bearing market

1. 1
Technology Study Report
on
Bearing Industry
- : Prepared By : -
MSME - Development Institute, Government of India
Ministry of Micro Small and Medium Enterprises
Bais Godam, Jaipur – 302 006 (Raj.)
Ph. 0141-2212098, 2213099, Fax. 2210553
e mail- dcdi-jaipur@dcmsme.gov.in
web- dcmsme.gov.in

2. 2
CONTENTS
Page
• SCOPE OF THE REPORT
• METHODOLOGY
1 PRESENT STATUS OF TECHNOLOGY 1 - 22
1.1 Introduction
1.2 Industry Overview
1.3 Global Collaboration
1.4 Status of Bearing and Bearing Component Cluster at Jaipur
1.5 Raw Material
1.6 Plant and Machinery in SME Sector
1.7 Manufacturing Process
2 IDENTIFYING TECHNOLOGY GAP 23 - 27
3 THRUST AREAS FOR TECHNOLOGY & TECHNOLOGY GAPS 28 - 32
4 PROPOSED ADVANCE TECHNOLOGY & ITS BENEFITS 33 - 39
5 PROJECT PROFILE 40 - 49
Annexures
a. Technology Providers
b. Quality Standards (BIS)
c. Chemical Composition of Through-Hardening Bearing Steels Composition
(%)

3. 3
SCOPE OF THE REPORT
This Technology Study Report on Indian bearings industry covers overview
of the industry, Present status of Technology being used by the MSME sector in
manufacturing the product, Technological Gap, Modernisation & technological Up
gradation aspect of bearing Industry & highlighting benefit of proposed technology
over the existing technology and its viability in keeping view of the competitive
markets as well as international competitiveness. The report is useful for bearings
and component manufacturers, end user industries like automobile, machine tools,
steel and equipment manufacturers ring, bearing component manufacturers, raw
materials suppliers like steel industry, commercial and investment banks,
investors, business analysts, consultants and students.

4. 4
METHODOLOGY
Technology Study Report is prepared as per guide line given by DC(MSME). The
interaction with following prominent Bearing & Bearing component Manufacturers were
carried out to know more about present status as well as latest proven technology has
been adopted by MSME & Large Bearing Manufacturers. Some advance plant &
machinery suppliers were also contacted over phone or through internet.
Contact Person Collaborations/ Products
Advance Technology
Mr. K. N. Kansara Nadella - France Rollers
KANSARA ENGINEERS PVT. NSK- Japan (CYLINDERICAL,
LTD. (A Unit of Sewaram Kansara NTN - Japan SPHERICAL,
Group), E-36,M.I.A. Phase II, NEEDLE, TAPER)
Basni, Jodhpur - 342005 (INDIA)
Phone : +91-291-2745500,
2745501, Fax : +91-291-
2435187, 2745502
Email :
skbearings@skbearings.com
Web : www.skbearings.com
Mr. Rohit Saboo, President & ( a. ) BRENCO Ball Bearing ,
CEO Incorporated , U.S.A. Steel Ball,
Email : rsaboo@nbcbearings.in Since 1982-For Tapered Roller
Mr. Devendra Mishra Vice Cartridge Tapered Bearing, Railway
President Manufacturing Roller Bearings for Bearing (Roller
devendramishra@nbcbearings.in Railway wagons and Bearing in Axle
NAIONAL ENGINEERING Locomotives. Box, Spherical
INDUSTRIES Ltd. www.brencoqbs.com Roller Bearing,
Khatipura Road,Jaipur -302 006 (b) NTN Corporation , Cartridge Tapered
Phone : 2223221 Japan Roller Bearing),
Fax : 0141-2221926.2222259 Since 1985-For Ball Large Diameter
E-mail : neisales@neibearing.com Bearings, Cylindrical & Bearing
Spherical Roller
Bearings.
Since 1997-For
Tapered Roller
Bearings.
http://www.ntn.co.jp (c)
Izumi Kinzoku Kogyo
Co. Ltd., Japan
Since 1996 - For re-
manufacturing,
retrofitting and
overhauling of grinding
and super finishing
machines for bearing
races.
http://www7.ocn.ne.jp/~
izk.co

5. 5
Mr. Vinod Agarwal, M.D. Hatebur Hotmatic Forged & Turned
Mr Namit Agarwal ,Director hotformers Bearing Race
Agrasen Engineering Industries (AMP 30 S)
Limited & Hatebur Coldmatic
F-198/199, Road No, 9F coldformers
Vishwakarma Industrial Area, Installation of Auto
Phone +91-141- 2330614 Turning Lines for Small
E-mail : DGBB from Tubes -
agrasenforge@gmail.com , Production capcity
namit.agarwal@agrasenengg.com 120,000 per day, SOP
. Mr. M.R.I. SHAIKH Hatebur Hatebur Hotmatic
( Indian Representative of M/S Umformmaschinen hotformers ,a fully-
Hatebur Umformmaschinen AG) AG automated Forging
CHRYSTEC MACHINE TOOLS Postfach 916 &Hatebur
PVT LTD, General Guisan- Coldmatic
103 Winner's Court, Lulla Nagar Strasse 21 coldformers
Pune 411040 CH-4153 Reinach produce precision
Maharastra, India Switzerland and complex parts
00912030527484 Tel.: +41 61 716 21 11 formed directly
Mobile: +91 (0) 9892249582 Fax: +41 61 716 21 31 from wire.
WEB SITE www.chrystec.com
Mr. M.K. Banthia, Director Ball Bearing Cage Ball Bearing
MANU YANTRALAYA production line Cages, Sheet
G-1/800, Sitapura Industrial Area, (Transfer Press) in Metal Components
Jaipur - 302 022, India Technical Collaboration and Dust Shields
TEL : +91-141-277 1412 with M/s Toho
FAX : +91-141-277 1410 Industrial Co. Ltd.,
E-mail : manujpr@sancharnet.in Japan was set up in
www.manuyantralaya.com 2000.
Mr. :- Pramod Mathur, Director Transfer Press Dust shield
M/S CHANDRA INDUSTRIES Form M/S CHIN FONG (Z-shield,)
A-1, Industrial Estate, Bais MACHINE
Godam, Jaipur-302006(INDIA) INDUSTRIAL CO.,
Phone:- +91-141- 2214246, LTD.
2213017, Fax:- =91-141-2211288 186 Chang Shui Road,
E-mail:- info@chandrashields.com Chang Hua, Taiwan
http:www.chandrashields.com 500 R.O.C.
TEL:+886-4-7524131
FAX:+886-4-7611920
E-
mail:sales@chinfong.c
om.tw
URL:www.chinfong.co
m.tw
Mr. Anil Agrawal , MD Conventional Lathes, Bearing Race
Low cost automated Turning
M/s Supersonic Turners Pvt. hydraulic lathes,
Ltd. Auto lathes (Ace
Works 1 & H.O. ,F-393(A), Road Machines) Perma line

6. 6
No. : 9F2,VKI Area, Jaipur-302
013 (Raj.) India
Works 2 : G-846, Road No. : 14,
VKI Area, Jaipur – 302 013
(Raj.) India
anil@supersonicjaipur.com
www. supersonicjaipur.com
Mr. Suryakant Gadia Conventional Set-Up KNK Bearing
M/S K.N.K.Bearings Pvt.Ltd., Suitable for Batch Type
114-115,Jhotwara Industrial Area Production
Jaipur, ( Raj.)
0141-2341952/2340638,
Fax:0141-2344133
knkbrg@dataone.in
www.knkearing.com

