OVALITY OBSERVED IN BALL BEARING

BY RITESH J PATEL (096380319590) Guided by MR.RAJESH RANA Asst.professor

Department of mechanical engineering Parul institute of engineering & technology (DS 2ndshift) (Affiliated to Gujarat technological university) P.O. LIMDA, TA. WAGHODIA, DIST. VADODARA391760. Gujarat, INDIA [2011-2012]

Parul institute of engineering and technology (DS 2nd shift)

PARUL INSTITUTE OF ENGG.& TECH.

AT POST LIMDA, WAGHODIA- 391760

CERTIFICATE
This is to certify that MR.RITESH J PATEL. of Diploma 5th Semester in mechanical engineering, Registration No.096380319590 has completed

satisfactorily his project-I entitled for the term 201112, He has under gone training at NHB BALL & ROLLER LTD. WORKS From 19/6/11 to 9/7/11

DATE:

Sign Of Guide

Sign of HOD

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INDUSTRY DEFINED PROBLEM / PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS

FIRST NAME LAST NAME MOBILE NO EMAIL COLLEGE NAME ADDRESS

BRANCH SEMESTER TEAM NAME SIGNATURE OF STUDENT

RITESH PATEL 9726798920 patelritesh50@gmail.com PARUL INSTITUTE OF ENGINEERING & TECHNOLOGY P.O. LIMDA. TAL. WAGHODIA391760 DIST. VADODARA , GUJARAT(INDIA) MECHANICAL ENGINEERING 5TH MB-1 R.J.Patel

------------- INDUSTRY COORDINATES---------------------NAME CONTACT ADDRESS MOBILE NO. EMAIL NIMESH HASMUKHBHAI PATEL KHARSAD, KODGARA FALIA, TA: JALALPORE DIST: NAVSARI +919825674899 info@nhbball.com

-----------------------------------INDUSTRY--------------------------NAME ADDRESS CONTACT NO NAME OF INDUSTRIAL ESTATE COMPANY LOGO NHB Ball & Roller Ltd. Andhkeshwar Road, Amalsad 396310, Dist: Navsari, Gujarat 02634-272255/56 AMALSAD

Parul institute of engineering and technology (DS 2nd shift)

INDUSTRY DEFINED PROBLEM STATEMENT FORM TITLE OF PROBLEM/PROJECT

OVALITY OBSERVED IN BALL BEARING.

DISCIPLINARY | INTERDISCIPLINARY

DISCIPLINE

PROBLEM SUMMARY The problem summery may be a concise description of the industry related technical issues which can state the problem, which the student has found out while visiting the industry. DETAILED DESCRIPTION OF PROBLEM The problem statement has to be well defined in 3-5 pages with detailed facts and figures as and when possible. The description can have figures/inputs from floor persons from industries/ parameters related to specific domain of technology. EXPECTED OUTCOME The students while interacting with industry persons have to note down the expected out comes (in 1-2 page) from that particular industry due to the proposed innovation either in product or processes. This will gauge the industrial needs and students progress while working on the final year project. OTHER DESCRIPTION (IF ANY) The students are advised to do some literature research related to the corresponding problem/innovation both before and after visiting the industry/MSME during summer vacation. They have to suggest some suggestions about the issues based on literature research of corresponding problems/projects in feasible cases. The format of documentation may be slightly modified as per the need of specific branch. For example in the documentation of any industrial waste, one may have to state. (Composition of waste, type of waste (Solid, Liquid, Gas, Semi-Solid), quantity of waste etc. The problem/project reports are scouted from Industries have to be submitted to Departmental HODs of corresponding GTU College in softcopy. GTU will evaluate them in August 2011 as a part of Curriculum.

Parul institute of engineering and technology (DS 2nd shift)

IDENTIFICATION

Name:Enrollment no.:Course:Branch:Semester:-

Ritesh J Patel 096380319590 Diploma Engineering Mechanical Engineering 5th SEM. [2nd shift]

Project name:- Ovality observed in ball bearing Study center:Parul Institute of Engineering & Technology, vadodara [Gujarat]

Parul institute of engineering and technology (DS 2nd shift)

ACKNOWLEDGEMENT
Gratitude is an attitude without which any person is incomplete. Hence, I take this space to thank all who involved directly or indirectly in this project.

It has been a very good experience for me to prepare this minor project on ovality observed in ball bearing I would like to thank my guide RAJESH RANA, who has help us a lot, without whose kind support this project would have been almost impossible. I thank my sir for having given the information about various resources.

Parul institute of engineering and technology (DS 2nd shift)

WHAT IS PROJECT?
A project is a temporary endeavor undertaken to create a unique result or change. Temporary means that the project has an end date. Unique means that the projects end result is different than the results of other functions of the organization Project means the whole of an action which has a potential for resulting in a physical change in the environment, directly or ultimately, and that is any of the following: An activity directly undertaken by any public agency, including but not limited to public works construction and related A project may be a group of related reclamation activities with a common objective within a political subdivision of a state or within a logical, geographically defined area..

