ACKNOWLEDGEMENT

I express my deep sense of gratitude to Dr. B.Ravi, Faculty advisor,

mechanical, IIT Bombay powni, Mumbai for encouraging me to take
training at this organization, Kansara Bearing Pvt. Ltd. Jodhpur,

I acknowledge with than ks the kind of patronage, Loving

inspiration and timely guidance, which I have received from my course
coordinatior Mr. B.L.sein,

To all those people, named unnamed an those other who have

encouraged me in writing this report, my very sincere thanks,

Dharmendra Chouhan
CONTENTS

1. Introduction
2. Characteristics
3. Types of bearing
4. Roller element bearing
5. Type of roller element bearing
6. Manufacturing of roller
7. Quality assurance
8. Common use
 INTRODUCTION:-

Defination:-

A bearing is a device to allow constrained relative motion

between two or more parts, typically rotaion or linear movement.
Bearings may be classified broadly according to the motions they
allow and according to their principle of operation as well as by the
directions of applied loads they can handle.

Charactristic:-

1. Bearing friction:-

Plain bearings are very wide used, and use

surfaces in rubbing contact. Particularly with lubricaion they often give
entirely acceptable life and friction.

On the other hand, low friction bearings are often

important for efficiency, to reduce wear and to faciliate extended use
at high speeds. Essentially, a bearing van reduce friction by virtue of its
shape, by its material, or by introducing and containing a fluid betwee n
surfaces or by separating the surfaces with an electromagnetic field.

. BY shape, gains advantage usually by using spheres or rollers, or by

forming flexure bearings.

. By meterial, exploits the nature of the bearing material used.(An

example would be using plastics that have low surface friction.)
. By fluid, exploits the low viscosity of a layer of fluid, such as a lubricant
or as pressurized medium to keep the two solid parts from touching, or
by rducing the normal force between them.

. Bu fields, exploits electromagnetic fields, such as magnetic fields, to

keep solid parts from touching.

Combinations of these can even be employed within the same

bearing. An example of this is where the cage is made of plastic, and it
separates the rollers/balls, which reduce friction by their shape and
finish.

2. Motions:-

Common motions permitted by bearings are:

. Axial rotion e.g. shaft rotation

. Linear motion e.g. drawer

. spherical rotation e.g. ball and socket joint

. hinge motion e.g. door

3. Loads:-

Bearings vary greatly over the size and directions of

forces that they can support. Forces can be
predominately radial, axial or moments perpendicular
to the main axis.
4. Speeds:-
Different bearing types have different operating speed
limits. Speed is typically specified as maximum relative
surface speeds, often specified ft/s or m/s. Rotational
bearings typically decribe performance in terms of the
product DN Where D is the diameter (often in mm) of
the bearing and N is the rotation rate in revolutions
per minute.
Generally there is considerable speed range overlap
between bearing types. Plain bearings typically handle
only lower speeds. Rolling element bearings are faster,
ultimately by centripetal force overcoming material
strength.

5. Play and elasticity:-

Some applications apply bearing loads from varying

dirctions and accept only limited play or “slop” as the
applied load changes. One source of motion is gaps or
“play” in the bearing. As example, a 10mm shaft in a
12mm hole 2mm play. A second source of motion is
elasticity in the bearing itself. As example, the balls ina
ball bearing are like sstiff rubber, and under load
deform from round to a slighyly flattened shape. The
race is also elastic and develops a sligh dent where the
ball presses on it.

Allowable play varies greatly depending on the use. As

example, a whellbarrow wheel supports radial and
 axial loads may be hundreds of newtons force left or
right, and it is typically acceptable for the wheel to
wobble by as much as 10mm under the varying load. In
contrast, a lathe may position a cutting tool to +-0.02
mm using a ball lead screw held by rotaing direction,
and must hold the ball lead screw to +-0.002mm across
that range of loads.

6. Life:-
Fluid and magnetic bearings can potentially give
indefinite life.

Rolling element bearing life is statistical, but is

determined by load, temperature, maintenance,
vibration, lubrication and other factors.

For plain bearings some materials give much longer life

than others. Some of the John Harrison clocks still
operate after hundreds of years because of the Lignum
vitae wood employed in their construction, whereas
his metal clocks are seldom run due to potential wear.
7. Maintenance:-

Many bearings require periodic maintenance to

prevent premature failure, although some such as fluid
or magnetic bearings may require little maintenance.
 Most bearings in high cycle operations need periodic
lubrication and cleaning . and may require adjustment
to minimise the effects of wear.

Types:-

There are many different types of bearings.

