A REPORT ON PRACTICAL TRAINING TAKEN AT National Engineering Industries Ltd. (NEI), JAIPUR, RAJASTHAN. FROM: 01.06.2012 to 30.06.

2012 IN THE PARTIAL FULFILLMENT FOR AWARD THE DEGREE OF Bachelor of Technology From Rajasthan Technical University

Session 2012-2013 Submitted To: Rajesh Ranjan Sir , Head of Department IIMET JAIPUR . Submitted by: Rahul Soni Mechanical Engineering, B.TECHIVYEAR, VII SEM IIMET.

Department of Mechanical Engineering International Institute of Management, Engg. & Tech. Sitapura Industrial Area, Tonk Road, Jaipur

ACKNOWLEDGEMENT
It is a matter of great pleasure for me to express my profound feelings of reference to my worthy advisor MR. LALIT MOHAN SHARMA [NATIONAL ENGINEERING INDUSTRIES LIMITED, JAIPUR (project head)]. As his inspiring guidance and everlasting enthusiasm have been valuable assets during the tenure of my training. The beatitude, bliss, and euphoria that accompany the successful completion of any task would not be complete without the expression of appreciation of simple virtues to the people who made it possible. So, with reverence, veneration honor I acknowledge all those guidance and encouragement has made successful in winding up this. It gives me immense pleasure in acknowledge the help I have received while making this report on NATIONAL ENGINEERING INDUSTRIES LIMITED, JAIPUR. I owe my profound gratitude By Mr.V.K.Agrawal (H.O.D., ME) for his kind patronage and generosity. A great deal of thanks to Ms. Kailash Meena (Seminar Coordinator), Ms.Monisha Jain (T.P.O.) and entire faculty member for imparting knowledge success of the project. A seminar of this type naturally gained number ideas of the field of Mechanical Engineering. We would also like to express our heartfelt appreciation to all other people who help us.

Submitted To: Rajesh Ranjan Sir , Head of Department IIMET JAIPUR .

Submitted by: Rahul Soni , Mechanical Engineering, B.TECH IVYEAR, VII SEM IIMET.

ABSTRACT

This paper presents details of a computer interface developed for vibration monitoring and diagnostics of tapered roller bearings, based on experiments conducted for bearing fault diagnosis. An experimental set up was designed and fabricated for testing various tapered roller bearings to obtain their vibration characteristics three defect-free and nine defective tapered roller bearings were tested. The defective bearings tested were: bearings with outer race defects, roller defects and combination of both. The bearing vibration data were acquired using NI DAQ and Lab View Virtual Instrumentation Software, which were further processed using computer interface developed for diagnostics. The computer interface used various time and frequency domain parameters like: peak to valley, RMS value, kurtosis, skew-ness, envelope analysis, etc. to diagnose faults in bearings. The interface was able to diagnose point defects in the tapered roller bearings. The above computer interface, with some modifications can as well be used for diagnosing defects in plain roller bearings also.

Submitted To: Rajesh Ranjan Sir , Head of Department IIMET JAIPUR .

Submitted by: Rahul Soni , Mechanical Engineering, B.TECH IVYEAR, VII SEM IIMET.

PREFACE

As a part of curriculum prescribed by the Rajasthan Technical University for the degree of B. Tech of engineering a total of 30 days practical training is required by the student of engineering, 34 days taken by me at:

NATIONAL ENGINEERING INDUSTRIES LIMITED, JAIPUR (RAJ.) From: 01 JUNE 2012to 30 June 2012.

The tanning report infects a summary of what my Practical Training under Large Dia. Bearing (LDB) Division. This report prepared during the practical training which is students first and greatest treasure as it is full of experience, observation and knowledge. The summer training was very interesting and gainful as it is close to real what have been studied is all the years through was seen implemented in a modified and practical form. The student wishes that this Gorgeous Private Sector undertaking success so that it may flourish and serve the nation which has reached significant years of its independence and has to achieve many goals. NATIONAL ENGINEERING INDUSTRIES LIMITED, JAIPUR

Submitted To: Rajesh Ranjan Sir , Head of Department IIMET JAIPUR .

Submitted by: Rahul Soni , Mechanical Engineering, B.TECH IVYEAR, VII SEM IIMET.