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INDEX
Company profile09 Ovality Summary11 Bearing Failure: Causes and Cures..15 Excessive Loads16 Overheating.17 True Brinelling18 False Brinelling..19

Normal Fatigue Failure..20

Reverse Loading21 Contamination22 Lubricant Failure23 Corrosion.24 Misalignment..25 Loose Fits26 Tight Fits..27 Seizure.28

Parul institute of engineering and technology (DS 2nd shift)

Ovality measurement systems26

Laser End Measurement System..30 OmniPro Vision Systems..33 AccuScan Measurement System36 Solution...41 Conclusion.43

Parul institute of engineering and technology (DS 2nd shift)

Company Profile Company logo:

Basic Information
Company Name: Business Type: Product/Service (We Sell): Product/Service (We Buy): Brands: Number of Employees: NHB BALL AND ROLLER LTD Manufacturer Steel Ball

Wire NHB 101 - 200 People

Trade & Market

North America Main Markets: South America Eastern Europe Western Europe Main Customers: SKF,FAG

Total Annual Sales Volume: US$1 Million - US$2.5 Million Export Percentage: Total Annual Purchase Volume: 61% - 70% US$1 Million - US$2.5 Million

Factory Information
Factory Size (Sq.meters): Factory Location: QA/QC: Number of Production Lines: Number of R&D Staff: Number of QC Staff: 5,000-10,000 square meters GUJARAT In House Above 10 5 - 10 People 5 - 10 People

Management Certification: ISO/TS 16949 Contract Manufacturing: OEM Service Offered

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Industry Review
The bearing industry comprises mainly ball and roller bearings. The prospects of the bearing industry are directly linked to the performance of automotive and industrial sector.

Automotive Industry
After the road-block of global economic recession, the automobile industry has come back in the top gear. The domestic automobile sales revived, registering stupendous growth in 2009-10. Exports too have recovered, albeit at a slower pace.

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OVALITY
SUMMARYOvality observed in ball bearing.

Ovality is a term to used to measure "out of roundness". Ovality designates how close to a perfect circle a bar is at the point being measured. Of all the machines in the process the grinder has the largest impact on ovality.

The grinder fine tunes the product but the turning machine has to get it right first. The pre-straightening machine is also important as the straighter the bar going into the turner the more consistent the roundness and finish coming out.

Parul institute of engineering and technology (DS 2nd shift)

In the peeling process, the bar moves horizontally thru the turner while carbide cutting tools rotate around the bar on a spindle peeling the bar which leaves a spiral mark which in the industry are called barber poles. The tools in the peeler, peels the rusty surface from the bar similar to the way a knife is used to peel an apple. When there is no overlap the bar receives one wrap or one peel per inch of length. Two wraps per inch gives a rounder better finished bar than one wrap. The more the wraps the better the quality of the bar produced. One has to decrease the thru put speed to get more wraps which means the cost of production increases. There is an obvious trade of between quality and production costs in both the turning machine and the grinder. A commodity bar will have the least number of wraps possible whereas, a customengineered bar will have the optimum number of wraps. If the grinder takes one pass to remove a certain amount of material the finish will not be as good as if it takes two passes. The amount of reduction in a grinder is a function of the grit in the grinding wheel. The rougher the grit, the more the reduction, but the rougher the finish. All things being equal the more the passes in the grinder the better the finish and the better the ovality.

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 Bearing Failure:

Causes and Cures

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 Excessive Loads

Excessive loads usually cause premature fatigue. Tight fits, brinelling and improper preloading can also bring about early fatigue failure. The solution is to reduce the load or redesign using a bearing with greater capacity.

Parul institute of engineering and technology (DS 2nd shift)

 Overheating

Symptoms are discoloration of the rings, balls, and cages from gold to blue. Temperature in excess of 400F can anneal the ring and ball materials. The resulting loss in hardness reduces the bearing capacity causing early failure. In extreme cases, balls and rings will deform. The temperature rise can also degrade or destroy lubricant.

Parul institute of engineering and technology (DS 2nd shift)

 True Brinelling

Brinelling occurs when loads exceed the elastic limit of the ring material. Brinell marks show as indentations in the raceways which increase bearing vibration (noise). Any static overload or severe impact can cause brinelling.

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 False Brinelling

False brinelling - elliptical wear marks in an axial direction at each ball position with a bright finish and sharp demarcation, often surrounded by a ring of brown debris - indicates excessive external vibration. Correct by isolating bearings from external vibration, and using greases containing antiwear additives.

