TOLIA TOLIA GROUP OF COMPANIES MANUFACTURER OF HIGH PRECISION BALLS & ROLLERS
“A continuous effort to reduce the imapct on environment.”
+91 22 25820465 / 22 25822449
toliaoverseas@tolia.com
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Publisher : Shilpa Dongre CEO : Shekhar Dongre Editor : Rajeev lyer Assistant Editor : Shweta Nanda
CEO CORNER
CMO: Shirish Dongre Marketing Team :
Bearing Industry : The bright future ahead
Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A. Purohit, Vinod Surve, Hiren Shah Online Marketing :
Bearings are highly engineered machine elements that reduce energy loss induced by friction in the rotary motion parts of various equipment and machinery. There are different types of bearings, including ball bearings, roller bearings, and plain bearings.
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As the automotive and general engineering sectors continue to gain more prominence in India, industries in the country have started purchasing and installing more expensive equipment to enhance their overall operational paradigm and ensure better efficiency in their day-to-day operations. The prospects of market growth of bearings are closely linked to growth in the production of high-performance industrial equipment and machinery. The bearings market in India will register a CAGR of about 12% over the period 20142019. Bearings industry is technologically as well as capital intensive industry, as end products finds application in critical applications like aviation, automobile engines, railways and others. Companies in the segment are adopting new technologies such as construction with light weight alloys, better forging techniques and low tolerances, among others. There is a distinct integration happening there. This has led to evolution of unitized bearings. This Integration can be achieved by better forging techniques, which helps OEMs achieve lightweight without compromising on the performance. Indian bearings market constitutes less than 5 per cent of global bearings demand. In terms of consumption, about 60 per cent requirement is catered through domestic production while remaining is met through imports. Indian bearing size is estimated at Rs 95 billion. Focus areas, where the companies are looking to work on to reduce the weight is by optimising the raw material in sync with the market requirement.
WEST (Maharashtra & Gujarat) : Pune - Kuldeep Kshirsagar : 09689403523 Nashik - Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) - Swapnil Bhatia: 09227909005 https://www.facebook.com/engrreview https://twitter.com/engrreview http://in.linkedin.com/pub/engineering-review/87/b31/97a Printed & Published by Shilpa Dongre. Printed at The Package Offset Printers, Maharshi Karve Marg, Ruby Garage Compund, Mumbai-400002, published from 303, Harmony Tower, Netaji Subhash Road, Court Naka, Kharkar Alley, Thane West, Thane-400602. Editor: Rajiv Iyer
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OCTOBER 2019 | ENGINEERING REVIEW 1
MESSAGE Bearing industry is witnessing tremendous technological changes and transformations. In a bid to highlight the latest advancements in the industry, Bearing EXPO India is being held at Nehru Centre, Mumbai on 15th and 16th October, 2019. Given the changes in distribution and application of bearings today, only organizations that adapt will be able to ensure success in the years ahead. The need of the hour for bearing manufacturers and distributors is to expand their services, stay ahead with the transformation while maintaining the price structure.
Mr. Shashi K.Shah - President EASTERN INDIA BALL BEARING MERCHANTS ASSOCIATION
The two-day Bearing EXPO India is a great step in covering every facet for the bearing manufacturer, distributor, solution provider and enduser. I am sure the event will serve as a unique platform to discuss common challenges and share the latest available market knowledge, technologies, innovative products and services. I take the opportunity to welcome all participants to the event and wish Bearing EXPO India a grand success.
EIBBMA EASTERN INDIA BALL BEARING MERCHANTS ASSOCIATION 1st Floor, 67A, Netaji Subhas Road, Kolkata – 700001 Call – 091 33 22428813 Fax – 091 33 22431568 E-mail: info@eibbma.net / help@eibbma.net Web: https://eibbma.net/eibbma/
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MESSAGE The worldwide bearing and power transmission industry is undergoing rapid transformation owing to several factors, such as rising protectionism, environmental issues, digitalization and increasing steel prices. This is creating both challenges and opportunities for industry players. Bearing Expo India, taking place at Nehru Centre Mumbai on 1516 October 2019, is a great platform that aims to help bearing manufacturers and distributors stay up-to-date on latest technologies and discuss industry-related issues.
Mr.Ramesh KR. ChaudharyPresident The All India Ball Bearing Merchant’s Association
I am sure as the expo brings together the entire bearing world at one place it will allow for relevant industry discussions and connections. Wishing Bearing Expo India a tremendous success.
AIBBMA The All India Ball Bearing Merchant’s Association 60, Shardhanand Marg, (G.B.Road), Delhi-110 006 Tel: 011-23213316 E-mail: Ltmp@rediffmail.com
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OCTOBER 2019 | ENGINEERING REVIEW 3
CONTENTS OCTOBER 2019
COVER STORY
URB : The brand recall for RELIABILITY & PERFECTION
6 COMPANY PROFILE
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CONTENTS OCTOBER 2019
COMPANY PROFILE
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INDUSTRY FOCUS
TECH NEWS
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NSK launches J-Line – a new range of JIS standard bearing units
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Simple Exchange of Gearbox Data New version of the standardized REXS interface with increased usability and expanded scope
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TECH TRENDS
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Indian Manufacturing Industry: Economic growth engine on track
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4 critical technologies for your lubrication program
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Professional installation and removal of rolling bearings www.engmag.in
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Bearing Industry Special 2019
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Napoleon Conquers Commercial Space Market
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How to build a WorldClass BEARING lubrication program...
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Success of the Ukrainian bearing industry spreads around the world market
Understanding damage tolerance in hybrid bearings
Turntable bearings in a C-arm x-ray machine
Air BushingsDiscover the Energy Savings Alternative to Ball Bearings
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Ceramic Rolling Elements for the Future
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Complete Machining of Spherical Components
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COVER STORY
URB : The brand recall for RELIABILITY & PERFECTION Q. Please brief us about the exports and overseas operations & what are the global alliances that has been made in order to out-front the competition?