7. 7
Chapter - 1
PRESENT STATUS OF TECHNOLOGY
1.1 INTRODUCTION
The technology used is conventional type in unorganized sector. But the
organized sector players are using state of the Art Technology to manufacture the
bearings as per the global standards. The unorganized sector players are also
gradually switching over to technology up gradation.
The cluster units at Jaipur for bearing and Bearing component
manufacturing units are employing conventional technology, but with the cluster
level intervention the units have initiated technology. upgradation by employing
CNC Machine for turning, grinding, finishing, testing, etc.
The machining operation involved in manufacture of antifriction bearings
include forging of the rings, turning, heat-treatment, face and outer dia -grinding,
Bore and track grinding, finish and super finishing grinding , Demagnetizing,
cleaning, inspection assembly and packaging, etc.
The Product
The Bearing is a machine element used in rotating parts of virtually every
machine. Bearing permit smooth low friction rotary or linear movement between
two surfaces. It employs either a sliding or a rolling action. If we could reduce
friction by only 10% in all the rolling bearing in use today, it would mean an energy
saving equivalent to the combined out put of Not less than 25 large Nuclear Power
Stations. Bearing can be broadly classified into two segments:-
• Bimetal
• Antifriction – Bearings
Bimetal bearings (also known as engine bearings) are primarily used in engines
of automobiles or machines. The bearings are meant to reduce the friction

8. 8
between the moving parts of the engine crankshaft or crank shaft or associated
support surfaces.
Antifriction Bearings include Ball Bearings and Roller Bearings. Roller bearings
can further be subdivided into tapered roller. Cylindrical roller, Needle roller, thrust
bearings and other special application bearings. The main components of an
antifriction bearing are the inner race (ring), the other race (ring) the rolling
elements, cages (retainers) and seals. The following are the major types of
bearing.
a. Ball bearing
b. Cylindrical roller bearing
c. Taper roller bearing
d. Needle roller bearing
Further classification of these major categories is given below:
Single row deep groove ball bearings
Maximum capacity type ball bearings
Single row angular contact ball bearings
Duplex angular contact ball bearings
Double row angular contact ball bearings
Four point contact ball bearings
Self aligning ball bearings
Radial Ball Bearings
Ball and Roller Bearings
Ball Bearings
Thrust Ball Bearings
Roller Bearings
Radial " Roller Bearings
Thrust Roller Bearings

9. 9
Single direction thrust ball bearings with flat back face
Single direction thrust ball bearings with seating ring
Double direction thrust ball bearings with flat back face
Double direction thrust ball bearings with seating ring
Double direction angular contact thrust ball bearings
Single row cylindrical roller bearings
Double row cylindrical roller bearings
Single row tapered roller bearings
Double row tapered roller bearings
Spherical roller bearings
Cylindrical roller thrust bearings
Needle roller thrust bearings
Tapered roller thrust bearings
Spherical roller thrust bearings
1.2 INDUSTRY OVERVIEW:
The bearing Industry in India can be divided into three segments; the
organized sector, comprising 12 leading manufacturers, located at Rajasthan,
Gujarat, Maharastra, Andhra Pradesh, Karnataka, Tamil Nadu, West Bengal and
Jharkhand primarily cater to the OEM Segment which are predominantly
automotive, Railway and other Industrial users. The unorganized sector includes
the small scale manufacturers and manufacturers of spurious bearings. The
unorganized sector contributes to about 18% of the total Industry turn over. The
unorganized sector players have a strong regional presence and mainly cater to
the needs of the replacement markets. The Indian bearing Industry is estimated at
Rs. 100 billion. The domestic Industry caters to the 74 % of total demand for
common varieties & sizes. The organized sector units contribute around 53% of
the Industry sales. The imports are about 26% of the total demand of the industry,

10. 10
while about 18% import comes through official channels. There is also estimated
8% illegal imports. Legal imports generally represent the specialized / super
precision bearings not manufactured in India. Illegal imports generally represent
the entry of spurious imports of bearings. The legal imports are about Rs.1 8.00
billion while the spurious imports is about Rs. 8.00 billion.
The small scale units manufacturing bearing are mainly concentrated in
Rajasthan and Gujarat having 15 and 50 units respectively. The bearing
manufacturing units are also present in Delhi, Punjab, and Maharastra. The state
of Rajasthan has major concentration of about 100 bearing components
manufacturing units with 1000 to 1200 Vendors carrying out turning job work.
There are substantial No. of component manufacturing units in Gujarat,
Maharastra, West Bengal and Punjab also. The bearing component manufacturing
units are the vendors of organized sector, and unorganized sector bearing
manufacturing units for supply of inner & outer races, balls, rollers, cages, seals,
retainers & rivets. These components are also exported to Europe, United States
of America and other global customers.
There are about 450 to 500 number of spurious bearing assembling units situated in the
State of Punjab, Delhi and Gujarat, eating the market of organized & unorganized sector
players.
A number of global bearing manufacturers have established their units in
India through joint ventures or 100% ownership and more are expected to follow
suit.The Big player of bearing sector are present in U.S.A, Russia, Japan, China
and eastern Europe. Some of leading bearing manufacturer are : -
- NSK Japan
- NTN Japan
- KOYA Seiko Japan
- FAG Germany
- SKF Sweden
- NRB France
- Timken USA

11. 11
International Bearing Market
1.3 GLOBAL COLLABORATION
All the manufacturers in the organised sector have entered into collaboration
agreements for supply of complete process know how as well as supply of major
manufacturing machinery. The collaboration agreements are still valid and the industry
gets all assistance for process, know-how product development,customer development,
tool design, production control techniques etc from them. Most of the big player are
having either technical or financial Collaboration with leading Auto Manufacturer.
International Collaboration gives Access to best technology in the world.
GLOBAL COLLABORATION
COMPANY COLLABORATION
SKF India SKF Sweden
FAG Bearing India FAG, Germany
NEI NTN
NRB Nadella, France
ABC Bearing Ltd. NSK Japan
TIMKEN India TIMKEN USA
Bimetal Bearing Ltd. Clevite Corporation USA
Gabriel India Suspension Italy

12. 12
The Indian Bearing Industry, especially the companies having technical and
financial collaboration with Global player are expected to garner higher price in
export market
In view of the growing industrial and automobile sector, the growth in this
industry is going to be substantial . The requirement of bearings increasing day by
day in India in both the OEM and replacement market and increasing number of
small manufacturing industries developing in Jaipur (Rajasthan) Rajkot and
Surrender Nagar (Gujarat) and Punjab have come up in unorganized sector.
These industries are manufacturing from complete bearings to components and
supplying to leading players.
The following are the major manufacturers of bearings in India:
1. Associated Bearing Company Ltd., Pune (Maharashtra)
2. Asian Bearings Company Ltd., Hosur (Tamil Nadu)
3. Karnataka Ball Bearing Corporation Ltd., Mysore (Karnataka)
4. HMT Ltd., Hyderabad (Andhra Pradesh)
5. Tata Iron and Steel Company Ltd., (Bearings Division) Kharagpur
(West Bengal)
6. Shriram Bearings Ltd., Ranchi (Bihar)
7. National Engineering Industries Ltd., Jaipur (Rajasthan)
8. FAG Precision Bearings Ltd., Vadodara (Gujarat)
9. Antifriction Bearing Company Ltd. Bharuch (Gujarat) Lonavala
(Maharashtra)
10. Union Bearings Manufacturing Co., Porbunder (Gujarat)
11. Needle Roller Bearing Co. Ltd., Thana/Jalna (Maharashtra)
12. Shriram Needle Industries Ltd., Ranchi (Bihar)
13. Deepak Insulated Cables Ltd., Mysore (Karnataka) (Needle Bearings
Division)
14. Austin Engg Company Limited Junagadh , Gujarat

13. 13
15. Karnataka Ball Bearing Co Ltd., Mysore
16. Mysore Kirloskar Ltd, Harihar (Karnataka)
17. Needle Roller Bearings Ltd, Thane
18. Needle Roller Bearings Ltd., Waluj
19. SKF India Limited, Chinchwad , Pune
20. SKF India Limited, Bommasandra, Bangalore
21. Timken India Limited, Jamshedpur
22. ZKL Bearings India Pvt. Ltd.,
23. NTN (India) Limited
Market share of Big Bearing manufacturer companies in India
30.00
26.00
25.00 21.40
20.00
Market share in %
15.70
15.00
10.00 8.45
7.04
5.00 3.16
2.90 2.60
1.60 1.50
1.34 1.30 1.25 1.19 0.96 0.93 0.77 0.73 0.63 0.55
0.00
SKF Bearings India
FAG Bearings India
National Engineering industries
Timken India
NRB Bearings
Tata bearings
HMT Bearings
Harsha
ABC Bearings Ltd.
Sujana Industries
Kirloskar Oil Engines
Bimtel bearings
ARB Bearings
Austin
Mipco Seamless Rings
Asian
SBL
Texspin
Others
Imports
Name of Companies