INDEX 1. INTRODUCTION 2. CERTIFICATE 3. ACKNOWLEDGEMENT 4. ABSTRACT 5. PREFACE 6. DEFINITION OF INDUSTRY 7. INTRODUCTION OF NEI 8. INTRODUCTION OF BEARING 9. INTRODUCTION OF LDB DIVISION [i] [ii] [iii] [iv] [v] [1] [2] [3-5] [6]

10.MANUFACTURING PROCESS OF ROLLER FOR LARGE SIZE BEARING a. Black Roller (From HT) b. OD Grinding (Centre less) c. Hardening(From HT) d. OD Grinding (Centre less) e. Head (Honing) f. OD Grinding (Finish) [7] [8-9] [10] [10] [11-13] [14-15]

11.STUDY ABOUT PNUEMATIC MACHINE[16-25] 12.TROUBLE SHOOTING 13.CONCLUSION 14.BIBLIOGRAPHY 15.REFERENCE [26-27] [28] [29] [30]

Industrial linkage
When one Industry depends on the output of another This can cause problems if one industry has production problems or closes down The CAR INDUSTRY is a good example each component (engine parts, lights, body etc.) may be produced by a different company before it goes to the ASSEMBLY PLANT.

Bearing Industry Global Scenario:The world Market of quality Bearing is very vast. The Big players of bearing sector are present in U.S.A, Russia, Japan, China and Eastern Europe. Some of leading bearing Manufacturers are: - NSK Japan - NTN Japan - KOYA Seiko Japan - FAG Germany - SKF Sweden - NRB France - Timken USA There are few of leading bearing manufacturer present in India. Most of the big player is having either technical or financial Collaboration with leading Auto-Manufacturer International Collaboration gives Access to best technology in the world.

BEARING INDUSTRY INDIAN SCENERIO:-

The Indian Bearing Industry is estimated at Rs. 30 Billion Approximately. The Industry has established a highly diversified product range of around 1000 type of Bearing having High Volume Demand. As much as 70% of the total Demand for common varieties and size of bearing is met by the domestic Industry, and the remaining demand to the tune of 30% is imported essentially for Industrial Application and special purpose. The Indian bearing Industry can be divided in to the organized sector and un-organized sector. The organized sector primarily caters to the original equipment Manufacturer (OEM) Segment, which predominantly comprises automotive industries and other mechanical Industrial users. The replacement market is dominated by unorganized Sector.
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ABOUT NEI

Bearing in India started with the setting up of manufacturing unit in JAIPUR by the Birla Group in 1946 under the name of "National Bearing Company Ltd." The 1st Bearing was manufactured in 1950 with a modest start of 30 thousand bearing in 19 Sizes. The Bearing Races (Soft) was Manufactured by the Tiny Unit in the Small Scale Sector at Jaipur during 1970 on Job Work basis. It is a view to utilize the end piece of the Stainless steel tube which could not be fed to the Multi operation of National Engineering Industries Jaipur. There after there is a continuous growth of this Industry and now it has grown to a level that Almost All the Leading Manufacturer of the country are procuring Soft Bearing Races from JAIPUR. The National Engineering Industries procure lakes of Ring every month from these Bearing Race Manufacturing Unit. The other leading manufacturer like S.K.F., FAG, TATA Bearing, NBC are also procuring the Bearing races from Jaipur. In addition to above, the Small Scale Units manufacturing bearing in the state of Rajasthan, Delhi, Gujarat and Punjab also purchasing Bearing Races and components from Jaipur.

BEARING:A bearing is a device to allow constrained relative motion between two or more parts, typically rotation 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.

TYPES:-

There are many different types of bearings. Type Description Friction Stiffness

Speed

Life

Notes

Rubbing surfaces, usually with lubricant; some Plain bearings use bearing pumped lubrication and behave similarly to fluid bearings.

Depends on materials and construction, PTFE has coefficient of friction ~0.05-0.35, depending upon fillers added

Good, provided wear is Low to low, but very some high slack is normally present

Widely used, relatively high friction, suffers from stiction in some Low to very applications. high - depends Depending upon application upon the and lubrication application, lifetime can be higher or lower than rolling element bearings.