Q. Please elucidate in brief about the company’s infrastructure & What are the measure that are being taken from the product manufacturing to distribution?
Our Primary markets for exports are USA, EU and India. The brand has a history of over 60 years and has a built a impeccable track record for quality and long life. This rich history and the desire to continuously improve our systems and processes to achieve excellence in manufacturing products has held us in good stead over long years.
The company is an unique position in terms of manufacturing, in the sense it look like that we are the only truly integrated manufacturer of bearings. While outsourcing has been the norm in the industry, we have stead fully held on to our belief that we can provide a quality product only if we have control over the entire manufacturing cycle. Keeping
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this as a core philosophy our Barlad operations is a unique location where the entire manufacturing is accomplished in one location starting from Forging to the assembly of the bearings. We believe that manufacturing has been one of our core strengths and the market does recognize an excellent product coming out of a truly word class manufacturer.
Q.What are the market prospects for the URB products in India and How do you plan to position these products? www.engmag.in
COVER STORY
The demand for URB products has improved substantially over the past few years & our growth in the last few years has been a testimony to this. We will continue to strive for better growth through customer acquisitions & new market penetration. We are a European brand & we cater to a variety of industries. Hence we would like to position as a very credible alternative to the established brands. It’s a brand on which the customer will derive the best value for money. That is why we are “The wise choice for ultra reliable bearings”
Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of Bearing industry? www.engmag.in
One of the main marketing strategies we have adopted is nearness to the customers. While the product quality has also been the brand’s USP the brand had its shortcomings in reaching out to the ultimate end customers due to legacy reasons. We have substantially improved in this front and are reaching out to the end customers with renewed vigor. This has resulted in significant improvement in the off take for our products.
enhance our market presence we went for a whole sale restructuring of the distribution network from one distributor to the present strength of 10 in various parties of India which has resulted in improved product availability and the consequence thereof is a significant reduction in counterfeits. We also introduced certain features in packing which has
Commenting specifically on India : We had significant disadvantages due to limited distribution network accompanied with huge counterfeit products entering the market. This could also have been due to limited reach. In order to significantly
A sample of specific ID code for each individual bearing
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COVER STORY enhanced the product experience. In order to assure our customers for the originality of URB products they are buying, we developed a specific ID code for each individual bearing we produce. Implementation of ID code was a project developed in order to offer in front of our customer a tool for brand check. This ID code is an individual identification code for each bearing which can be used to check the originality of the products. This code can be checked in our system if this info is provided through our website section referring to reporting the fake bearings (http://www. checkurbbearings.com/). This ID code was implemented also in order to protect the brand and the customers in front of fake products market.
Q.Brief us about the R&D and Quality policy for your business? Our strategy for quality and R&D has been documented. I can briefly summarize like; Permanently offering products to fully meet customers’ quality requirements, the applicable safety requirements, legal and regulated applicable requirements
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and other relevant interested parties requirements as well; Providing a framework for establishing objectives related to quality, research and development and planning of actions and allocating resources - materials, humans and financials - for their fulfillment; Identifying the technical solutions through research and development activities in order to improve the products quality and their performance according to applicable actual requirements; Assuring a framework to establish a connection for collaboration and cooperation with customers, suppliers and National or International Research Centers, and also with Technical
Universities in order to develop common projects for improvement of resources consumption and products and technologies approaches; Transferring and implementing the results and knowledge obtained in different research programs in our own processes in order to be able to create new and sustainable products and technologies, useful to a continuous changing business environment; Creating the intellectual property and develop the brand management strategies in order to encourage the innovation and research at all business levels. The research and development activities are focused on
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COVER STORY products and process optimization. Developing the products in order to increase the customer satisfaction and also our own portfolio. Currently, for this purpose the normal spherical bearings was developed in EC design. The benefits of the EC design to our customers are related to: load capacity increased, longer service life, thermal reference speed increase, lubrication coefficient increase which leads to the increase the bearing life, kinematics improved and also material structure improved (residual austenite content). All these improvements were possible by using the simulation and the research results and know-how based on practical experience in bearing design and manufacturing.
Q. Please comment on the current Bearing scenario in India ? For URB , India is a very important destination. We feel that there is still tremendous scope for the manufacturing sector to grow in India. This in turn will help in improving the demand for bearings. We are one of the youngest European companies in India, we are quite upbeat about the scenario & we would like to be present to tap all opportunities coming our way.
Q. Could you brief us on Indian & Global perspective of Bearing industry? What are the distinguishing factors?
With increased globalization there are no significant differences in various markets. The products we make for any our premier EU/US customers are the same we supply to the Indian market.
Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? GST has been a major land mark reform in the indirect taxes sphere. It has significantly rationalized the tax regime with seamless credit and has been one of the major factors for our increased sales. India operates within the WTO framework and as a major international manufacturer it’s the only level playing field we can ask
New improved ‘EC’ design for spherical bearings with steel cage www.engmag.in
for.
Q. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? These are challenges faced by every company today not only in India but everywhere. We continue to invest in technology, improve our productivity and operate in as much as possible in niche areas providing value to the customer through reduced cost of ownership.
Q. What is your vision for your company? We’ll continue to be the wise choice of our customers as the number of them develops consistently.