14. 14
The Government of India has set up bearings cluster for development of
unorganized segment in Small and Medium sector and understand the market and
quality linkage and make them competitive and prepare them with the best benchmarking
practices in the sector.
1.4 STATUS OF BEARING AND BEARING COMPONENT CLUSTER AT JAIPUR
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 Ist 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. with
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 lakhs of Ring every month
from these Bearing Race Manufacturing Unit. The other leading manufacturer like
S.K.F., FAG, TATA Bearing, ABC are also procuring the Bearing races from
Jaipur. In addition to above , the Small Scale Units manufacturing Bearing in the
state of Rajasthan, Delhi, Gujrat and Punjab also purchasing Bearing Races and
components from Jaipur. Apart from Bearing Races there are Bearing
manufacturing SSI Units, Ball manufacturing Unit, and cage manufacturing unit
present in Cluster.
In the Jaipur Cluster, There are Approx 11 No. of SSI Bearing Manufacturing
Unit, about 90 No. of Outer & Inner Soft Races Manufacturing SSI Units and about
2000 No. of outer /Inner Races turning Tiny/Artisan units. Apart from above there
is one large scale bearing manufacturing unit at JAIPUR namely M/s. NEI Ltd.
owned by Birla Group.
The Bearing Manufacturing SSI Units of Cluster are producing 36 Lacs of
Bearing worth of Rs. 8 Crore and The Bearing Races 50 Lacs Quantity and other
Bearing components having the Approx worth of Rs. 100 Crore are produced In

15. 15
the Cluster. The Bearing and Bearing components units at Jaipur Cluster are
engaged in manufacturing of outer & Inner Races, Cages Dust shield, Balls, & Ball
Bearing.
The Detail of type and size of Bearing Races are as under:-
S.No. Type of Bearing Races Inner Dia Range
1. Ball Bearing Races 10mm to 80mm
2. Taper Roller Bearing Races 17mm to 100 mm
3. Cylindrical Roller Bearing Races 20mm to 75 mm
4. Special type of Bearing Races
for Transport Vehicles (Thrust Bearing) 20mm to 75 mm
5. Axle Box Bearing Races for Railway
passenger coaches and wagon 100mm to 200mm

16. 16
1.5 Raw Material
. 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 Spherodised Annealed Steel. Alloy
Steel wire rods are used for the manufacture of rollers & balls. The cages and
retainers are made out of plain carbon steel of 1008 & 1015 grade.Other materials
like stainless steels are also used as per the customers requirements .
Approximate required composition for BEARING RACEs are:-
• Constitute % Composition
• Carbon 0.95 to 1.1
• Chromium 1.4 to 1.6
• Manganese 0.50 max.
• Silicon 0.15 to 0.35
• Sulphur 0.025 (Max.)
• Phosphorous 0.05
• Oxygen Content Note more than 15 ppm
CAGE'S
• The Material for manufacturing cages is CRCA Strips of
• C2015 Bearing grade steel having carbon percentage at
• 0.08% max. and Magnesium ranging from 0.25% to 0.45%
BALL'S
• Steel Balls of grade 20, 16 &10 with close tolerance,
• smooth surface made by using SAE 52100 High Carbon
• Chrome Bearing Steel.
1.6 PLANT AND MACHINERY IN MSME SECTOR

17. 17
The plant and machinery in Different Category of Units are as
follows
Activity Plant & Machines presently in use Approx.
Cost ( Rs. In
Lakh )
Manufacturing Bearing Bar turning Machine 12-15
Races By Bar Route & Centre Lathe 8-10
Seamless tube Method Lathe Addahs 0.50
(Drilling and trepanning Low cost automated hydraulic lathes 8-10
Operation are not Tools cutter Grinder 12
required ) CNC Machine for 15-20
Races Turning/Machining.
Auto lathes (Ace Machines) Perma 6-8x4
line
Forging Bearing Race
Shearing Gas cutting and hacksaw machines 10-13
and modern shearing machines for
raw material cutting
Heating Induction Heating Furnace for 15-2-0
Forging 300 kw, 3 KHz - For all
Lines.
Oil Fired furnace 12-15
Forging,Trimming 300 tone power press 20-25
200 tone power press 15-20
100 tone power press 10-15
50 tone power press 7-10
Screw press having capacity : 350 22-25
tone
Rolling Hydraulic ring rolling machine 25-30
capacity to roll up to 300 mm.
diameter
Tempering With the help of oil fired furnace / 6-10
electrically heated furnace forgings is
treated with sperodise anealing to
remove residual stresses
Die Making Special die sinking machine ,EDM 6-10
Inspection Hardness testing machine 0.50
equipments
Laboratory for testing of final 2-5
products of forging with chemical
composition and micro examination
Heat Treatment : Hardening & Tempering

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1 - Heating 850 ° C Natural salt bath Pit type furnace 0.65-2
(Austenitizing) to alter the with pre-heating Furnace
structure of the material
2 - Quenching 40 ° C Mar quenching processes
Rapid cooling to fix the
structure of the material
and thus increase
hardness.
3 - Tempering 170 ° C" Electric Furnace 3-4
Reheating" to reduce the
effects of thermal shock
(quenching) inside the
structure and stabilise the
material.
Washing Races Tumbling Barrel 0.1-.0.15
Blackening of Races Quenching oil Tank with Cooling 0.1-0.12
System
Grinding Followed by The Machinery being used for
Honing of Outer & Inner Grinding & honing by the
Races SSI Bearing Manufacturing Units are
Imported & Second Hand
Machinery.
Face Grinding Face Grinder ( Rowland ,USA)-1No 8-10
Centreless Ginding Centreless Grinder ( WMW, USA) 1- 5.3 -8
No
Centreless Grinder ( ,Lidkoping USA) 3.45- 6
1-No
Bore Grinding Bore Grinder (Jung Germany)1 -No 0.5-3
Bore Grinder (UVA, USA)1 -No
Outer Track Grinding Outer Track Grinder ( Heald, USA)-1 3.48-5
N0
Outer Track Grinder 5.22-7
( Bryant,USA,1No
Inner Track Grinding Inner track Grinder( Norton) 1 -No 1- 3
Inner track Grinder( Newall,USA) 1 -
No
Duplex Machine 1.5-2
Honing of Track Honing Machine 5Nos 1.40-4
Washing of Races Washing Machine (Self Fabricated) 1-1.4
Lapping Machine Lapping M/c 12-15
Cages & Shields Steel Cages are manufactured by 15-20
Manufacturing Unit using Bearing Grade
Blanking, Bending, Steel Sheet. These sheets are
Drawing, Piercing, stamped with the help of Hydraulic
Cleaning, Inspection Presses and various dies to provide
the desired form and size of
Steel Cage
Pinning ( Pinning in Pinning Press (Electro Magnetic 0.1-0.2
cages) Process ,20 Ton -1 No

19. 19
Riveting cages in Riveting Press ,Hydraulic 20 ton,1- 0.2-0.3
Bearing No1
Ball Manufacturing Unit
Cold Heading Cold Header Machine 10-12
Flashing Ball Flash removing M/c. 4-6
Heat Treatment Hardening followed by Tempering on 20-25
Rotary type furnace
Tumbling Tumbler 2-3
Ball Grading Ball Grading M/c. 3-5
Rough Lapping Lapping M/c. 4-6
Abrasive Lapping Abrasive Lapping M/c. 2-3
Oil Lapping with the help of H.S. Diesel oil and 3-6
Chromium Oxide
Caustic Soda Washing
Inspection
Grading
Greasing
Packing
Assembly of Outer &
Inner Races with Balls /
Roller & Cage
duly suited and locked by
power press
Marking Machine and 3-4
Comparator
Cleaning, Checking & Final Inspection
Measuring & Inspection Tools and Gauge, Comparators, Dial 7-10
Gauges, Demagnetisers, Micrometer,
Slip gauge, Surface Plate,Telescope
Gauge, Cylindrical Gauges etc
Testing Laboratory Equipment 2-3
Load ,RPM, Noise, Load ,RPM, Noise, Temperature etc 1-2
Temperature etc Checking For final inspection Set-up
Checking For final
inspection
Packing Sleeve packaging machine/Shrink 0.7-1
Packing
Work Shop M/c Tools Surface Grinder/Duplex Grinder 7
Bench Drilling machine 0.1
Pedestal Grinder 0.15
Tool post Grinder 0.1
Electric Arc Welding M/c 0.5
Fitter Bench & Measuring 8-10
Instruments, Gauges, Fixtures etc.

