CASE STUDY ON TAPER ROLLER BEARING

 Design input parameter:

1. Inner diameter =Ø 65.0 mm
2. outer diameter =Ø120.0 mm
3. Total width = 32.75 mm
4. Load:-
Static = 15.9 tones
Dynamic = 21.6 tones
5. R.P.M. = 500
6. Quantity of bearing = 1000 nos.
7. Material = SAE 52100

 Design procedure:
1) Assembly drawing
2) Detail drawing
 Parameter:
1) No of roller = 19
2) roller angle( 4˚)
3) roller size = Ø 15 x 21.5 mm
 Cycle time (per 1000 piece)
Procurement - 10 days
Forging - 1 week
Heat treatment - 3 days
Turning - 3 days
Grinding - 3 days
Assembly -3 days
Packing -1 days
Total time -30 days

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 Manufacturing Procedure:

1.Material Procurement:- The material has to buy from

the vendors of appropriate size.
2. Material Inspection: Metallurgical inspection has to
carried out to check the raw material defects and
composition.
3. Raw material (SAE52100) cutting
Calculation for dia & length
Weight = (π/4) x (Do2 –Di2) x density x 1.08.
The raw material has a add some allowances as
3.5mm per side for machining and H.T. (depends on its
size)
It should be also consider 8% for burning loss in the
forging.
4.Forging : Forging is the "mechanical deformation of
metal when heated to a permanent deformation".
The forging operation will improve the mechanical
properties of metal like toughness, hardness, strength,
etc.
Mainly closed die forging is done to get the closer size.
And reduce the cycle time.
RAW MATERIAL FORGING TURNING
(mm) (mm) (mm)
I.D. O.D. W DIA L I.D. O.D. L

I.R. 58 98 35 60 60.7 62 94 33

O.R. 92 127 32 65 58.1 95 124 29

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5.Annealing:-
- Spherodizing annealing: To improve the mach inability
of the annealed hypereutectoid steel Spherodize
annealing is applied. This process will produce a spheroid
or globular form of a carbide in a ferritic matrix which
makes the machining easy.
-The benefits of a Spheroidize
annealing are :
• Improved ductility.
• Removal of residual stresses
that result from cold working or
machining.
• Improved machinability.
• Grain refinement

6.Metallurgical testing:- The

metallurgical inspection of the
material as mention in the table for soft condition.
7.Turning:- the turning operation is mainly done in the
lathe machine to get closer size having grinding and
H.T. allowances.
-Rough:- the rough tool is used to cut the material with
more depth of cut then finishing.
-Finish: the finished tool is used to cut the material.
8.Dimensional & visual testing:- this testing is to be
done after each machining operation.

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9.Heat treatment
-Quenching: In this process bearing is heated in
furnace at 845-850 °C & quenched into quenching oil
at about 75 °C.Due to this the hardening of the bearing
increases at 60-64 HRC.
Zone 1st :- 795+10˚
Zone 2nd :- 825+10˚
Zone 3th :- 850+5˚
-Shocking time:- It is also a great factor for heat
treatment. It calculated by
Thikness x 4.8 x 60 = _____ seconds
The constant may varies from 4.32 – 5.28.
-Tempering :In this process the material is heated
uniformly at about 170-220°C and then cool
uniformaly to relief stress in the bearing.
10.Metallurgical & Dimensional test:- The metallurgical
inspection of the material as mention in the table for
heat treated condition.
Austenitized at 1450˚F (790˚C) or 1550˚F( 845˚C) for
½ hour, oil quenched, tempered at 350˚F (175˚C) for 1
hour. Black areas are bainite, grey areas are tempered
martensite, white dots are carbide particles that did not
dissolve during austenitizing. The test is in
4% natal:- nitric acid & alcohol.
4% picral:- pictric acid & alcohol.

11.Inprocess store: In this store the materials are

classified on the basis of grinding operations.
12.Face Grinding: In this operation facing is done
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13.OD Grinding :
Outer race: This is used to maintain the outer diameter
of the bearing.
14.ID Grinding:
Inner race: This is used to maintain the outer diameter
of the bearing
15.Lip Grinding: In this operation small corner slots are
provided for oiling & better assembly.
16.Track Grinding :
Inner race :It is used to maintain taper(11°4’) & outer
diameter
Outer race:It is used to maintain taper(15°4’) & outer
diameter.
17.Superfinishing :
Honning :It is a abrasive machining process that
produce a precision surface by scrubbing an abrasive
stone against it along a control path.
-It is primarily used to improve geometric form of
structure & surface texture.
18.Tumbling:-
Tumbling is done after heart treatment to remote the
black film from the roller surface and after grinding
process is finished to get the mirror polished surfaces.
In tumbling process, rollers are gathered in the drum is
rotated by electric motor at 40 to 50 RPM..
19. Assembly:
The assembly of the inner race, outer race, retainer
and roller are done.
20. Demagnetize:
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 It is used to remove residual magnetic field.
21.Cleaning & oiling of bearing:
Washing with the kerosene and then oiling of bearing
done to improve life of the bearing. Then it is checked
by rotation.
Some of the bearing require Greasing which doesn’t
require oil washing.
22. Marking:
Laser beam machine (etching) is for marking which
contain company name, bearing specification and
country.
23. Packing:
The bearing are packed in the plastic wrapper and box.
24. Bonded storage room:-
This department is responsible for the record keeping
of manufactured bearing, dispatch of bearing and also
keeping the record of customers to which bearing are
yet to be supplied.
 General notes:
The elements of bearing should be made according to
geometrical tolerances like eccentricity, circularity,
squareness, parallisum, cylindricity, concentricity,
angularity, etc.. within 5- 8 µm.
This above tolerance is effect the life of the bearing.

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INNER RACE OF TAPER ROLLER BEARING

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