Unique ID code for all individual bearing to ensure authenticity
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COMPANY PROFILE
Mantri Bearing House: Focus on Quality, Quantity and Service
Mr.Rajesh Mantri MANTRI BEARING HOUSE
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n operations since 1998, Mantri Bearing House is a reliable provider specializing in Indian and imported bearings for rolling mills, crushers, cement plants, paper mills, etc. The company is also a purveyor of spherical roller bearings, taper roller bearings, ball bearings, four row cylindrical roller bearings, to name a few. With an empiricism, forbearance and experience of about two decades in exporting the bearings from one of the largest inventories in Tri-city –Chandigarh, the company stocks a wide range of products from the best of manufacturers. Courtesy its focus on Quality, Quantity and Service (QQS), Mantri Bearing House has thousands of gratified customers across the country.
In line with its vision, the company continually strives to be a handpicked and preferred source for high-quality bearings. To meet this vision, the company is committed to acquiring and disbursing finest bearings for rolling mills, crushers, cement plants, and paper mills. “We are blessed with the trust and confidence of our regulars, habitué and suppliers from past 20 years. It is our constant endeavour to be worthy of this faith and to meet and exceed customer expectations. High moral, ethical values and good interpersonal relations make the foundation of our organization,” says Rajesh Mantri Mantri Bearing House. As per the company, its success largely stands on the basic fundamentals of supplying genuinely good quality bearings and ensuring higher reliability of customer’s equipment, needless to say at competitive prices and accurate deliveries. Ensuring customer satisfaction and providing support is at the heart of the company’s operations. “We do not consider our responsibility to end when the ordered materials have reached our valuable customer’s equipment or be fitted on them. In fact, it starts from there,” concludes Rajesh Mantri
For more information www.mbhbearings.com www.engmag.in
COMPANY PROFILE
TPI BEARING: Pioneering the bearing technology excellence
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PI is perceived as a corporate entity that’s innovative, unique and proactive. A pioneer in plastic bearings, the company designs and manufactures plastic bearings and assemblies as well as mouldings that offer multifarious advantages over traditional steel bearings. The company’s vast product range covers over 700 types of bearings designed to suit varied industrial applications. These include bearings which are non-corrosive, non-magnetic, lightweight, and self-lubricating plastic bearings and housings. TPI’s plastic bearings have distinct advantages. They are hygienic and flexible, entailing low friction and noise. They feature shock load suspension and have low inertia. Delrin, the key ingredient used for making these bearings yields good tensile strength, smooth finish, high lubrication and feather touch movement. Incorporated in 1990 with the prime objective of manufacturing plastic bearings, TPI has come a long way, honing its expertise and adding new dimensions to its range and scope. Today, the company produces over 30 million pieces of bearings annually, meeting the diverse needs and specifications of its customers spread across the length and breadth of the country and beyond the shores. TPI has a sprawling manufacturing facility equipped with the latest production machines and a dedicated and a highly committed workforce
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(L-R) Mr. Amit Shah - Director & Mr. Kirti M. Shah - Director Nozzle Auto Association Pvt.Ltd. striving for excellence. “We aim to develop technology and infrastructure on a continual basis so that we are able to offer the contemporary technology to meet the expectations of our customers and the ever-changing demands of the marketplace,” says Kirti M. Shah – Director. TPI has an impressive list of satisfied customers, which includes leading names, such as Godrej & Boyce, Gemini Film Laboratory, Zenith Industries, Hyphen Industries, Prasad Film Laboratory, IDMC, Hindalco, SVP Packing, Vega Conveyors, Techno Link Conveyor Systems, HBL Power System, Janak Health Care, PSL Group, Star Alubuild, Shiva Steel, S P Fabricator, TVH Estate India, Nagarjuna Construction, Jaypee Group, Innofit Systems and RNP Transmission & Roller Systems, to name a few. The company is steered by a dynamic Board of Directors headed by Kirti Mulchand Shah, a veteran trader
turned industrialist, who has been in the bearing industry for almost four decades. Hansa K. Shah and Amit K. Shah are the other directors. Amit Shah also heads Slide System Inc. (All India Distributor for SAMET, MEPA), a leading brand in hardware fittings for applications in kitchen, wardrobes, furniture, glass and architectural building products. Among the management’s believes and values are: Investing in human resources as a tool to improve the life of people which in turn would enhance the quality of its products; improving their inter-personal relations to knit them into a larger family; motivating the employees, infusing team spirit; improving their creativity and inculcating the spirit of co-operation among them. These help in building a vibrant organization.
For more information Web: www.tpibearings.com www.engmag.in
COMPANY PROFILE
Doshi Sons: Legacy of Excellence (L-R) Mr. Sarthak K Doshi - Director, Mr. Dinkar A Doshi - Director
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stablished in 1971, Doshi Sons has come a long way since its humble beginnings. Being a family-owned company in the business for the past three decades, the company has made its mark as a dependable importer, supplier, trader, wholesaler and distributor of various kinds of high-grade industrial bearings and flange units. The company mainly deals in supreme quality pillow block bearing units, spherical roller bearings and machinery vbelts. In a bid to provide world-class quality products to customers, the company has a joint venture with a Chinese factory. Providing high quality and performance products has been
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the foundation of the company’s business success. “Our vision has always been to provide excellent quality and high-performance bearings to our diverse customer segment using standardized techniques,” asserts Dinkar A Doshi – Director, Doshi Sons. The company constantly strives to meet the expectations of its customers by working as their reliable partner and working in the direction of fulfilling their unique demands. With the legacy and expertise of three decades of business, the company has eyes firmly set on continuing to evolve in order to meet customer demands.
Our vision has always been to provide excellent quality and highperformance bearings to our diverse customer segment using standardized techniques” Dinkar A Doshi – Director, Doshi Sons.