20. 20
Material Handling Chain Pulley & Hoist 0.5-.7
Electric D.G.Set 20 KVA 3-4
Air Pipe line Compressor 1-1.2
Centralised Cooling Centralised Cooling Tank with 0.6-0.8
Tank with filtration filtration System ( Superior )
System

21. 21
1.7 Manufacturing Process
These are following three methods which are being used by units manufacturing
bearing races (Soft Turned).
BAR ROUTE :-
Bar route method is considered to be most economical method
manufacturing of soft turned Bearing Races. The following steps are involved in
this method. For the Inner Diameter upto 25mm , this method is more economical
as compared to the other method. That is why this method is more popular and it's
estimated that 70% of Bearing Races soft turning upto 25 mm I.D. size and 50%
Races of the total quantity of soft races manufactured by using this manufacturing
technology. Beyond 25mm I.D. this method is not much cost effective
Bar Turning
Drilling, Parting & Trepanning
(Trepanning is the operation in which the outer race & inner race is parted off from
a single piece of Bar).
Inner Diameter Machining & Facing
Outer Diameter Machining & Facing
Radius Formation
Track Formation
Ready for Dispatch for further operation.
Seamless Tube Method:-

22. 22
In the Seamless Tube Method the Drilling and trepanning operation are not
required , the remaining operations are as follows :-
Parting
I.D. Machining & Width Machining
Outer Dia Machining & Facing
Track and Radius Formation
Ready for dispatch for further operation
This process technology is preferably being used for the outer Dia of 25mm or
higher size. Apart 40% of the total volume of Soft Races turning is being produced
by using above mentioned method in the cluster.

23. 23
Forging Method:-
Bearing Races are manufactured by Hot Forging Method. The operation of Drilling,
parting, and trepanning are not required while using Forging Method. The Metallic
closed Dies are used in Hot Forging Method. This method is more suitable and
economical for outer Dia of 30 mm and above size. In the cluster Approx. 10% of
Bearing Races are produced by using Forging Method. The Forged Bearing Races
are machined/finished as Indicated in the earlier method.
Further Operation for Bearing Manufacturing
The Bearing Outer & Inner Races manufactured by using any one of the
method mentioned above are then supplied to large scale and small scale Bearing
manufacturing Unit. The further sequence of operation for manufacturing of
Bearing are as under
Hardening & Tempering of Outer & Inner Races.
Grinding Followed by Honing of Outer & Inner Races
Assembly of Outer & Inner Races with Balls / Roller & Cage duly suited and
locked by power press.
Cleaning, Checking & Final Inspection
Packing
Ready for dispatch

24. 24
Heat Treatment
Heat Treatment increases material hardness.
At each of the three steps, different processes are available, depending on the product.
Heating 850 ° Austenitizing) to alter the structure of the material.
C-
Quenching 40 ° Rapid cooling to fix the structure of the material
C-
and thus increase hardness
Tempering 170 ° "Reheating" to reduce the effects of thermal shock (quenching)
C
inside the structure and stabilise the material.
Grinding
Various Machines are used to perform Grinding operations:
• Surface grinding
• Outer ring outer diameter grinding
• Inner ring inner diameter grinding
• Inner ring outer diameter grinding (raceway)
• Outer ring inner diameter grinding (raceway)
• Super-finishing : Improves the condition of raceway surfaces by polishing with a
grinding rod.
Manufacturing Process of Other Bearing Component

25. 25
Steel Ball :-
Steel Ball with Close tolerance and desired surface finish are produced by using
SAE-52100 Steel Rod. The process flow diagram for
Ball Flashing Operation Deburring Machine Rill Filing Machine
Wire is fed from de-coilers into cold Header Machines when ere it cut into Blanks,
then pressed into balls between hemispherical dies.

26. 26
Manufacturing of steel ball is as under:-
Flow chart
Cold Heading (on Cold Header Machine)
Flashing (on Ball Flash removing M/c.)
Heat Treatment (Hardening followed by Tempering on Rotary type furnace)
Tumbling (on tumbler)
Ball Grading (on Ball Grading M/c.)
Rough Lapping (on Lapping M/c.)
Abrasive Lapping (on Abrasive Lapping M/c.)
Oil Lapping (with the help of H.S. Diesel oil and Chromium Oxide)
Caustic Soda Washing
Inspection
Grading
Greasing
Packing

27. 27
Steel Cage's:-
Steel Cages are manufactured by using Bearing Grade Steel Sheet. These sheets
are stamped with the help of Hydraulic Presses and various dies to provide the
desired form and size of Steel Cage.
The Process flow diagram for manufacturing of Bearing Cages is as under:
Blanking
Bending
Drawing
Piercing
Cleaning
Inspection
Ready for dispatch
Cage’s Manufacturing Process

28. 28
Metal Shields - Bearing Metal Shields is protective closures which retains lubricants and assist
in preventing contaminants from reaching internal surfaces.
Dust
Shields - The aperture usually found in the top cover housing is sealed to form a barrier to
assist prevention of airborne contamination into the contact area
Shielded Bearings - A shielded bearing has a metallic shield on the backside and
Shielded bearings are not sealed bearings. With the shielded type of bearing, grease may
enter the bearing readily, but dirt is restricted by the close fitting shields. If there is no
shield on the backside of this bearing, the excess grease can escape into the inner
bearing cap of the equipment bearing housing.
Assembly : Assembly of various items, performing additional functions (greasing,
marking, etc.) During each of these steps, the bearing manufacturing process layout is
carried out in compliance with total quality (self-inspection, SPC and TPM).
Chapter-2
IDENTIFYING TECHNOLOGY GAP

29. 29
The following section present on Analysis of Business operation for the Bearing
and Bearing Component Cluster Jaipur. The following factors have been taken into
consideration in the Analysis.
• Raw Material
• Technology (Machinery & Production)
• Quality Standard
• Product & Marketing
• Entrepreneur & their Enterprises.
• Finance & working capital.
• Man Power Requirement
• Infrastructural Facilities.
• Business Development Service.
The raw material SAE 52100 Spherodised bearing steel only available from few Indian
Supplier.
• Indian Seamless Metal Tube, PUNE
• Indian Seamless Steel & Alloy, PUNE
• Mahindra Ugine Steel Company Khapoli.
Internationally, the accent is on achieving higher and higher quality levels of bearings.
Higher precision, minimum handling damages and maximum cleanliness are the thrust
areas for development. Individual units have their own grading of quality. SKF, for
example, designates t, as Q77, Q66, Q55, where Q66 is reported as the prevalent level
and Q55 as the level aimed at International manufacturers are moving towards special
bearings, and sub assemblies involving bearings, where production of small batch
quantities becomes more attractive.
High rates and consistency of productivity have been achieved by the manufacturers
abroad by line manufacture. The market demands there, permit mass production
techniques and thereby bring in economies in production.

30. 30
- As regards materials, closer grade and specification ratings are emphasised.
- Upgrading of technology has generally come not from within or from market forces
but usually from the collaborator's insistence, if the latter has stakes, either financial or
through its name.
The following testing facilities are not available in most of the cluster units.
• Chemical examination of steel.
• Non Destructive Testing of Material.
• Metallographic
The Machinery and equipment used by majority of SSI units for manufacturing of Bearing
Races are of sub standard and obsolete. Even the SSI Bearing manufacturing units are
using the second Hand Imported Grinding & Honing Machine which are having Lesser
Tolerance Accuracy so the bearing manufactured by these units are not preferred by
International Industrial Buyer.
The Product require high degree of precision the manufacturer are unable to
maintain Accuracy with in 2 microns. In accordance with the standard of International
Market. The existing plant & machinery can give accuracy with 4 microns.
The profile cutting operation of Bearing Races is not properly done due to Non
Availability of optical profile grinder.
Therefore lot of technological intervention need to be done in the area of
Machinery and Production in order to make final product as per International Standard.
The following observation need technological Intervention:-
(1). Use of Kerosene for Splash Cleaning for Assembled Bearing and Swab Cleaning
of Individual Parts.
(2). Inspection of Contamination level of the Bearing not inspected.
(3). Dust free Room/Assembly shop of Bearing not maintained.
(4) Erroneous measurement of parallelism, concentricity, flatness, taper, straightness,
radial and Axial clearance.
(5) Non Uniform Temp. in Shaker Hearth Furnace
(6) Mar Quenching Oil is being used for Quenching, but Mar Quenching Salt is not the
practice.