Ball or rollers Rolling are used to element prevent or bearing minimize rubbing

Rolling coefficient of friction with steel can be ~0.005 (adding resistance due to seals, packed grease, preload and misalignmen t can increase friction to as much as 0.125)

Good, but some slack is usually present

Moderat e to high (often requires cooling)

Moderate to high (depends on lubrication, often requires maintenance)

Used for higher moment loads than plain bearings with lower friction

Off-center Jewel bearing rolls in Low bearing seating

Low due Low to flexing

Adequate (requires maintenance)

Mainly used in low-load, high precision

Fluid is forced Zero friction Very Fluid between two at zero high bearing faces and held speed, low in by edge seal

Very high (usually limited to a few hundred feet per second at/by seal)

Virtually infinite in some applications, may wear at startup/shutdow n in some cases. Often negligible maintenance.

work such as clocks. Jewel bearings may be very small. Can fail quickly due to grit or dust or other contaminants . Maintenance free in continuous use. Can handle very large loads with low friction.

Zero friction at zero speed, but constant power for levitation, Faces of eddy bearing are currents are Magneti kept separate often by magnets Low c induced bearings (electromagnet when s or eddy movement currents) occurs, but may be negligible if magnetic field is quasi-static

Active magnetic bearings (AMB) need considerable Indefinite. No power. Maintenance practical Electro free. (with limit dynamic electromagnets) bearings (EDB) do not require external power.

Very high or Limited low depending range of Material flexes on materials and movement, Very strain in Flexure to give and Very low Low no backlash, high. application. bearing constrain extremely movement Usually smooth maintenance motion free. Stiffness is the amount that the gap varies when the load on the bearing changes, it is distinct from the friction of the bearing.

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LARGE DIA. BEARING DEVISION

(High Chromium Steel) Heading Machine Flashing (Rough Grinding) (High Grind Oil + H2O) Soft Grinding ( (High Grind Oil + H2O) Heat Treatment Work Hardening Tumbler Hard Grinding (G2) Finish Grinding (G3) (Kerosene) Rough Lapping (L1) Finish Lapping (L2) Ultra Sonic Washing Machine (Kerosene) Visual Inspection Anti-Rust Oil Packaging Maxi Grind Oil + H2O and High Grind Oil +H2O (Coolant)

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BLACK ROLLER (Heat Treatment Process) LDBs Tapered Roller Bearing:Tapered roller bearings are designed in such a way that vertices of the cone for each roller and those for the inner and outer raceways coincides on the bearing axis or extensions of the raceways and rollers converge at a common point on the axis of rotation. This results in true rolling motion of the rollers on the raceways at every point along the rollers. The tapered roller bearings support radial loads and axial loads from one direction only. The line contact between rollers and raceways provide the bearings with a high load carrying capacity. Steep angle tapered roller bearing with exceptionally steep cone angle enables the bearings to take heavier axial load. The bearings are of separable type, enabling separate mounting of cups and cones. Since the tapered roller bearings can absorb thrust loads in one direction only, these bearings should generally be installed as opposed mountings. The correct amount of radial and axial clearance is obtained by adjusting the two bearings against each other. Besides, double row and four row tapered roller bearings are also widely used for heavy loads such as rolling mills. The inner and outer ring raceways are segments of cones and the rollers are also made with a taper so that the conical surfaces of the raceways and the roller axes if projected, would all meet at a common point on the main axis of the bearing.

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OD GRINDING (CENTRELESS) LDBs Taper Roller Bearing:This conical geometry is used as it gives a larger contact patch, which permits greater loads to be carried than with spherical (ball) bearings, while the geometry means that the tangential speeds of the surfaces of each of the rollers are the same as their raceways along the whole length of the contact patch and no differential scrubbing occurs. When a roller slides rather than rolls, it can generate wear at the roller-to-race interface, i.e. the differences in surface speeds creates a scrubbing action. Wear will degenerate the close tolerances normally held in the bearing and can lead to other problems. Much closer to pure rolling can be achieved in a tapered roller bearing and this avoids rapid wear. The rollers are guided by a flange on the inner ring. This stops the rollers from sliding out at high speed due to their momentum. The larger the half angles of these cones the larger the axial force that the bearing can sustain. Tapered roller bearings are separable and have the following components: outer ring, inner ring, and roller assembly (containing the rollers and a cage). The non-separable inner ring and roller assembly is called the cone, and the outer ring is called the cup. Internal clearance is established during mounting by the axial position of the cone relative to the cup. RAW MATERIAL:The Races & Rolling elements of Bearing are subjected to stress on a very small contact surface must be of such material also as to with stand wear and have high elastic Limit & fatigue Limit. The raw material being used by the Industry for Manufacturing of various Bearing components are as under:

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CUP AND CONE:The raw material used in the Manufacturing of bearing Races is SAE 52100 high Carbon Chrome bearing steel, which has composition similar to EN-31 (100 CR 6 As per BIS specification). The raw material for Bearing Races is in the form of Rods & Seamless Hollow Tubes. This is a Spheroids Annealed Steel. Approx. 80% of the Seamless Hollow tubes are purchased by the Industry from M/s. Indian Seamless Metal tube PUNE, while the rest of the tube used in the cluster is imported material. The Steel bars are purchased from M/s. Indian Seamless Steel & Alloy Pune & M/s. Mahindra U gin Steel Company KHAPOLI (Maharashtra). Some of the units are buying the steel scrap rod for manufacturing bearing races. Bearing Races material and their heat treatment are required to be selected carefully, taking account the mechanical strength and required life of the Bearing, Approximate required composition for bearing races are Constitute % Composition Carbon Chromium Manganese Silicon Sulphur Phosphorous CAGE'S:Cage is used to return balls at proper distance to prevent them from containing each other and to prevent a temperature rise and resultant damage due to friction. The Material for manufacturing cages is CRCA Strips ofC2015 Bearing grade steel having carbon percentage at0.08% max and Magnesium ranging from 0.25% to 0.45% MANUFACTURING PROCESS OF TAPER ROLLER BEARING Forged rings (De-scaled) as raw material (SAE 52100 steel) Turning Operation Centre Less Grinding
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0.95 to 1.1 1.4 to 1.6 0.50 max. 0.15 to 0.35 0.025 (Max.) 0.05

Heat Treatment Hardness Testing Rough Grinding Finish Grinding Honing & Super Finishing Washing Application for Rust Preventive Ready For Dispatch to Assembly HARDENING (Heat Treatment Process) Heat treatment process is the process of hardening the soft material. The row material is soft material and it has to be hardened before grinding, and hardening increase the life of bearing. Hardening is done in a special furnace named CHUGAIRO furnace. The soft machined material is feed in the furnace and washed at 600 C, then send to a chamber where the material heated in four chambers the first chamber has the temperature 8400 C and further chamber contains the 8500 C temperature. Then it dipped into an oil tank at temperature 250C where the material get quenched then it washed and then it tempered in water about 90 min. at temperature 1050 C . then dried and cooled in air. The hardened material is obtained.

The systematic flowchart is shown in following fig:

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Fig2: flowchart of heat treatment

After heat treatment following process are done: HEAD (HONING) DIFFERENT PROCESS FOR CONE:Dimensions Checking:Before starting the grinding process, various dimensions of cone should be checked in a machine or manually. Various dimensions to be checked are: Flange diameter Cone width Cone track diameter Bore diameter Face Grinding:Face is the surface at side of the inner and outer race , face should be finished indeed to get the desire width of the bearing and since the bearing is a mating part and it has to be assembled
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somewhere in the machine where it should be fit precisely. The face grinding is done in a machine where the faces are grinded in between the grinding wheel. Size Limit : : Width Variation : UCL +35 m LCL 5m -35 m

There are various semi-automatic face grinding machine installed in taper section for cone 1. DAISHO MACHINE 2. NISSEI MACHINE 3. NISSEI MACHINE

OD (Outer Dia.) Grinding OD is the circumferential surface of the outer race of the bearing. The OD should be surface finished since the bearing has to be assembled in machine. It is obtain in an OD grinding machine. In this machine the outer race is rotated between two grinding wheel.The outer race is passed in machine three times to get highly finished as follows: 1. 2. 3. Rough1 Rough2 Fine finish : : 15 to 35 m +30 m

Size Limit Target Size

Flange Grinding:The flange should be surface finished since the bearing has to be assembled in machine. It is obtain in the flange grinding machine. In this machine one grinding stone is used to cut and grind the flange portion of cone. NC Mode Feed Mode Override AUTO AUTO 120% (used to change machine speed.)