For more information E-mail:ktndsh9@gmail.com www.engmag.in
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Stronger. By Design. As the world changes, so do our customers’ needs. With more than 100 years of technological and industrial experience, we are continuously expending our capabilities in engineering, metallurgy and precision manufacturing to meet those needs. We are committed to solve technical problems of our customers, no matter how simple or complex. Because we succeed when they do. Timken engineers apply their know-how to improve the reliability and performance of machinery in diverse markets worldwide. The company designs, makes and markets industrial components, including, gears, chain and related mechanical power transmission products and services.
104A, 1st Floor, A-Wing, Eastern Court Bldg, Near Aditi Hotel, Parleshwar Road, Vileparle (E), Mumbai - 400 057, Maharashtra, India Tel. : +91-22-26128878 / 79, Mob. No. 9819898878 Email : seworld@rediffmail.com/shreyansenterprise@outlook.com
39-42, Electronic City, Phase I, Hosur Road, Bangalore-560100 Tel: +91 (80) 41362000 I Email: salesbangalore@timken.com
www.timken.com/en-in
COMPANY PROFILE
Mahalaxmi Bearings: Built on the foundation of quality and innovation
Mr. Ankit Garg, Director, Mahalaxmi Bearings India Pvt. Ltd Mr. Ankit Garg, Proprietor, Garg International
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ith over three decades of existence in the bearing industry, Mahalaxmi Bearings India Pvt. Ltd. possesses rich experience of selling all kinds of bearings to diverse sectors of the manufacturing industry. Incorporated by Subhash Garg in 1985, Mahalaxmi Bearings is one of the pioneers of steel mill bearings, offering high-quality bearings to serve unique requirements of wide range of customers. Over the years, the company has proved its reliability and its client portfolio is a testimony to its success. In line with the continual growth, Mahalaxmi Bearings has scaled and diversified into different sectors apart from steel industry. With second generation taking reigns, Garg International was incorporated in 2014 by Ankit Garg, son of Subhash Garg.
The company was established with the vision to promote its in-house brands to all major industries which require heavy-duty and high-quality bearings. Today, the company has successfully penetrated into diverse sectors including stone crushers, cement industry, sugar mills, mining industry, steel industry, etc. The company is associated with reliability and well known for high-quality products. “Main pillars of our company are - Quality, Accountability, Integrity and Service. With these values, we have come forward a long way and hopefully these values will lead us to become one of the largest in Industry,� asserts Ankit Garg, Director, MAHALAXMI BEARING INDIA PVT. LTD. For more information www.mwgsbearings.com OCTOBER 2019 | ENGINEERING REVIEW
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COMPANY PROFILE
Vely International: Expertise in Industrial Bearing Technology
Mr. Jignesh Mehta- Director VELY INTERNATIONAL
V Authorised Importers & Distributors of URB Bearings
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ely International is a notable importer, supplier and distributor of a vast coalition of durable and high-end range of bearings in different specifications. The company has carved a niche in the market as a leading provider of high-quality bearings for various applications. Established in 1987, the company has a vast client base and has a firm focus on customer satisfaction, product quality and service. Through its wide-ranging portfolio, Vely International continually strives to meet the diverse requirements of different verticals. The company’s optimum variety of industrial bearings is procured from reliable vendors of the international markets like URB Group. “We have been following a stringent selection and procurement process to choose the right vendor for our business. We constantly search the market to select the best vendor on the basis of ethical business practice, experience and product quality,” says Jignesh Mehta- Director, Vely International.
The company continues to strive to offer valuable solutions designed to offer maximum performance with no maintenance and wear for years.
Vely International’s range of products include: • Deep Groove Bearing • Spherical Roller Bearing • Cylindrical Roller Bearings • Needle Roller Bearings • Tapered Roller Bearings • Spherical Roller Bearings • Thrust Ball Bearings • Cylindrical Roller Thrust Bearings • Spherical Plain Bearings • Rod Ends • Linear Ball Bearings Bushing • Pillow Blocks • Cam Rollers • Support Rollers • Rolling Elements • Accessories
For more information E-mail: velyinternational@yahoo. co.in Web:www.velyinternational.com
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COMPANY PROFILE
LAXMI BEARINGS : Recognition for perfection
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(L-R) Mr. Kishor Shah - Director Mr. Bhupatrai Shah - Director & Mr. Chirag Shah - Director Laxmi Bearings Private Limited
e are pleased to introduce ourselves as one of the leading Authorised Industrial Distributors of Schaeffler Products (FAG / INA Bearings – both Indigenous & Imported) and have been associated with FAG / Schaeffler since last 30 years. We were established in the year 1968 in name of Laxmi Engineering Co. at Mumbai. We are humbled that with your valued support, we have completed 50 years in the exciting field of supply of bearings. Our company was formed by our Managing Director, Mr Bhupat Shah in the year 1968 who was later joined by his brother Mr Kishore Shah in 22 ENGINEERING REVIEW
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1972 and son, Mr Chirag Shah in 1997. Subsequently, we started our Branch at Vadodara in Gujarat in the year 2005 and have been successfully servicing our Customers in Gujarat since then. For the last 5 decades, we have been trusted by Leading business houses as a one stop shop for meeting their requirements pertaining not only to supply of bearings and accessories but also add value to their operations with our various initiatives like VMI / Bearing Bank enabling our Customers to maintain Zero / minimum inventories, advising Customers to achieve optimum usage of Bearings, provide
Technical Services, conduct Bearing Training Programs etc. With our vast experience and knowledge of individual Customer requirements, we are able to maintain required stocks / achieve minimum delivery lead times coupled with providing our Customers with the peace of mind that comes with genuine bearings. We are thus able to reduce our Customer’s Bearing worries to a bare minimum in all regards. We are sure that we will continue to serve the Industry’s Bearing needs and this will be possible only with your valued support. For more information info@laxmibearing.com www.engmag.in
COMPANY PROFILE
Leadership in High Precision Balls & Rollers
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(L-R) Dharmesh Gandhi Tejas Gandhi - Partners N.Gandhi & Co.