31. 31
(7) Blackening Salt is full of Contamination.
(8) Sampling System is Erroneous.
(9) Roundness Testing is used for setting parameter of M/c.
(10) Micro Structure Like Type of Martensite, Retained Austenite, Benetic Structure , is
not being inspected.
(11) Sub-Zero Treatment is not being done in the cluster
(12) Micro Hardness measurement is not practice .
(13) Speed, Feed and Depth of cut for Turning and grinding are not optimum .
(14) Precision Measuring Instrument are all shop made.
(15) Fatigue Testing of Bearing not being carried out.
(16) No phosphating of Inner and outer ring .
(17) Go-No-Go gauges practice is not existed.
(18) Forging Dies are made of H 11 & H13 Hot Die Steel and Hot H21 & H 23 material.
The Quality of Bearing Races is concerned SSI Units have to follow the relevant
specification, drawing and other instruction provided by the purchaser. The system of
100% inspection is being followed without any process wastage. However some of the
Bearing manufacturer permit 1% process wastage. In the event of rejection the unit has
to make payment for loss of the raw material the Bearing Manufacturer.
The main defects of Ball Bearing Races are Track Centre out (for which Unit is 100
Micron) eccentricity in outer Dia and Track Dia or Base and Track Dia. The Radius form
on Outer Dia and base of race is not proper which Account for major rejection.
The gauge calibration facility are not available as the gauge are required to be calibrated
periodically in order to ensure the quality of product. The most of SSI/Artisan Unit of
Cluster do not have the well organized marketing channel and Demand forecasting
system and are facing marketing problem due to lack of availability of sufficient fund and
other resources required for Advertisement & Publicity, Credit required by the buyers,
Branding, Market Assessment etc.
Most of Artisan Units are having defective Product pricing system. The units are cutting
prices due to cut throat competition.

32. 32
The Bearing Manufacturing SSI Units are only supplying to replacement market.
There is very vast scope to supply OEM & Other sector if they produce standard quality of
Bearing.
The Problem of duplicating and Reconditioning of old Bearing are another
Constraint in the Industry.
SSI Bearing Manufacturing Units are also facing challenge from Indian Large
Scale Bearing Manufacturer like SKF, NEI, TATA Bearing etc. as large scale unit have
made Huge Investment for Product Technologies, Collaboration from world leader of
Bearing Industry. Large Scale units have employed the professionally qualified work force
and producing at higher volume as compared to SSI Units, and hence taken a lead in all
the functional Area of Manufacturing, R & D, Marketing etc. More over these units are
using latest and Innovative technique to have their higher productivity, quality and
profitability. The SSI Units are far away and yet to adopt these technique tool for their
betterment 25 % of total demand for bearing industry is met by imports. While a part of
the imports come through official channels, there is also a huge volume of illegal imports.
legal Imports generally represent the specialized bearings not manufactured in India.
There are a large variants of imported bearings, each holding a small market share in
India. Though, the quality of bearings manufactured by large players in India is
comparable to world standards, domestic manufacture is not viable due to the small size
of the market segment.
It becomes uneconomical to manufacture such type of bearings as it includes huge
capital expenditure. Illegal imports generally represent the entry of spurious imports of
bearings. In the past, the Indian bearings industry was highly protected on account of
very high import duties ranging from 150% to 240% ad valorem. As a result, illegal
imports via smuggling and under invoicing of imports was the order of the day, accounting
for a high 45-50% of total imports. While duty rates have come down over the last few
years, a few countries like China, Russia, Eastern Europe dump their excess production
at a very low rate. This leads to a huge price differential between domestic and imported
bearings (almost 40-50%), encouraging imports.
• Most of the unit, the enterprise structure is proprietary or partnership type. The
proprietor/ partner himself look after the Management Aspect and Keep over all control of
the functioning of the unit and in most of the cases they do not posses the required
technical/Managerial back ground.

33. 33
• Technological Awareness of Entrepreneur are not upto the level. It need to be improved
so they can successfully compete the era of liberalization and globalization.
Finance is the most critical problem of the Industry in term of shortage of finance,
delayed payments, difficulties in getting bank finance and additional requirement of credit.
• Units require to maintain large inventory and it's the experience of manufacturer that the
working capital need are not fully realized by the bank & financial institution and it directly
affect their market.
• The SSI Units faces common problem regarding availability of skilled man power, A
worker After working for a period of few year in this Industry leave the Job to start his own
turning unit or to get higher wages from another unit.
• There is no regular training facilities available where the manufacturer and worker
undergo need based training.
• The SSI Units also faces problem about less availability of trained man power such as
turner, tool maker etc.
- The Tiny/Artisan Units are scattered in Different Area. They are functioning under
rented shop and due to availability of lack of space, the placement of machinery &
handling of material with in the unit is not proper.
- Due to frequent power cuts production is hampered.
- There is dearth of quality BDS in the Area of technology, Marketing, Export, Health
& Safety etc.
• Networking among R & D Centre, Technical Training Centre, Testing Centre are not
present in cluster.

34. 34
Chapter 3
THRUST AREAS FOR TECHNOLOGY & TECHNOLOGY GAPS
The reflections of technological achievement are seen in the quality of the product.
The bearings manufactured by the Indian industry have to improve considerably to meet
international standards. If the roots of the problem are to be identified, one comes to the
following conclusions:
Machine Tools - precision, productivity
Materials - quality, consistency
Operations - process mastery, assembly, quality control Skill
These broad areas can be identified as "Technology Gaps" in bearing manufacture.
Although considerable efforts have been made in these directions, the gaps have not yet
been bridged.
Technology Gaps:
Activity Plant & Machines Proposed plant and
presently in use Machinery
Manufacturing Bearing Bar turning Machine . Installation of Auto
Races By Bar Route & Turning Lines for Small
Seamless tube Method Centre Lathe DGBB from Tubes -
(Drilling and trepanning Production capcity
Operation are not Lathe Addahs 120,000 per day,
required )
Low cost automated
hydraulic lathes
Tools cutter Grinder
CNC Machine for
Races Turning
/Machining.
Auto lathes (Ace
Machines) Perma line
Investment Range Investment Range : Investment Range :
Rs. 10-20 Lakh Rs. 100-200 Lakh
Forging Bearing Race
Gas cutting and hacksaw Automatic Hot & Cold
machines and modern Forming machines
shearing machines for
raw material cutting

35. 35
Induction Heating
Furnace for The outstanding features
Forging 300 kw, 3 KHz - of the forging shop
For all include:
Lines.
Oil Fired furnace • Automatic bar
300 tone power press loading
200 tone power press • Induction heating
100 tone power press • Laser sensor
50 tone power press assisted ESA
Hydraulic ring rolling technology for
machine capacity to roll precise bar feed
up to 300 mm. diameter control and auto
Screw press having Bar End Ejection
capacity : 350 tone • On line control &
Special die sinking monitoring of
machine forging
Bar shearing machine temperature
Hardness testing • Highly sensitive
machine equipments press load
Laboratory for testing of monitoring system
final products of forging • High speed forging
with chemical process
composition and micro eliminating risk of
examination cracks due to
temperature drop.
• Auto monitoring
system for yield &
tool life.
With the help of oil fired
furnace / electrically
heated furnace forgings
is treated with sperodise
anealing to remove
residual stresses
Investment Range Investment Range : Investment Range :
Rs. 200-250 Lakh Rs. 1400-1700 Lakh
Heat Treatment :
Hardening & Tempering
1 - Heating 850 ° C Natural salt bath Pit Temperature Controlled
(Austenitizing) to alter the type furnace with pre- Energy Efficient Heating
structure of the material. heating Furnace Funace
• Liquid carburising
processes
• Gas carburising
processes
• Continue
hardening
processes