Tool movement during grinding is in all three dimensional axes i.e. X, Y, Z axis.

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Bore Grinding:Bore is the inner circumferential surface of the bearing. The bore should be surface finished since the bearing has to be assembled in machine. It is obtain in the bore grinding machine. In this machine the grinding stone is moved in X and Y axis. Size Limit : +4 m to -4 m.

TOOL movement during grinding is in only two dimensional axes i.e. X, Z axis.

Auto Dimension Check:Various dimensions of cone are checked in this machine. This machine includes various sensors for sensing the dimension of cone. This machine use weight sensors and position sensors to identify the position and weight of cone. All dimensions should be checked in this machine. M1 M2 M3 M4 M5 M6 0.7 2.1 -2 -0.2 1.6 0.9 ID1 - X ID 2 - X TAPER ID1 - Y ID 2 Y OVALITY

It automatically discards the work piece if its dimensions are not compatible with pre-feed data. The limitations of size are: Size limit TAPER OOR CHATTER SQUARENESS Honing Machine:Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture. : : : : : +4m to -4 m. 5 m maximum 5 m maximum 3 m maximum 5 m maximum

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DIFFERENT PROCESS FOR CUP:OD Grinding:OD is the circumferential surface of the outer race of the bearing. The OD should be surface finished since the bearing has to be assembled in machine. It is obtain in an OD grinding machine. In this machine the outer race is rotated between two grinding wheel. The outer race is passed in machine three times to get highly finished as follows: Rough1, Rough2, Fine finish.

Size Limit Target Size Honing Machine:-

: :

15 to 35 m +30 m

Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture.

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OD GRINDING (FINISH) ASSEMBLY LINE:Once respective CUP and CONE of corresponding bearing is finished, they are sent in the Assembly line where these cup and cone get assembled with retainers having rollers in them and after some important test, they are finally packed and are ready for use.

Laser Printing Machine:It is a machine which is used for marking purpose of the company brand and specification on respective cup or cone. This technology utilizes laser beam for marking. The movement of laser beam is controlled by automatic 3d table movement. The point on metal surfaces where these laser beams hits leave marks as required. Names of few Laser Machine which are installed in Taper Bearing Section are: 4. 5. AKSHAR FIBER-PRO. SAJIAJANAND Laser Technology ltd.

Roll Filling Machine:It is an automatic machine which is actuated by pneumatic technology. In this machine, first Retainer is placed on first station where rollers are inserted at their respective position. Then they are sensed by position sensor, actuated by pneumatic and then cone is fixed within cage. Pressing Machine:It is an automatic machine which is actuated by pneumatic and hydraulic technology both. The Cone is pressed against Retainer with down stroke powered by hydraulics and upstroke powered by pneumatics. Weight check:At this station, Weight of bearing is checked and if the weight is not compatible with the given standard of weight limits, machine will reject the work piece sample. Demagnetizer:It is a machine which is used to remove magnetism induced during the above process. It is done by impact hitting. Washing: Then the bearing is washed by fast stream of kerosene jet.
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Noise checking: The bearing is supposed to be produce low noise hence this machine rotates the bearing at certain rpm and noise is checked. The noise limit is nearby 0.1 Mpa.

Press checking:At this station, the bearing is checked whether its assembly is pressed properly or not. Final checking:This machine has 2 or 4 stations where various dimensions of final bearing are checked. If any bearing is found incompatible with the given dimensions and tolerances, they are rejected by the machine. In ideal position 1, width of bearing, run out and comment or clearance of bearing is checked. And at ideal position 2, bore size, taper and roundness are checked. All those bearings which does not have compatible size and tolerance with the given data, they are rejected by the machine itself. Ideal position 1 Ideal position 2 : : width, run out, comment bore size, bore taper, bore roundness

Oiling and Drawer Machine:In this machine, bearing is subjected to a fast flowing stream of coolant which is used to lubricate the bearing parts. And then the excess oil is again sucked by the machine. Visual Inspection:Now, the bearing is checked manually by the operators. All the dimensions and surface properties are checked and rejected work piece are sent again for correction. Packing:Finally, finished product is packed for market use and export.