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aving provided tailored solutions for Precision Balls for more than 3 decades, N. Gandhi & Co. is considered as a trusted source for industries like the Automobile, Aeronautic Sector, Cosmetic, Chemical and Mechanical domains. NGC balls are used in a multitude of ways: ball bearings, safety valves, body jewellery, steering column, safety belt applications, and so on. The company has broadened its product base over the years to include Grinding media and Rollers along with metallic and non-metallic balls including ceramic, glass & plastic. The long standing commitment to excellence and dedication to our customers has earned us advanced expertise and a thorough understanding of hundreds of very specific applications and processes in industries which has
helped us in providing customized solutions in all materials, sizes and tolerances. All the balls we provide are produced in accordance with the standards required by the (DIN), (ABMA) and (ISO). Our quality assurance is also certified by the International Organization of Standardization, Standard 9001 : 2015 by Bureau Veritas. The company’s commitment to its customers and business integrity reflects in its widespread popularity - with a client base that’s not only spread all across India but also in other parts of the world.
APPLICATIONS • Aerosol Pumps • Automotive Door Assembly • Ball Bearings • Ball Pen
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COMPANY PROFILE • Ball Screw • Ball Transfer Unit • Ball Valves • Bicycles • Bobbin Holder • Body Jewellery • Castor Wheels • Cosmetics • Gas Regulator • Household Appliances • Jewellery • Liner Motion Bearing • Rod End • Steering Column • Safety Belts • Toys • Watches • Wind Mill Bearing
QUALITY CONTROL The Company is ISO 9001:2015 certified and our QC Dept is equipped with high tech control machines to meet a broad spectrum of needs and guarantee best quality at all times. We follow Intensive
Quality Analysis and provide certificates for each batch inspected.
WAREHOUSE The specific strength and power of
our Group is as a one point contact to respond to all your needs and demands. Quipped with all essential infrastructures, our warehouses are constantly filled with widest range of sizes, materials and grades, completely available in one source of supply to satisfy the requirements of our worldwide customers in the shortest terms. In addition to special and open orders, we have over 250 standard balls of different types and sizes in stock For more information, Corporate Office
N.Gandhi & Co 102, E-square, Subhash Road, Vile Parle ( E), Mumbai-400057, Mahrashtra. India Tel: +91 22 68380200 (100 Lines) E-mail: marketing@ngandhi.com Web:www.ngandhi.com www.engmag.in
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INDUSTRY FOCUS
Super Slide: The linear motion intelligence In over two decade of its existence, Superslides & Ballscrews Co. India Pvt. Ltd has made its mark as a reputed provider of world-class linear motion and automation products. The company has a strong customer portfolio and high market share to its credit. Now, the company is ready for its next big leap with plans to set up a manufacturing facility in India in the next 2-3 years. In an exclusive interview with Machine Tools World, Mr. Rajiv Desai, Managing Director, Superslides talks at length about the company’s journey and milestones, its success mantra and future plans. Excerpts: Q. Please take us through the journey of Superslides & Ballscrews Co. India Pvt. Ltd. How far along has the company come since establishment and what have been significant milestones? Superslides has come a long way since its establishment in 1999. We started our journey from a very small set-up, with the idea of bringing international quality engineering components to India. Superslides set out as a sole agency and distributorship of Precision Motion Industries, Inc. (PMI) Taiwan-based manufacturer of linear guideways & ballscrews. In our initial days, we faced some acceptability issues as there was limited awareness around both for Superslides as well as PMI products both being new names in the industry. However, once customers started noticing the dual advantage of supreme quality with reasonable cost and excellent service, there has been no looking back. Today, we represent various international manufacturers in India, with PMI still being our prime principal. In over 20 years of our existence, we have grown from strength to strength and have established ourselves as a premium and reputed supplier, channel partner and authorized distributor for a wide range of hi-tech engineering components. Our strong client base of 1500-plus customers and high market share in both our key product segments ball screws 26 ENGINEERING REVIEW
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Mr. Rajiv Desai - Managing Director Superslides & Ballscrews Co. India Pvt. Ltd. and linear guideways is a testimony to our growth. We have now expanded our operations and have a state-ofthe-art office space, warehouse and service centre.
Q. Tell us more about your product range and the industries you cater to? Superslides offers a range of engineering products such as High Precision Ground Ballscrews, Precision Rolled Ballscrews, Hollow Ballscrews, Nut Coolant Type Ballscrews, Roller Type of Linear Guideways, Ball caged Type of Linear Guideways, Stainless Steel Miniature Rails & Blocks, Precision Locknuts, Support Units, Hardened & Ground Shafts, Linear Bearings, Rack-Pinion, Gear-Box etc. Our products find application in a number
of high growth sectors, including machine tools, printing & packaging, automation and robotics. Apart from these industries, we are eyeing huge opportunities in semiconductors and electronics sectors. India is looking to become prominent manufacturing hub of mobile phone in the world according to findings from a market research firm IHS. This opens a new door of opportunity for the Indian machine-tool industry with application of our products. Talking about machine tools segment specifically, Superslides and PMI products have carved out their niche and we supply to all the major players. In fact, around 80% of machine tools players use products supplied by us. Some of our most valued customers are LMW, ACE Designers, AMS, BFW, MICROMATIC Grinding, www.engmag.in
INDUSTRY FOCUS Jyoti CNC, HMT, COSMOS, LOKESH Machines, MACPOWER CNC, Electronica, Solitaire Machine, Kennametal, L&T, BHEL, Godrej, to name a few as OEMs. Hyundai Motors. Maruti Suzuki, TATA Motors, M&M, Hero MotoCorp, Indian Railways and many other for replacement business.