36. 36
2 - Quenching 40 ° C Mar quenching
Rapid cooling to fix the processes
structure of the material
and thus increase
hardness.
3 - Tempering 170 ° C
"Reheating" to reduce the
effects of thermal shock
(quenching) inside the
structure and stabilise the
material.
Investment Range Rs. 0.6-2 Lakh Rs.20-30 Lakh
Grinding Followed by The Machinery being Automatic Lines,
Honing of Outer & Inner used for Grinding &
Races honing by the
(Surface grinding, Outer SSI Bearing
ring outer diameter Manufacturing Units are
grinding, Inner ring inner Imported & Second Hand
diameter grinding, Inner Machinery.
ring outer diameter
grinding (raceway), Outer Bore Grinding Machine
ring inner diameter
grinding (raceway), Track Grinding Machine
Superfinishing (Internal Grinding
Improves the condition of Machine)
raceway surfaces by Center less Grinder
polishing with a grinding (External Grinding
rod. Machine )
Honing Machine
Investment Range 100-200 Lakh 800-1000 Lakh
Cages & Shields Steel Cages are Press Section
Manufacturing Unit: manufactured by using (Blanking Transfer
Blanking, Bending, Bearing Grade Press M/S Chandra
Steel Sheet. These Industries &M/S Manu
Drawing, Piercing, sheets are stamped with Yantralaya have adopted
Cleaning, Inspection the help of Hydraulic transfer Presses and
Presses and various dies have good market share
to provide the desired in SME manufacturers in
form and size of India.
Steel Cage
Investment Range 50—100 Lakh 100-200 Lakh
Ball
Manufacturing
Unit

37. 37
Cold Heading (on Cold Automatic Lines M/S
Header Machine) Kansara Engineers Pvt.
Flashing (on Ball Flash Ltd. (A Unit of Sewaram
removing M/c.) Kansara Group), E-
Heat Treatment 36,M.I.A. Phase II, Basni,
(Hardening followed by Jodhpur - 342005
Tempering on Rotary (INDIA) has adopted
type furnace) automatic line and have
Tumbling (on tumbler) good market share in
Ball Grading (on Ball SME manufacturers in
Grading M/c.) India
Rough Lapping (on
Lapping M/c.)
Abrasive Lapping ( on
Abrasive Lapping M/c.)
Oil Lapping (with the help
of H.S. Diesel oil and
Chromium
Oxide)
Caustic Soda Washing
Inspection Grading Machine
Grading
Greasing
Packing
Assembly of Outer & Hydraulic power press AUTO INNER & OUTER
Inner Races with Balls / DIAMETER
Roller & Cage INSPECTION,
duly suited and locked by AUTO IR & OR ULTRASONIC
power press WASHING MACHINE, AUTO
CONSERVATION OIL
SPRAYING MACHINE
Automatic Lines(AUTO
COMBINING & CAGE
ASSEMBLY MACHINE),
AUTO GREASING &
SHIELDING MACHINE,
AUTO
DEMAGNETIZING
MACHINE, , AUTO BALL
BEARING ASSEMBLY
MACHINE ,
Pinning Press
Marking Machine Laser Marking M/C

38. 38
Cleaning, Checking & Tools and Gauge,
• Chemical
Final Inspection Comparators, Dial
Gauges, Demagnetisers, composition of raw
Micrometer,
material Including
Slip gauge, Surface
Plate,Telescope Gauge, Microscopic
Cylindrical Gauges etc
examination
• Ultrasonic Testing
• Oxygen contain
Checking
• R.A. Value
measurement for
Rough
measurement.
• Calibration Testing
equipment
Testing Nominal Laboratory
Equipment
Load ,RPM, Noise, Load ,RPM, Noise, AUTO DOUBLE SIDE
VIBRATION & NOISE
Temperature etc Temperature etc
INSPECTION MACHINE, AUTO
Checking For final Checking For final DOUBLE SIDE SENSITIVITY
inspection inspection Set-up INSPECTION MACHINE, AUTO
RADIAL INTERNAL
CLEARANCE & SENSITIVITY
INSPECTION MACHINE ,
Packing Sleeve packaging
machine/Shrink Packing
Packing Sleeve packaging
machine
Work Shop M/c Tools Surface Grinder/Duplex CNC M/ C Tools
Grinder
Bench Drilling machine
Pedestal Grinder
Tool post Grinder
Electric Arc Welding M/c
Fitter Bench & Measuring
Instruments, Gauges,
Fixtures etc.
Chapter 4
PROPOSED ADVANCE TECHNOLOGY & ITS BENEFITS

39. 39
Bearing Steel :
The most common material used in the manufacture of bearing rings, balls
and rollers is Alloy steel conforming to specifications SAE 52100. This material has
become standard material for the industry all over the world. While the basic
material remains the same, the steel manufacturers all over the world have been
improving this material in order to improve the life span and quality of the bearing.
The Indian steel manufacturers although manufacturing steel to specifications SAE
52100, are not able to meet the requirement of the bearing manufacturers in so far
as purity and oxygen content is concerned. Therefore, bearing Steel
Manufacturers should be equipped with Vacuum Degassing & Vacuum Oxygen
De-Carburising Equipment (LEYBOLD HERAEUS, Germany.) In order to
maintain Oxygen content < 15ppm . The tubes are tested to ensure that the steel
is free from injurious imperfections such as piping, cracks, porosity, segregation or
injurious inclusions as referred to in ASTM-381.The inclusion rating is evaluated in
accordance with Plate III of ASTM E-45,The tubes are spheroidized and annealed
to ensure that the microstructure consists of spheroidized commentate in a ferrite
matrix with carbide size conforming to Plates 2 to 4 as per IS 4398-1972 and CG
2.1 - 2.3 as per SEP 1520-78.Spherodise annealing and normalising improves the
machinability of the annealed hypereutectoid steel and improves its microstructure.
To accomplish spherodise annealing and ormalising,temperature controlled energy
efficient electrically heated furnace with a capacity of 6,000kg and oil fired
furnaces with capacities of 3,500kg to 4,000kg are being proposed for SME sector
. The spherodise annealing and normalising process provides improved ductility,
removal of residual stresses, improved machinability and grain refinement.
Race Turning :
Auto lathes (Ace Machines) /CNC Machines/ SLC-100G/Machines for Ring
Turning CNC Turing centers of HMT, GD Weiler and other reputed makes,
capable of components upto 100mm diameter are being proposed for SME sector.
Though some units in MSME sector have already installed f Auto Turning Lines for
Small DGBB from Tubes - Production capacity 120,000 per day, One of them M/s
Supersonic Turners Pvt. Ltd , Jaipur is performing well in this sector.
Benefits :
These machines are built on the Modular concept for Productive, trouble free
Running with minimal operator Intervention. They are ideally suited & developed
for small to medium sized disk type components that are made in large volumes
like bearing rings, water pump rings, sleeves, brake pistons etc. These machine
offers many high productive features that enhances productivity significantly
1.High rate of production
2. Cost effective
3. Less wastage

40. 40
4. Better and consistent quality
5.Less power consumption
The CNC, SPM and convectional turning machines for centreless, cylindrical and
round operations. SPM type convectional turning machines for proof turning and
some other special operations. PLC and hydraulic type convectional machining
centres for various operations are being used in SME sector as advance
technology .
HEAT TREATMENT : Following Plant & equipment for Heat Treatment are
being proposed in SME Sector
• Liquid carburising processes
• Gas carburising processes
• Continue hardening processes
• Natural salt bath processes
• Mar quenching processes
• quenching ( Cryogenic or Nitrogen Mathanol system ): To eliminate retained
Austenite,the quench temperature has to be lowered
Forging : Manufacturers of closed die Forgins for Bearing Race equipped with
Following Equipments in SME Sector.
• Induction Heating Furnace for
Forging 300 kw, 3 KHz - For all
Lines.
• Well equipped furnace
• 300 tone power press
• 200 tone power press
• 100 tone power press
• 50 tone power press
• Hydraulic ring rolling machine capacity to roll up to 300 mm. diameter
• Screw press having capacity : 350 tone
• Special die sinking machine- EDM
• Bar shearing machine
• Hardness testing machine equipments
• Full equipped laboratory for testing of final products of forging with chemical
composition and micro examination