1. Plain bearing:- A typical plain bearing is made of two parts. For

example, a rotary plain bearing can be just a shift running through
a hole. A simple linear bearing can be a pair of flat surfaces
designed to allow motion ( for example, a drawer and the slides it
rests on.)
2. Rolling element bearing:- A rolling element is a bearing which
carries a load by placing round elements between the two pieces.
The relative motion of the pieces cuses the round elements to roll
with very little rolling resistance and with little sliding.
3. Jewel bearing:- jewel bearing is a bearing in which the load is
carried by rolling the axle slightly off-center.
4. Magnetic bearing:- magnetic bearing is a bearing in which the
load is carried by a magnetic field.
5. Flexure bearing:- flexure bearing is a bearing in which the motion
is supported by a load element which bends.
6. Fluid bearing:- Fluid bearings are bearing which solely support
the bearing’s loads on a thin layer of liquid or gas.
 Rolling-element bearing

A rolling element bearing is a bearing which carries a load by placing

round element between the two pieces. The relative motion of the
pieces causes the round elements to roll with little rolling resistance
and with little sliding.

One of the earliest and best-known rolling-element bearings are sets of

logs laid on the gound with a large stone block on top. As the stone is
pulled, the logs roll along the gound with little sliding friction. As each
log comes out the back, it is moved to the front where the block then
rolls on to it. It is possible to imitate such a bearing by placing several
pens or pencils on a table and placing an item on top of them.

A rolling element rotary bearing uses a shaft in a much larger hole, and
cylinders called “rollers” tightly fill the space between the shaft and
hole. As the shaft turns, each roller acts as the logs in the above
example. However since the bearing is round, the rollers never fall out
from under the load.

Rolling-element bearings have the advantage of a good tradeoff

beatween cost, size weight. Carrying capacity, durability, accuracy,
friction, and so on. Othe bearing designs are often better on one
specific attribute, but worse in most other attributes, although fluid
bearings can sometimes simultaneously outperform on carrying
capacity, durability, accuracy, friction, rotation rate and sometimes
cost. Only plain bearings have as wide use as rolling element bearings.
Design:-

Typical rolling-element bearing range in size from 10mm diameter to a

few metres diameter, and have load-carrying capacity from a few tens
of grams to many thousands of tommes. A particularly common kind of
rolling-element bearing is th ball bearing. The bearing has inner and
outer races and a set of balls. Each race is a ring with a groove. Thus, in
principle, the ball contacts each race at a single point. However, a load
on an infinitely small point would cause infinitely high contact pressure.
In practice, the ball deforms (flattens) slightly where it contacts each
race, much as a tire flattens where it touches the road. The race also
dents slightly where each ball presses on it. Thus, the contact between
ball and race is of finite size and has finite pressure. Note also that the
deformed ball and race do not roll entirely smoothly because different
parts of the ball are moving at different speeds as it rolls. Thus, there
cause bearing drag.

Most rolling element beaings use cages to keep the balls separate. This
reduces wear and friction, since it avoids the balls rubbing against each
other as they roll, and precludes them from jamming.

Types of bearings:-
There are many types of rolling-element bearings, each tuned for a
specific kind of load and with specific advantages and disadvantages.
For example:

Ball bearing:-

Ball bearings use balls instead of cylinders. Ball bearings can

support both redial (perpendicular to the shaft) and axial loads (parallel
to the shaft). For lightlyloaded bearings, balls offer lower friction than
rollers. Ball bearings can operate when the bearing races are
misaligned.

Roller bearings:-

Common roller bearings use cylinders of slightly greater length

than diameter. Roller bearing typically have higher radial load capacity
than ball bearings, but a low axial capacity and higher friction under
axial loads. If than inner and outer races are misaligned, the bearing
capacity often drops quickly compared to either a ball bearing or a
spherical roller bearing.

Roller bearings are the earliest known type of rolling-element –bearing,

dating back to at least 40 BC.

Needle bearing:-

Needle roller bearings use very long and thin cylinders. Often the
ends of the rollers taper to points, and these are used to keep the
rollers captive, or they may arrangement. Since the rollers are thin, the
outside diameter of the bearing is only slightly larger than the hole in
the middle. However, the small-diameter rollers must bend sharply
where they contact the races, and thus the bearing fatigues relatively
quickly.