Q. As a leading supplier to machine tools industry, what kind of trends and growth are you observing in the segment? Indian machine Tools industry has been on a high growth trajectory and shows good future ahead. The manufacturing sector of India has a potential to reach US$ 1 Trillion by 2025, as per industry reports, machine tools industry is projected to grow 4 times by 2025. The trend is towards machine tools with automation. Due to skills shortage looming large over the sector coupled with the demand for quick delivery time and quality, there is an increased demand for high-end precision machines with automation. Also, there is a requirement for compact size machine with multi-functional capabilities to offer multiple operations using a single machine.
Q. Highlight key opportunities in the Indian machine tools industry. Machine Tool is the mother industry for any manufacturing activity,
without good machine one cannot produce high quality components may it be a metal part, plastic part or a paper part. India is one of the fastest growing markets and there are opportunities galore. The country’s manufacturing landscape is conducive with government’s policies, such as Make in India. Also, with the introduction of GST, there is a visible difference in ease of doing business and standardization. Looking at this opportunity, several Taiwan, Korean, Japanese and European companies are planning to set up manufacturing in India. With increasing manufacturing activities, demand for machine tool is also constantly rising. Currently, 50% of the machine tool demand in the country is fulfilled by Indian players, whereas 50% requirement is fulfilled by importing. There is a significant opportunity for Indian players to take on this share by manufacturing high-end machines. At Superslides, we are focused to fully tap the India market—although we have penetrated and established our brand in major areas throughout the country, there are still few untouched territories where we are planning to make our mark.
Q. How does Superslides & Ballscrews facilitate the customers and ensure their evolving
demands are met? We at Superslides constantly strive to provide the latest technology, systems, products and solutions to keep in line with new industrial automation & development trends. In terms of our products, PMI is very focused on innovation and works on the aspects of constantly upgrading the speed, accuracy, reliability and performance as per the customer requirements. Backed by a strong R&D center and strict quality check conditions, where each component passes through 48 inspection stages before dispatch, PMI products have gained immense trust from Indian customers. At Superslides, we are committed to satisfy our customers in terms of quality, price, service and timely supply. Superslides not only sells but also works alongside the customers’ design & development team to not only ensure the right selection of the product but to ensure the latest and best in technology and products are given at the right price. Apart from standard products from PMI, we also offer customization services to our customers to meet their requirements. Further, we follow a very strict quality check processes to ensure that material received by the customer is in line with the technical requirements.
Q. What is your future vision and growth plans for the company? In the coming years, we will continue to be focused on satisfying our customers and expand our presence further in India. Also, looking at the immense opportunity of manufacturing in India, we at Superslides along with PMI are committed to set up a factory in the country. We are also looking at tapping semiconductor, electronics, medical, aerospace and defence segment by supplying high-precision machine tool components. 28 ENGINEERING REVIEW
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INDUSTRY FOCUS
Tolia : The tradtion of trust & quality
(L-R) Mr. Viresh N. Tolia, Mr.Harsh S. Tolia, Mr. Shailesh N. Tolia, Mr. Rajesh N. Tolia, Ms. Shreni R. Tolia, Mr. Manan V. Tolia Directors of the �TOLIA Group of Companies�
Q. Can you tell us a little bit about your past / present and future? The Tolia group of companies established the first steel ball unit in the year 1979 (Needumbra Industries Pvt Ltd). Our grandfather, late Mr. Nyalchand R. Tolia was the sole spirit at the time who bought the light in our family on the steel balls. Ever since then, there has been absolutely no looking back in the three generations that have and are putting in their heart and soul to help a tiny part of the world spin. In 1987, three brothers namely, Rajesh Tolia, Shailesh Tolia & Viresh Tolia put up together another 30 ENGINEERING REVIEW
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milestone in our growth history, together they set up Forward Precision Engineers Pvt Ltd, yet another steel ball manufacturing unit. In 1993, the Tolia team achieved another Milestone, this time something special and different. The team set up a cylindrical roller & taper roller manufacturing plant. Our present today has a younger team involved into various aspects of the business. We as the younger team, are fully committed to carry the legacy set up by our forefathers. The future most definitely is exciting for all of us.
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TOLIA TOLIA GROUP OF COMPANIES AISI 440C
AISI 304 / 304L / 316 / 316L / 316L-Ti
AISI 420 / 420B / 420C / 430 / 430L
52100 / 100Cr6 / 100CrMnSi-4 / 100CrMnSi-6
Aluminium
Tool steel / Rockbit / S2
Ball transfer unit
Brass
40 years of Manufacturing and Technical Knowledge. Precision steel balls catered to customer specific requirements best suitable for specific applications. We provide detailed technical support to our clientel. Excellent quality, On-time deliveries and After sales service. Excellent Research and Development workforce.
MANUFACTURER OF HIGH PRECISION BALLS & ROLLERS
+91 22 25820465 / 22 25822449
toliaoverseas@tolia.com
www.tolia.com
INDUSTRY FOCUS Q. Would you please tell us a more about the products and services you offer?
growth has always lied in the growth of our existing clientele.
We are steel ball, cylindrical & taper roller manufacturers. We manufacture products of different materials ie. Stainless and Alloy steel for balls and Alloy steel for Rollers. We provide technical suggestions to our clients to help them improve the performance of their product, of course with the most economical proposals to help them achieve their absolute competitive advantage in terms of pricing and quality.