Parul institute of engineering and technology (DS 2nd shift)

 Normal Fatigue Failure

Fatigue failure - usually referred to as spalling - is a fracture of the running surfaces and subsequent removal of small discrete particles of material. Spalling can occur on the inner ring, outer ring, or balls. This type of failure is progressive and once initiated will spread as a result of further operation. It will always be accompanied by a marked increase in vibration. The remedy is to replace the bearing or consider redesigning to use a bearing having a greater calculated fatigue life.

Parul institute of engineering and technology (DS 2nd shift)

 Reverse Loading

Angular contact bearings are designed to accept an axial load in one direction only. When loaded in the opposite direction, the elliptical contact area on the outer ring is truncated by the low shoulder on that side of the outer ring. The result is excessive stress and an increase in temperature, followed by increased vibration and early failure. Corrective action is to simply install the bearing correctly.
Parul institute of engineering and technology (DS 2nd shift)

 Contamination

Contamination is one of the leading causes of bearing failure. Contamination symptoms are denting of the bearing raceways and balls resulting in high vibration and wear. Clean work areas, tools, fixtures, and hands help reduce contamination failures. Keep grinding operations away from bearing assembly areas and keep bearings in their original packaging until you are ready to install them.

Parul institute of engineering and technology (DS 2nd shift)

 Lubricant Failure

Discolored (blue/brown) ball tracks and balls are symptoms of lubricant failure. Excessive wear of balls, ring, and cages will follow, resulting in overheating and subsequent catastrophic failure. Ball bearings depend on the continuous presence of a very thin -millionths of an inch - film of lubricant between balls and races, and between the cage, bearing rings, and balls. Failures are typically caused by restricted lubricant flow or excessive temperatures that degrade the lubricants properties.
Parul institute of engineering and technology (DS 2nd shift)

 Corrosion

Red/brown areas on balls, race-way, cages, or bands of ball bearings are symptoms of corrosion. This condition results from exposing bearings to corrosive fluids or a corrosive atmosphere. In extreme cases, corrosion can initiate early fatigue failures. Correct by diverting corrosive fluids away from bearing areas and use integrally sealed bearings whenever possible.
Parul institute of engineering and technology (DS 2nd shift)

Misalignment

Misalignment can be detected on the raceway of the nonrotating ring by a ball wear path that is not parallel to the raceways edges. If misalignment exceeds 0.001 in./in you can expect an abnormal temperature rise in the bearing and/or housing and heavy wear in the cage ball-pockets. Appropriate corrective action includes: inspecting shafts and housings for runout of shoulders and bearing seats; use of single point-turned or ground threads on non hardened shafts and ground threads only on hardened shafts; and using precision grade locknuts.
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Loose Fits

Loose fits can cause relative motion between mating parts. If the relative motion between mating parts is slight but continuous, fretting occurs. Fretting is the generation of fine metal particles which oxidize, leaving a distinctive brown color. This material is abrasive and will aggravate the looseness. If the looseness is enough to allow considerable movement of the inner or outer ring, the mounting surfaces will wear and heat, causing noise and runout problems.

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Tight Fits

A heavy ball wear path in the bottom of the raceway around the entire circumference of the inner ring and outer ring indicates a tight fit. Where interference fits exceed the radial clearance at operating temperature, the balls will become excessively loaded. This will result in a rapid temperature rise accompanied by high torque. Continued operation can lead to rapid wear and fatigue. Corrective action includes a decrease in total interference.

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Seizure

Meaning= to bind or fasten together Results: Discoloration, and welding of raceway surface, rolling contact surfaces

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 Causes: Poor heat dissipation Poor lubrication or improper lubrication. Smaller Clearance. Excessive load (or pre-load). Installation error.

Solutions Improper dissipation of heat from bearing Prevention of misalignment Improvement in clearance Selection of suitable lubricant and determination of optimum lubricant feeding rate

Parul institute of engineering and technology (DS 2nd shift)

 Ovality measurement systems

Laser End Measurement System OmniPro Vision Systems

AccuScan Measurement System

Parul institute of engineering and technology (DS 2nd shift)

 Laser End Measurement System

Laser End Measurement System, which measures external and internal diameters, wall thickness, external and internal ovality and eccentricity.

Market Situation
Increasingly, the offshore industry demands tighter dimensional tolerances on pipe ends in order to reduce installation cycle time. For line pipe subject to high dynamic loads, such as Steel Catenary Risers and fatigue sensitive flowlines, a full geometrical assessment of pipe ends enables a more efficient alignment prior to welding.
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Process
Laser End Measurement System utilizes laser optical displacement sensors, which measure the distance between the sensors measuring head and the surface of the tube with great accuracy.