Tapered roller bearing:-

Tapered roller bearings use conical rollers that run on conical

races. Most roller bearings only take radial loads, but tapered roller
bearings support both radial and axial loads, and generally can carry
higher loads than ball beaings due to greater contact area. Taper roller
bearings are used, for examople, as the wheel bearing of most car,
trucks, buses, and so on. The downsides to this bearing is that due to
manufacturing complexities, tapered roller bearing are usually more
expensive than ball bearings; and additionally under heavy loads the
tapered roller is like a wedge and bearing loads tend to try to eject the
roller; the force from the collar which keeps the roller in the bearing
adds to bearing friction compared to ball bearings.

Spherical roller bearings:-

Spherical roller bearings use rollers that are thicker in the middle
and thinner at the ends; the race is shaped to match. Spherical roller
bearings can thus adjust to support misaligned loads. However,
spherical rollers are difficult to produce and thus expensive, and the
bearings have higher friction than a comparable ball bearing since
different parts of the spherical roller run at different speeds on the
rouded race and thus there are opposing forces along the bearing/race
contact.

Thrust bearings:-

Thrust bearings are used to support axial loads, such as vertical

shafts. Spherical conical or cylindrical rollers are used; and non rolling
element bearing such as hydrostatic or magnetic bearings see some use
where paricularly heavy loads or low friction is needed.

Bearings has four parts

1. Inner
2. Outer
3. Net
4. Body

Roller is the most critical component of roller bearings. It has to rotate

at several times higher speed than the bearing itself and at the same
time it has to carry the entire load of the equipment where it is used.
Obviously the performance of the bearing in terms of its speed,
strength and serivce to a great extent depends on rollers. And to create
the roller to meet the stringency required calls for better material,
better Manufacturing and better microgeometry.

Range of diameter of roller:

Larger End Diameter: 4.75mm. to 25.50mm.

Smaller End Diameter: 4.50mm. to 18.50mm.

Length: 8.00mm. to 45.00mm.

Another size of roller can be made against customer requirement.

 Manufacturing Of Roller

The first step in manufacturing is to design tooling. Faculty of computer

aided design ensured the geometry.

Material used is steel wire. Which is made out of carbon chrome steels.
This steel is normally conforming to SAE 52100/100cr6/SUJ2
specification which is popularly known as bearing steel.

Steel wire is cold forged into the shape of taper roller. Forging process
help in correct grain structure. This process is going on in the machine
called header.

These rollers are tumbled in tumbling machine. After this rollers are
heat treated in furnace. These furnaces are controlled by temperature
controller of one degree celsius accuracy which is verified every day by
quality assurance department. Rollers in rotary furnace are heated
indirectlyin the presence of a preventive atmosphere of controlled dew
point for ero decarburisation. Than the rollers are quenched in a tank of
mechanically agitated oil bath whose temperature is maintained by
controllers and heart exchangers for proper microstructure and to
achieve hardness of 62+-2 HRC.

These bearing are grinded to make bearing soft. After grinded bearing
are not perfect round to make perfect round bearing are shot blasted.

Before packing, these bearings undergo mirror test, in this test bearings
are put infornt of mirror and checked for proper quality.
Rollers are packed with adequate rust protection in a easy to carry
carto with handle, weighing around 10 Kgs. This carton has a label
describing roller type, meterial quality, batch no.s, size and relevent
details.

Quality assurance

Metrology instruments:

We are equipped with computerized roundness measuring equipment

from the TAYLOR HOBSON U.K. as below:

. TALYROND-252

. From TALYSURF SERIES-2

The above instument are having facilities to measure:

1. Roundness
2. Harmonics
3. Cylindricity
4. Cone angle
5. Body profile
6. Face run out
7. Surface finish on body
8. Surface finish on end face

Based on these parameters rolers are checked throughout process for

quality assurance purpose and the data is stored for further analysis.
Metallurgical: Raw materials and hardened bearing are checked for
good micro structure accordind to percentage of martensite, austenite,
bainite, carbon steel.

Microcleanliness: microcleanilness is checked by spectrometer.

Strength: strength is measured by universal testing machine. Hardness

is measured by hardness test.

Common uses:

Aerospace bearings

Aeropace bearing are installed in aircraft and aerospace systems in

order to ensure a high precision aeronautical or aerospace system.
Precision miniature ball guidance systems, and other types of
aerospace systems.

Axles

These bearing are often used for axles due to their low rolling friction.

Other

Most rolling element bearing designs are for rotating or oscillating

loads, but there are also linear bearing designs,. A common example is
drawer-support harware. Another example is a bearing for a shaft
which moves axially in a hole axial-motion bearings often work like the
stone and log example, with a pathway so rolling element that fall off
the end are pushed around to the other end, and the load rolls on to it.
These are called recirculating bearing and were used in automotive
steering units before the extensive intorduction of the rack and pinion
unit.