Q. Can you name a few objectives of the Tolia Group?
Q. What are some strengths you would like for our readers to know about? With 40 years of manufacturing experience our strength is the quality of product we manufacture. We have always believed in providing excellent quality and service to all our clients, and our
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• To pursue excellence in everything we do as company and achieve it through continual improvement of processes in all areas leading to customer satisfaction. • Understand, install & continually improve the effectiveness of the quality management system. • Device a suitable monitoring and measurement system to have proper control on the effectiveness of quality control. • Reduce the impact of our industry on the environment by continuously adapting new techniques and more so over by educating & motivating our team members to pass this message on to the generation below. For more information Web: www.tolia.com
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COMPANY PROFILE
Roulements INC: Fiedality of excellence
W
e at Roulements INC have inherited hands on experience from our parent company that was established in the year 1949 by late Mr. Balwant Rai Mehta, who was one of the founder members of All India Ball Bearing Merchants Association & one of the first authorised distributors & innovators for many Reputed Bearing manufactures across the world.. Roulements Inc is truly a master distributing company of High Temperature Bearings for SWC Wälzlagerfabrikation SW GmbH based in the schweinfurt Region of Germany, we specialise in rotational solutions for high temperature applications predominantly in the bearing series of 6000,6200 and 6300 which can handle temperatures from 150oC to 350oC.
Being a highly skilled, techno commercial & solution driven company, our core strength lies in• Locating hard to find obsolete bearings across Europe & USA. • Supplying small and large size Ball & Roller Bearings with a range of 1mm bore to 6000mm bore according to the customers need. • Providing adequate remedies and repair solutions. • Linked with the best inspection bearing team in Europe & USA that provide the correct inspection report
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The SWC Bearings Group Milestones of the Group:
for all type of bearings. • Associated with a team of special application engineers who have a long held experience in this field. • Roulements Inc is a partnership firm having partners as Mr. Moniel Mehta & Yashel Mehta.
SWC Bearings Group SWC was founded in 1994 after FAG Schweinfurt decided to outsource the high-temperature bearing section. The long experience of the company founder in the field of high-temp bearings and bearings filled with special grease became a trademark of the company. Since 2000, high-temp deep groove ball bearings and an extensive range of other products are manufactured in the company’s production facility and warehouse in Niederwerrn, Germany.
The Technology – High Temperature Bearings • Originally developed by FAG Kugelfischer Georg Schäfer, during the tenure of Mr. Franz Pfennig who was in charge of High Temperature Bearings and Compressors. • He worked as part of FAG Kugelfischer Georg Schäfer from 1978 to 1994 and is considered the “Father” of the technology. • Mr Franz Pfennig opened his own company in 1994, devoting his time to further development of the technology. SWC is now considered the industry leader in High Temperature Bearing Technology.
Our Mission To assist customers in analyzing problems related to Bearings operating in a high temperature environment, and to work out suitable solutions. SWC attaches importance to quality not only of the manufactured products but also of the processes within the company. Therefore our company is certified according to ISO 9001:2008 and is audited every year by LRQA Germany in order to guarantee high quality standards in every single department. For more information Web: www.roulements.in www.engmag.in
COMPANY PROFILE
NS Industries : Leadership In Tungsten Carbide Toolings l ea
TM
T ality rust S Qu
W
e manufacture and export High precision, special purpose tools in TUNGSTEN CARBIDE. The carbide tooling’s are mfg from selected best carbide inserts grade for longer tool service life.
Quality Management System As per
ISO 9001 : 2015 Evidence of conformity with the above standard has been furnished and certified for
N.S. INDUSTRIES Plot No. C - 5, 1st Floor, Nandanvan Indl. Estate, Opp. ACC, LBS Marg, Thane - 400 604, Maharashtra, India.
Tungsten Carbide Tooling’s Products For. 1) Steel Ball Industries. 2) Bearings Industries, 3) Fastener Industries. 4) Wire Industries. 5) Oil & Gas Industries. 6) Aeronautic Industries. 7) Steel Industries. 8) Railway Industries. 9) Tablets Industries.
Mr. Meghal Tolia - CEO NS Industries
N S Industries : Members & Affiliations . a) MSME. b) NSIC. c) DGS&S d) Udyog Aadhar. e) Ministry Of Defense : Aero & Ordnance Plants.
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Scope. Manufacture & Exporter of Cold and Hot Forming Carbide Toolings for Steel Balls, Fasteners, Bearings, Defense & Aeronautics Industries. Certificate Registration No. 91/Q/6348 Original Issue Date : 24th September 2012 Certificate Issue Date : 31st January 2019
Certificate Expiry Date: 30th January 2022 Audit Cycle :12 Months
This certificate is valid for a Period of three years & subject to the satisfactory completion of annual Surveillance Assessment, lack of fulfillment of conditions set out for issuance of this certificate may render this certificate invalid.
_______ Managing Director
CB-024-MS
Global Presences : Offices At UAE , South Africa , Italy .
For more information Web: www.nsindustries.in
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COMPANY PROFILE
YOGI HI TECH PVT.LTD: Leadership in Bearing technology
Y
Mr. Rajan Patel - Director YOGI HI-TECH (P) LTD.
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OGI HI TECH PVT.LTD. is a Rajkot-based company that is exclusively promoted by Ramnik Patel and Dinesh Patel. A thoroughly established firm in bearing industry with a track record of over 22 years, YOGI HI TECH PVT. LTD. has evolved as a symbol of trust and goodwill amongst the Indian bearing industry manufactures and customers. Over the years, the company has made its mark as a leading player having vital collaborations with major bearing manufacturing companies. ZXL BEARINGS is built and well equipped with ultra-modern and latest machinery. YOGI HI TECH PVT. LTD. manufactures cluth release bearings, kingpin bearings, steering bearings, four point contact bearings , cylindrical roller bearings , tapper roller bearings , center bearings assembly, ball bearings, wheel bearings and hub unit, thrust bearing, tensioner / idler, water pump bearings, needle roller bearings and cages. The plant is strategically located at GIDC Industrial Estate, Rajkot – Gondal National Highway, Gujarat, which is the third largest bearing
zone in the world, Along with being equipped with skilled labor, raw materials and necessary infrastructure required for undistracted operations, the plant is well connected by all forms of transportation. “Easy access to the plant location by air (Rajkot airport -20kms), road (NH 27-A), rail (Rajkot railway station – 20kms), and waterways (Mundra / kandla -180 kms), provides us with flexibility and ease of access to all forms of logistics to meet supply chain demand of our foreign customers,” says Rajan Patel Director YOGI HI-TECH (P) LTD.