41. 41
Hot & Cold Automatic Forming plant operates at an average speed of 110 ppm
providing the utmost production efficiency when compared to the conventional
forging process. The Hotmatic AMP 30 S/AMP-50S three-station hotformer is
ideally suited to the production of parts for the automotive, fittings and bearing
industries are being suggested for large scale units .
Benefits :
• Simple operation and conversion
• High production output (up to 140 parts/minute)
• Accurate transfer
• Broad range of parts (e.g. cams for passenger vehicles)
• Fully developed and proven machine design
Note : M/s Agrasen Engineering Industries Limited is equipped with
HotmaticAMP-30S, propelling towards future with an outstanding growth rate.
The outstanding features of the forging shop include:
• Automatic bar loading
• Induction heating
• Laser sensor assisted ESA technology for precise bar feed control and auto
Bar End Ejection
• On line control & monitoring of forging temperature
• Highly sensitive press load monitoring system
• High speed forging process eliminating risk of cracks due to temperature
drop.
• Auto monitoring system for yield & tool life.
Ring Rolling Process :. The raw material is heated in an induction bar heater and
in precisely temperature-controlled furnaces, which provide scale free heating. The
plant is equipped with gas cutting and hacksaw machines and modern shearing
machines for raw material cutting. The plant uses pneumatic, mechanical and
hydraulic power presses for forging. Sun Forge C-1/285, G.I.D.C.,Phase II, Aji Ind.
Estate,Rajkot - 360 003, Gujarat have equipped with such technology .
Cold Rolling Plant : Ring Rolling Machin- D51A, D51B, D52 and D53K series ,
D51A & D51B series of vertical type Ring Rolling (Zhucheng Shengyang
Machinery Co., Ltd ) and Hatebur Coldmatic coldformers (AKP 3-5 | AKP 4-5 |
AKP 4-6 S | AKP 5-5 ) produce precision and complex parts formed directly from

42. 42
wire. The parts produced this way are characterized by precision tolerances,
quality surface finish and overall strength, are being also used in Bearing sector.
Benefits :
Machine have advantages of small volume and compact structure and saving
material and power and so on, which also widely used for hot rolling of ring like
blank in bearing forging and auto gear and flange manufacture industry. D52 &
D53K series of CNC horizontal type Ring Rolling Machine have the following
advantages: advanced structure, numerical programme control, high automation
degree and productivity and saving material and power and so on. Especially
D53K CNC Ring Rolling Machine, it can roll rings simultaneously in radial and axial
direction and is the ideal equipment of processing large scale seamless rings,
which has been widely used in spaceflight, aviation, ship, petrochemical industry
and power industry and so on.
Manufacturing of Bearing Cage & Shields : The following plant & Machineries
are being suggested for SME Sector
• AIDA Transmax TMX Transfer Press or Straight Side 2-point Transfer
Presses
• software’s provided by Forming Technologies (I) Pvt. Ltd
• Transfer Press – 50 (Aida, Asahi Seiko, Kyori, Chin Fong Machine
Industrial Co., Ltd.186 Chang Shui Road, Chang Hua, Taiwan
other)15Ton~150Ton
• Rivet Insertion Machines – 43 (Toa Seiko, Shimizu Seiko)
Press Section (Blanking Transfer Press
The main process in the production of a bearing cage. At first stage, in a process
called blanking, a round ring is being cut out of a steel coil. Then, in a process
called transfer pressing, a proper cage is formed by pressing out from a blank.
BLANK Pre-forming Forming Piercing

43. 43
Rivet insertion
Rivet, which is a part of bearing-cage, is manufactured from a steel wire. . The process of
rivet insertion is implemented by specialized machines. The cage set is made of two
identical cages joined by a rivet.
Rivet Insertion Machines – 43 (Toa Seiko, Shimizu Seiko)

44. 44
Advanced Flow Chart to manufacturer Bearing Cages
Benefits :
Convenient to integrate with the 2D/3D transfer unit to increase production
Minimal overall clearance derived from high-precision components
Low noise and low vibration which contribute to extended die life
Note: Manu Yantralaya has adopted transfer presses & consistently marching
ahead to furnish the needs of customers belonging to ball bearing industry..
Assembly Section : Automatic Line from R& S Machine China are being proposed for
large scale
Quality control : Some advance Machine & equipments are being used as mentioned
under:
• TALYROND - Roundness , squarness, concentricity and coaxiality of
bearing and components ,Testing instrument, FORM TALYSURF
• Profile and surface finish testing instrument etc. from - Taylor Hobson,
U.K.
• Bearing Eccentricity stand, Dial Calibration Instrument and Gauss Meter
(Residual Magnetism Tester) etc.

45. 45
• Form and surface finish measuring instrument is being used for checking the micro
geometry, it evaluate parameters like Form geometry and surface finish of components
• Roller Sorting Machine
• Bearing Noise Level & Vibration Tester
.
ADVANCE TESTING EQUIPMENTS : The following testing equipment s are being used
by M/S KANSARA ENGINEERS PVT. LTD.Jodhpur .
• Carl ZEISS Microscope
model No. AXIOVERT 100 A – Germany
• Taper Roller Head Radius Measuring Instrument
• Talyrond 262- U.K.
• Dial Calibrator
• Talysurf FTS- U.K.
Intra 2 System with Ultra Comprising
• Profile Projector
• Surface Roughness Tester
• ATC Calibrator
Chapter – 5
PROJECT PROFILE
Product : Forged Bearing Races
NIC Product Code : 356601005
Product Code ( ASICC ) : 71243

46. 46
Plant Capacity per annum : 7200MT ( Two Shift )
Job work per annum : Rs, 9,36,00,000
Month & Year of Preparation : March, 2011
: Prepared By : -
Micro Small and Medium Enterprises Development Institute,
Government of India
Ministry of Micro Small and Medium Enterprises
Bais Godam, Jaipur – 302 006 (Raj.)
Ph. 0141-2212098, 2213099, Fax. 2210553
e mail- dcdi-jaipur@dcmsme.gov.in
web- dcmsme.gov.in
Forged Bearing Races
1.0 INTRODUCTION : The profile envisage to set up Automatic Hot &
Cold Forming Forging Plant to manufacturer Bearing Races .The
operation of Drilling, parting, and trepanning are not required while
using Forging Method. The Metallic closed Dies are used in Hot
Forging Method. This method is more suitable and economical for
outer Dia of 30 mm and above size.. The Forged Bearing Races are
turned /finished on turning Lines.
2.0 MARKET & DEMAND ASPECT : The demand for bearing industry is
derived from demand in two key user segments - automobile and
industrial sector growth. The automobile industry is the largest growth

47. 47
driver for OEM market as it accounts for almost 45% of total bearing
market.
Engineering sector, which accounts for 28% of total share, holds the
second growth driver. Considering the high reliance of bearing industry
on automobile sector, the fate of bearing industry is largely dependent
on production of vehicles.
The demand of bearing is also linked to heavy-duty industrial
application in rolling stock, rolling mills, heavy earth moving
equipments and other heavy machinery, accounting for 21% of total
bearing market. However demand in the latter category is met through
imports and therefore does not have significant impact on domestic
growth .
Up Swing in Automobile Sector ,The Indian Automobile sector has
grown 16.5% in FY03 contributed by export growth of 65.3% and
domestic growth of 14.8%. The automobile industry comprising of
commercial vehicles, passenger cars, multi-utility vehicles, two/three
wheelers and tractors has performed extremely well in FY03. The
sharp growth of this sector has been partly driven by the impact of
lower interest rate on demand, intermediated by a competitive financial
sector, which has steadily cut prices of automobile loans as interest
rates went down.
Infrastructure has received a fillip in last 2 years through N-S-E-W
corridor and Golden Quadrilateral projects. The transformation of road
transport industry through these initiatives will lead to higher demand
for commercial vehicle industry. Passenger cars continue to grow in
double digit driven by rising aspiration levels and easy availability of
cheap finance. Within two wheelers, we expect motorcycle industry
growth to continue on its growth path.
After two bad years, the tractor industry is also likely to witness a
revival with completion of inventory correction phase and good
monsoons likely to drive demand. The positive outlook for auto sector
augur well for bearings demand and we expect all segment of
automobile industry to report strong growth in the coming year.
Export Potential
Exports of bearings companies has increased at a CAGR of 13% in
last seven years from 1995-96 to 2001-02 at Rs2.5bn.Big players in
Indian ball and roller bearing have been already exporting a part of
their production to developed countries like US, Europe etc. Domestic
players are already sensing the outsourcing opportunity and have
initiated the process of manufacturing a range of bearings for meeting
the requirements of global customers.
The Indian bearing industry, especially the companies having
technical/ financial collaboration with global players like SKF Bearings,