Applications
Replaces manual inspection and provides 100% automated process control. Provides information about each pipe end (OD, ID and WT max, average and min). Additional services that can be offered to simplify welding operations are: - Identification of pipes with families of tolerances - Identification of pipes sequences and the rotation angles for all the pipes that comply with the max Hi/Lo required. The sequences are calculated by Tenaris Best Match software using Laser End Measurement System data, evaluating the best fit that can be achieved with pipes accurately aligned on ID axis.
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Advantages
Offers the capability to record 100% of the data, which can be customized and saved on a CD. Provides a full dimensional scan of pipe ends with very detailed information (up to 1,000 measurements). Performs the inspection offline/online so that the information is available as soon as the material is ready for shipment, reducing time, logistics and costs. Reduces the chance for human error. Sorts information by families or best sequence for welding, based on customer requirements.

Capabilities
Outside Diameter Range from 5 1/2 to 16. Inside diameter larger than 110 mm. Takes up to 1,000 measurements per turn. Measures in a section whose position can be set up to 120 mm from the pipe end. If requested, additional measurements can be agreed. Data output tailored to customer requirements and recorded on CD.

Parul institute of engineering and technology (DS 2nd shift)

 OmniPro Vision Systems

Inspection system for ovality measurement
Cross section profile measurement by light section methods Over 1000 profile measuring points Continuous inline measurement and product roundness control Different gauge heads depending on accuracy demands Reject reduction by process optimization Fast integration in the production process

Advantages
Complete contour image Trend display No abrasive wear Maintenance free Easy to calibrate Fast and easy integration in production lines
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Data for reliable production quality adjustment Product quality optimization

Results ovality measurement

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Application range Cable, wire and bearings Round steel bars and other round profiles Pipes, tubes and inner tubes

Features
Contactless roundness measurement Gauge heads with variable resolution Display of all relevant dimensions, e.g. minimum, maximum and average radius/Diameter, ovality etc. Acceptable tolerance monitoring and alarm function Measurement data logging for continuous process quality documentation Seamless PC-integration in an available Windows network

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 AccuScan Measurement System

AccuScan systems from Beta LaserMike provide online precision measurements of the diameter and ovality of cables. Using laser scanning technology, AccuScan systems are able to perform diameter measurements in an intelligent gauge head during production and communicate those measurements to a host system or controller.

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The AccuScan Advantage Increase measurement accuracy with uniquely designed and crafted optics. Increase measurement repeatability with intelligent Digital Signal Processor (DSP). Increase up-time and reduce maintenance cost with built-in air purge system that keeps lenses free of dust and debris. Increase durability with rugged construction sealed to IP 65 (NEMA 4) standards. Flexible communication integration with RS232, DeviceNet, and Profibus protocol support.

Parul institute of engineering and technology (DS 2nd shift)

Parul institute of engineering and technology (DS 2nd shift)

Laser Scanning Measurement

Principle

In 1972, the founders of Beta LaserMike introduced the worlds first laser scanning micrometer (the LaserMike). AccuScan gauges employ this laser scanning measurement principle, which uses a low-power helium-neon laser that is scanned at high speed through a measurement window and across the cable.
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When the laser first scans across to the receiver, the light hits the photocell and the voltage rises. The voltage drops when the light is blocked by the cable and rises again when the light reaches the photocell. The change in time ( t) that the light is blocked by the cable is proportional to the cables outside diameter.

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SOLUTION
Three ways to benefit from use of Low Ovality Technology
1. Reduce ovality of coiled pipe (by up to 60%)
# Eliminates need for re-rounding on site. # Enables easier jointing and improves joint integrity. # Improves coil stability, minimising coil failure during storage and risk of coil rejection by customer.

2. Supply standard coil lengths at smaller dimensions

# Reduce transport costs by increasing the number of coils per truck. # Reduce requirement for use of special low trailers.

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Quality Bar mandates the following qualitycontrol steps in its manufacturing process:
1. Incoming hot rolled raw bundles are inspected for split ends and serious surface defects. 2. Bars are visually inspected when exiting the # 1 prestraightener. 3. Bars are randomly tested for ovality as they exit the turner. 4. Bars are randomly in-line tested for straightness as they exit the #2 post straightener. 5. Every bundle of TP bars is tested for finish and ovality before packaging with the test results being saved with the order. 6. Bars are continually monitored via a digital readout for ovality during grinding. 7. 100% of the TG&P bars are inspected after grinding. 8. Every bundle of TGP bars is tested for finish and ovality by the packer before packaging and their results are saved with the order. 9. Bars throughout the process are randomly tested off line for straightness.

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Conclusion Bearing Maintenance

1. Statistical Method (bearing life estimation)
Probabilistic rolling contact fatigue. Few bearings breakdown earlier than their life. Unnecessary replacement of few perfectly good condition bearings.

2. Bearing Condition Monitoring

Detect crack size. Warns if crack area > 6.45 mm2 (0.01 in2). Needs crack propagation theory (-ies)

Parul institute of engineering and technology (DS 2nd shift)