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THE PNUEMATICS TECHNOLOGY INVOLVED IN ROLL FILLING AND PRESS WORKING MACHINE.
In todays challenging environment, technology departments are in danger of being crushed between the pincers of growing business expectation and an unstinting focus on cost control and development. Introduction of pneumatics:A fluid power system is one that transmits and control energy through the use of pressurized liquid and gases. In pneumatics, the power comes from the atmosphere and it is reduced by compression, thus increasing its pressure. Compressed air is mainly used to do work by acting on a piston or vane. Basic application of pneumatics:6. 7. 8. Operation of system valves for air, water and chemicals. Lifting and moving in slab molding machine. Holding in jigs and fixtures in assembly machinery and tools.

Basic pneumatic system:Pneumatic cylinders, rotary actuators and air motors provide the force and movement of most Pneumatics control system, to hold, move, and form and process material. To operate and control these actuators, other Pneumatics components are required i.e. air service unit to prepare the compressed air and valve to control the pressure, flow2 and direction of movement of the actuators. A basic Pneumatics system consists of 2 main sections: 9. 10. 11. 12. 13. 14. 15. 16. 17. The air production and distribution system The air consuming system Air production system Compressor Electric motor Pressure switch Check valve Tank Pressure gauge

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18. 19.

Air dryer Line filter

Air consuming system:20. 21. 22. 23. 24. Air take-off Auto drain DCV Actuators Speed controllers

Block diagram of roller filling and press machine:-

No cone No roller Roller unit Cone supply transfer orientation

Cage positioning

set

Assembly unit

press

check

discharge

No cage

Cage Assembly Unit Cage supply

Major process carried out by pneumatics in roll filling and press machine:Main components of roll filling and press machine which are actuated by pneumatics: 25. 26. 27. 28. Cage supply Cage positioning Roller filling in cage Cage and roller assembly check
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29. 30. 31.

Cone supply Pressing Check and discharge

Direction control valve:A directional control valve determines the flow of air between its ports by opening, closing and changing its internal connections. The valves are described in terms of the number of ports and the number of switching position, its normal position, and the method of operation. The first two points are normally expressed in terms 5/2, 3/2, or 2/2etc

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25

Mono-stable and bi-stable valve:Spring returned valve is mono-stable. They have a defined preferred position to which they automatically return. A bi-stable valve has no preferred position and remains in either position until one of its two impulse signals are operated.

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Valve types:-

Poppet valve Direction Control Valve Sliding valve Spool valve Rotary valve Plane Slide valve

Elastomer seal

Metal seal

Poppet valve:- flow through a poppet valve is controlled by a disc or plug lifting at right angles to a seat, with an elastic seal. Sliding valve:- spool, rotary and plane slide valves use a sliding action to open and close ports. Spool valves:- a cylindrical spool slides longitudinally in the valve body with the air flowing at right angles to the spool movement. Spools have equal sealing areas and are pressure balanced. Elastomeric Seal:- common seal and seal arrangements are as shown in figure. O rings are fitted in grooves on the spool and move in a metal sleeve. Two of them are crossing output ports, which are divided into a great number of small holes in the sleeve.

Metal seal:Lapped and matched metal spool and sleeve valves have very low frictional resistance, rapid cycling and exceptionally long working life. Plane slide valve:Flow through the ports is controlled by the position of a slide made of metal, nylon or other plastic.

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Rotary valves: A metal ported disk is manually rotated to inter connect the ports in the valve body .Pressure supply is above the disc.