48. 48
FAG Bearings, Timken India, ABC Bearings and NRB Bearings are
expected to garner higher price in export market.
The OEM and replacement market control the market dynamics of
Bearing. The OEM and replacement market both account for 40% of
total demand of Bearing Industry individually. The Bearing
Manufacturer are only supplying to replacement market. There is vast
market of OEM Sector The SSI Bearing Manufacturing units of cluster
are mainly supplying to the replacement market of Bearing. On the
other hand a number of SSI Races Manufacturing Units are supplying
the Soft turned Bearing Races to the following large scale units. In the
Bearing & Bearing component manufacturers cluster Jaipur Approx.
10% of Bearing Races are produced by using Forging Method.
Name of Large Scale Unit : No. of Vendor in Jaipur
Cluster
(i) NBC : 30 No.
(ii) SKF : 05 No.
(iii) ABC : 02 No.
(iv) FAG : 04 No.
(v) TATA :02 No.
(vi) TIMKEN : 01 No.
The Bearing Manufacturing SSI Units are only supplying to
replacement market. There is very vast scope to supply OEM & Other
sector if they produce standard quality of Bearing.
3.0 RAW MATERIALS : 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 The Project
profile envisage to perform job work of large scale Bearing
manufacturers.
4.0 MANUFACTURING PROCESS & SOURCE OF TECHNOLOGY :
Manufacturing process begins by sending hot rolled bar material
through Induction Heaters to achieve the proper temperature needed
for forming the part. The material then proceeds into Hatebur 3 station
or 4 station hot former. Depending on the job specifications, these
machines pancake the part, then form and punch the inside diameter
through the product. Both machines possess the added feature of
combination forging, which produces two parts at the same time thus
reducing material waste.
At this point, depending on the application, the product can go
through forge normalizing or spheroidize annealing furnaces, cold ring
rolling process, shot blasting or visual inspection areas prior to the
shipping area.

49. 49
4.1 Quality System :
The tests are conducted as per I.S. & A.S.T.M. standards. In the Laboratory, tests
such as Chemical Composition, Including rating, carbide Bending, Grain Size and
other tests are conducted. Once the material s approves after spherodized
Annealing, it is send for turning process where Inspection of pre-turned races is
done, continuous dimension inspection during turning process,100% Crack
Detection testing,100% Visual Inspection for dent, forging spots, rust & Burr of
turned races is done. After getting approval material is transferred for dispatch.
5.0 BASIS OF PROJECT SELECTION : The spurt in prices of the import
raw material-steel tubes, has compelled the industry to look for an
alternative form of material, which has been seen in forged/formed
rings.The proposed . Hatebur machines are impressive not only for
their precision and flexibility, but also because of their ability to
produce large volumes of parts at a high production rate which in turn
yields good production efficiency. In anticipating future demand &
keeping view of global trend only such a plant may be a approved
vendor of large scale bearing manufacturers.The proposed proven
technology has already adopted by M/S Agrasen Engineering
Industries Limited , Jaipur this technology , running very well , Hence it
justified the project selection.
6.0 PRESUMPTIONS: -
(1) To improve the energy efficiency of the plant, it has to run
continuously.
The scheme is based on two shift of 75% efficiency 25 days/month
and 300
days per annum
(ii) Labour wages has been taken as per market rate. It is likely to vary
depending upon the location of the project .
(iii) Rate of interest has been taken 12% on an average on fixed and
working capital. It is likely to vary due to financial outlay and the
location of the unit.
(iv) The operative period of the project is estimated to be about 8 years
considering technology obsolescence.
(v) Value of machinery & equipment is estimated on the basis
Quotations received & prevailing cost of the local mkt.
(vi) As the cost of raw Material is major part of working Capital and is
very high and as per the mrket trend the working capital is being taken
for 1.5 months only.
7.0 PRODUCTION CAPACITY :

50. 50
The proposed ATEBUR-HOTMATIC® AMP 30 S work with one shearing
and three forming stations for the production of forging parts up to
67 mm diameter and 0.7 kg input weight & 84- 140 strokes per minute.
In keeping view plant capacity and presumptions made over capacity
calculated as under :
8.0 Plant Capacity per annum : 10533.6 MT ( Two Shift )
Value per annum : Rs, 79,10,73,360/-
9.0 UTILITY REQUIREMENTS : 1500 KW
Hot Forming Plant
Electrical:
- Power supply (start and production) 120 kVA
Compressed air:
- Pressure 5,5-10 bar
- Consumption (non compressed state) 3 Nm3/h
Cooling water:
- Pressure 4 bar
- Max. flow rate (depending on part) 30 m3/h
10 IMPLEMENTATION SCHEDULE :
S.No. Activities Period in
Months
1 Preparation of project report and selection of site 1
2 Registration 1
3 Application for Electricity Connection 1
4 Availability of finance& Procurement of machinery 6
6 Electrification & installation 2
7 Recruitment of staff 1
8 Trial run 1
Total 13
11 FINANCIAL ASPECTS:
i) Land : The requirement of land for the proposed unit would be 3000 Sq. Mtr.
purchased @ 2500 3000 2500 7500000
Shed & Building Constriction 1000 5000 5000000
TOTAL 12500000
b PLANT & MACHINERY
S.No. Description of machine Qty. Price Amount

51. 51
1 HATEBUR HOTMATIC® AMP 30 1 133879000 133879000
S with one shearing and three
forming stations for the production of
forging parts up to 67 mm diameter
and 0.7 kg input weight. With 6 inline
Induction heater and cold ring rolling
machine & Shot Blasting
2 Noise abatement cabin. 1 7964550 7964550
3 Adaptation to tropical conditions. 1 653,400 653400
For ambient temperature higher than
40° C and for relative humidity higher
than 90 %, it is necessary to install a
larger cooler and a heater to keep
condensation from forming inside the
cubicle during machine standstill. The
heater is controlled by temperature
controller and hygrostat and allows a
temperature difference of max. 15° C.
4 CNC Lathe 200 mm 1 2000000 2000000
5 Cylindrical Grinder 1 400000 400000
6 Internal Grinder 1 300000 300000
7 Vertical milling Machine 1 450000 450000
8 Spare Parts 1 5440050 5440050
9 Changeover Aids 1 2393820 2393820
Other Conventional M/c Tools like 1 200000 200000
drill, weld bench vice , portable
grinder etc
10 Accessories 1 10032660 10032660
Total 163786480
vat, Taxes, Installation & Electrification @ 10% 16378648
TOTAL 180165128
9 Office Equipment, Dies & Tools LS 7614585 7614585
Total Investment In Plant & 187779713
machinery
Pre operation Charges i.e. for Getting 3755594.26
Electricity Connection etc.
c Total Investment In fixed assets 204035307.3
D. WORKING CAPITAL
i Personnel
S.NO. DESIGNATION No. Salary Total (Rs.)
1 Workshop in charge 1 30000 30000
2 Supervisor cum clerk 2 1200 2400
3 Skilled Worker 8 8000 64000
4 Semi skilled worker/ Helper 4 4500 18000
5 Peon / Watchman 3 3000 9000
Total 18 123400
Additional Perquisites @ 15% 18510
Total Expenditure in Salary & Wages 141910