Ritu Ovality Project

Parul institute of engineering and technology (DS 2nd

shift)

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. VADODARA-

391760.

Gujarat, INDIA

[2011-2012]


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PARUL INSTITUTE OF ENGG.& TECH. AT POST – LIMDA, WAGHODIA- 391760

C E R T I F I C A T E

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 2011-

12, 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 RITESH

LAST NAME PATEL

MOBILE NO 9726798920

EMAIL [email protected]

COLLEGE NAME PARUL INSTITUTE OF

ENGINEERING & TECHNOLOGY

ADDRESS P.O. LIMDA. TAL. WAGHODIA-

391760 DIST. VADODARA ,

GUJARAT(INDIA)

BRANCH MECHANICAL ENGINEERING

SEMESTER 5TH

TEAM NAME MB-1

SIGNATURE OF STUDENT R.J.Patel

------------- INDUSTRY COORDINATES----------------------

NAME NIMESH HASMUKHBHAI PATEL

CONTACT ADDRESS KHARSAD, KODGARA FALIA,

TA: JALALPORE DIST: NAVSARI

MOBILE NO. +919825674899

EMAIL [email protected]

-----------------------------------INDUSTRY---------------------------

NAME NHB Ball & Roller Ltd.

ADDRESS Andhkeshwar Road, Amalsad – 396310,

Dist: Navsari, Gujarat

CONTACT NO 02634-272255/56

NAME OF INDUSTRIAL ESTATE AMALSAD

COMPANY LOGO


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INDUSTRY DEFINED PROBLEM STATEMENT FORM

TITLE OF PROBLEM/PROJECT

OVALITY OBSERVED IN BALL BEARING.

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.

DISCIPLINARY | INTER-

DISCIPLINARY

DISCIPLINE


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IDENTIFICATION

Name:- Ritesh J Patel

Enrollment no.:-

096380319590

Course:- Diploma Engineering

Branch:- Mechanical Engineering

Semester:- 5th SEM. [2nd shift]

Project name:- “Ovality observed in ball bearing”

Study center:- Parul Institute of Engineering & Technology, vadodara [Gujarat]


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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.


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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 project’s

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 profile………………09

Ovality

Summary………………………11

Bearing Failure: Causes and Cures………………………………..15

Excessive Loads…………16

Overheating……………….17

True Brinelling……………18

False Brinelling…………..19

Normal Fatigue Failure..20

Reverse Loading…………21

Contamination……………22

Lubricant Failure…………23

Corrosion………………….24

Misalignment……………..25

Loose Fits…………………26

Tight Fits…………………..27

Seizure……………….28


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Ovality measurement systems…………………26 Laser End Measurement

System……………………………..30 OmniPro Vision Systems..33 AccuScan Measurement

System………………………………36 Solution………………………...41

Conclusion…………………….43


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Company Profile

Company logo:

Basic Information

Company Name: NHB BALL AND ROLLER LTD

Business Type: Manufacturer

Product/Service

(We Sell): Steel Ball

Product/Service

(We Buy): Wire

Brands: NHB

Number of Employees: 101 - 200 People

Trade & Market

Main Markets:

North America

South America

Eastern Europe

Western Europe

Main Customers: SKF,FAG

Total Annual Sales Volume: US$1 Million - US$2.5 Million

Export Percentage: 61% - 70%

Total Annual Purchase

Volume: US$1 Million - US$2.5 Million

Factory Information

Factory Size (Sq.meters): 5,000-10,000 square meters

Factory Location: GUJARAT

QA/QC: In House

Number of Production

Lines: Above 10

Number of R&D Staff: 5 - 10 People

Number of QC Staff: 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

SUMMARY-

Ovality 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.


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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 custom-

engineered 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.


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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.


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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.


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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.


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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.


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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.


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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 lubricant’s properties.


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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.


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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


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Ovality measurement

systems

Laser End Measurement System

OmniPro Vision Systems

AccuScan Measurement System


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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 sensor’s

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.


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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 on-line 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 RS-232, DeviceNet, and Profibus protocol support.


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Laser Scanning Measurement

Principle

In 1972, the founders of Beta LaserMike introduced the world’s 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 cable’s 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 quality-

control 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 pre-

straightener.

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)

Ritu Ovality Project

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