Basic Rules For Drawing Pneumatic Circuits & Symbols Pneumatic circuits are represented by common symbols and should be drawn following several basic guidelines. By following these guidelines engineers can quickly and simply construct circuits that can be easily and safely interpreted by all those involved in system design, specification, manufacturing and maintenance. The symbols used for constructing fluid power systems and for defining individual components are detailed in the standard ISO 1219, which covers both pneumatic and hydraulic devices. This states that: A symbol consists of the lines, letters and abbreviations which identify the purpose and method of operation of the component represented. The symbols show connections, flow paths and the functions of the components represented. The symbols do not indicate the physical location of ports or the position of control elements on actual components. With certain obvious exceptions symbols may be reversed and/or rotated without altering their meaning. It should be noted, however, that the ISO standards do not always keep abreast of developments in pneumatics technology, so that new products often fail to be clearly defined until sometime after their introduction. As a result, product manufacturers often use proprietary symbols until such time as a standard unit is defined. The situation can be further confused by the fact that the Japanese Industry Standard (JIS) and the American Standards Authority (ASA) also use differing sets of symbols. All three standards authorities use common symbols for air preparation equipment and, with a few exceptions, valves; the JIS, however, reflecting the greater diversity of equipment originating in Japan, often uses different symbols for special purpose or newly developed actuators. For most pneumatic circuits, however, the standard ISO nomenclature is adequate, with the
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majority of air preparation, air treatment, actuators, valves and ancillary components being defined by common symbols. A complete list of symbols and guidance on their construction is available. When constructing a circuit diagram, there are always basic rules that should be followed. The flow of working energy in a circuit diagram is drawn from the bottom to the top of the diagram The sequence of the working cycle is from left to right of the circuit diagram; the air supply is therefore shown at the lower left, with the cylinder that performs the first stroke of the cycle being situated in the upper left. Power valves are drawn directly below the cylinders they operate. All circuit components are shown in their rest position, with the supply under pressure. Electrical connections are not generally shown. Mechanically operated valves, controlling the rest position of cylinder driven parts, are operated in the rest position and must be drawn accordingly; external connections are drawn to the valve symbol square on the operator side.

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Fig: ISO symbols for Air Treatment Equipment

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Basic Pneumatic Circuits:-

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TROUBLESHOOTING:Appearance Small indentations around the raceways and rolling elements. Dull, worn surfaces. Cause Action Photo Outer ring of a spherical roller bearing with raceways that have been worn by abrasive particles. It is easy to feel where the dividing line goes between worn and unworn sections.

Lack of Do not unpack cleanliness before bearing until just and during before it is to be mounting mounted. Keep operation. workshop clean and use clean tools.

Grease discolored green.

Ineffective seals

Check and possibly improve the sealing. Always use fresh, clean lubricant. Wipe the grease nipples. Filter the oil.

Lubricant contaminated by worn particles from brass cage

Appearance

Cause

Action

Photo

Worn, frequently mirror-like, surfaces; at a later stage blue to brown discoloration.

Lubrication has gradually been used up or has lost its lubricating properties.

Check that the lubricant reaches the bearing. More frequent re lubrication.

Outer ring of a spherical roller bearing that has not been adequately lubricated. The raceways have a mirror finish.

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Appearance
Depressions in raceways. These depressions are rectangular in roller bearings and circular in ball bearings. The bottom of these depressions may be bright or dull and oxidized.

Cause
The bearing has been exposed to vibration while stationary.

Action
Secure the bearing during transport by radial preloading. Provide a vibrationdamping base. Where possible, use ball bearings instead of roller bearings. Employ oil bath lubrication, where possible.

Photo
Outer ring of taper roller bearing damaged by vibration during operation.

Vibration damage to the ring of a cylindrical roller bearing. The damage has arisen while the bearing was not running.

Inner and outer ring of a cylindrical roller bearing exposed to vibration. The inner ring has changed position.

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CONCLUSION

My training at NATIONAL ENGINEERING INDUSTRIES, JAIPUR was very fruitful and I gained a lot of practical knowledge about various manufacturing processes and techniques. I also got the opportunity to realize the challenges faced and expertise required in manufacturing processes for mass production. It was indeed a great experience undergoing training at the plant.

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BIBLIOGRAPHY

PLANT RECORD (Notes) A COURSE IN MECHANICAL POWER PROTECTION OF POWER SYSTEM POWER TRANSFORMER ELECTRICAL ENGINEERING PRODUCTION ENGINEERING

: : : : : :

Files R.K.Bansal B. Ram Tata Magr. Hill Tata Magr. Hil P.C. Sharma ArvindPalmgren James J.Oconnor Arvind Palmgren

BEARING CONTENTS AND ENGINEERING: LUBERICATION ENGINEERING :

BALL AND ROLLER BEARING ENGINEERING:

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REFERENCE

WEB-SITES:1. 2. 3.
4.

www.wikipidya.com www.powersystems.com www.powerengg.com www.protectionofelectricalsystem.com

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