ oil.
    Feeding of balls is done by vibrating sheet. 
    TUMBLING

                      This is called TTS operation means Tumbling


    Test for Soft Balls for softness. The purpose of this
    sectional operation is to remove all scale nearly, which
    have deposited due to heat treatment. This is achieved
    in tumbler, which are octagonal bodies having lesser
    dimensions of upper part as compared to lower one.
    These are inclined at certain angle and then are made
    to rotate by means of motor and pulley arrangement.
    FINISHING PROCESS

                After tumbling, balls come into grinding section


    here they first send to visual Inspection, where Balls are
    rolled over a plane paper under a beam of light. Here
    balls with irregular shaper are drawn out. Remaining
    Balls passed through different operations .
    HARD GRINDING

    Specifications of N G 800 Machine used for hard


    grinding. 

    Load size (+100mM + 5)


    Finish size (+30 + 5mM)
    Pressure 10 to 20 kgf/cm2
    Time required 20 hours
    Dressing pressure 8 kgf/cm2
    R.p.m. of machine 90
    Batch weight 800 kg
    Coolant is similar 2%
    FINISH GRINDING

    It is also NG 800 but having different grinding wheel in


    the machine load size +30 mM, Finish +7 mM, Pressure
    required 8 to 15 kgf/cm2, Finishing pressure 8 kgf/cm2. 
    GRINDING DEPARTMENT 

    Grinding is one of the most important sections in producing Ball


    Bearing. Grinding is the process of removing small excess metal
    (Material) to finishing stage. The main features of this process
    are good surface finish and close accuracy.

    Bore diameter of inner races, faces and outer diameter of outer


    races is grinded. The grinding operation is done after heat
    treatment, when due to exposure of race sin atmosphere; they
    are oxidized and become black in color. This defect is removed
    and close tolerances are achieved. Before sending these to
    assembly shop, honing is done. 
    The operational steps in grinding of outer races are- 
    Facing.

    O.D. Grinding.
    Track Grinding.
    Track Honing.
    Washing.
     
    The operational steps in grinding of inner races are- 
    Facing.

    O.D. Grinding.
    Track Grinding.
    Bore Grinding.
    Track Honing.
    Washing.
    NEW HONING SECTION

     
    This section has various super-finish process machines. 
    These are

    •HONING MACHINE

    Honing is the process of super finishing Material removal is accomplished at lower


    cutting speeds than in grinding, heat and pressure are minimize resulting in an
    excellent size and metallurgical control. It is done on multiple honing machines in
    which work pieces can be bonded at a time.
    LAPPING PROCESS

    The purpose is to produce geometrically true surfaces, correct


    minor surface, imperfections removed, and dimensional
    accuracy or provide a very close fit between two contact
    surfaces. Lapping is used on flat cylindrical, spherical surface.
    In honing material is removed but in lapping operation no
    material is removed. 
    VISUAL INSPECTION 

    After lapping process, washing of inner and other races is


    done by spraying Kerosene oil on them. Then they are
    brought to be checked for accuracy on Dial Gauge. In dial
    gauge inspection air with pressure flows, when inner race is
    inserted in knobs, from where air is coming. Air comes through
    a little orifice between Knob and inner diameter feeding
    pressure which is given on dial gauge. 
    LUBRICATION OF BEARINGS:-

     
          The fundamental principal of efficient lubricant is to make a
    strong lubricant film, which prevents metal to metal contact of
    the sliding parts of the bearing most effectively & economically
    & thus prevents wear & tear resulting from this under operating
    conditions. It also reduces the rolling friction by keeping the
    rolling elements & tracks heat. It also minimizes the bearing
    noise & prevents corrosion
    Thanks

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