For more information Web:www.zxlbearings.com
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COMPANY PROFILE
HENNIK IMPEX: On the forefront of delivering quality with perfection
Mr. Kaushik Ghelani - Director HENNIK IMPEX
I
ncorporated in the year 2004, HENNIK IMPEX has been serving the bearing industry since 1990. With dedication and hard work of its proprietor, the company has carved out a niche for itself and achieved great heights. The company started the business as a stockiest and seller of bearings, today it is an authorized dealer of ZKL bearings as well as importers and distributors of pillow block bearings under brand name TUVX and ODQ. It also deals in leading brands, including ETK, FAG, URB, SKF, to name a few. The company’s range of bearings has wide usage in industries, such as agriculture, chemical, stone crushers, pharmaceutical, bottling plants, food industry, etc. The company has scaled and grown over the years and serves
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Mr. Henik Ghelani - Director HENNIK IMPEX
customers in India and overseas. “We have one branch in Ahmadabad, Odhav to serve our customers better and to channelize our work. We serve in different states in India and also export the same in other countries. The reason of our company’s continual growth is best quality products with competitive price. Courtesy our outstanding services, we have been able to retain all our customers from the day we started our journey and we firmly believe that dedication and hard work of our team will definitely help us reach all the goals,” says Henik Ghelani – Director, HENNIK IMPEX. The company is all set to evolve considering the changing customer requirements and expectations. “Our objective is to reach greater heights and be our own competitors
by severing more customers. We are working toward further expanding our business in other states of India taking everybody together like our staff and our customers. We are also committed to serve our society and be socially responsible,” shares Kaushik Ghelani - Director HENNIK IMPEX. The company is all set to push it boundaries under the guidance of Kaushik Ghelani by gaining from his immense knowledge and wideranging experience and further solidify its position in the bearing industry.
For more information, E-mail: asiaticexpo@yahoo.com www.engmag.in
COMPANY PROFILE
PRIMEROLL : The legacy of quality excellence
R
ollway brand was created in the year 1908 in Syracuse, New York, USA by Rollway Roller Bearing Company. Today, with a range of more than 7000 types of Ball and Roller Bearings – both radial as well as thrust types - Rollway is a preferred brand in General and Heavy Engineering Industries in USA , Europe and other Industrialized countries. Areas of use of Rollway bearings are quite diverse and covers almost all industrial applications e.g., Electric Motors, Mining Equipment, Steel Mills and other Metal Working Industries, Power Plants, Oil Field Equipment, Refineries, Gear Box and other Power Transmission Equipment , Material Handling Equipment, Fans, Pumps, Compressors, etc. Rollway bearings are not strangers to India either. Indian Oil and Gas Industry, Power Generation, Mining and Construction industries and Electric Motor Manufacturers are regular users of this brand of bearings. Founded in 1905, McGill patented the CAMROL(R) Cam-follower bearing, which today is offered in more than 1400 different combinations and configurations. McGill Products also include Aerospace Bearings, Needle and Spherical Roller Bear-
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ings. SealMaster was founded in 1935, and today, it is considered as the most preferred brand of premium quality Mounted Ball and Spherical Roller Bearings. All these brands belong to Regal Power Transmission Solutions – a Division of Regal Beloit USA. Regal Power Transmission Solutions is a family of respected product brands that supply a variety of power transmission components designed to increase both uptime and productivity of a Manufacturing Plant. Besides Rollway, McGill and SealMaster, the other offerings from Regal Power Transmission are Browning Speed Reducers and V Belt drives, Jaure and Kop-Flex Couplings, Morse Roller-chain Drives and System Plast Plastic Conveying Chains and Belts. Primeroll International Private Limited, Kolkata, has been appointed by Regal Beloit, as the Authorized Exclusive Distributor of Rollway Products and an Authorized Distributor of “McGill” and “Sealmaster” range of products for the territory of Republic of India. Primeroll’s founder-Directors have been involved in the bearing distribution business in India since 1975 and are the top bearing distributors in India. This unique association between Regal and Primeroll brings to Indian customers field expertise, market knowledge and quality products and technical services that are used by industries all over the world. Primeroll International Private Limited has its Head Office and Central Warehouse in Kolkata, branches in Kolkata, Gurgaon, Mumbai and Chennai and a network of Dealers strategically situated all over India.
For more information Web: www.primeroll.in www.engmag.in
COMPANY PROFILE
INDO Engineering Corporation: Heritage of Excellence
I
Mr.Jignesh Vora -Director INDO Engineering Corporation
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NDO Engineering Corporation has been in the field of bearing trade for the last 50 years. With its wide product range and unrelentless focus on quality and service, the company today has a well-established clientele across India. The company serves various types of customers from MRO and OEM segments. From MRO segment, the company serves myriad industry sectors, including cement, steel, pharmaceutical process plants, mining & processing, paper mills, food processing plants, chemical plants, textile manufacturing plants. In OEM segments, it offers products and services to cater to the requirements of electric motor manufacturers, pump manufacturers, machine tool manufacturers, construction machinery manufacturers, conveying & material handling , printing machinery manufacturers, textile machinery manufacturers, industrial transmission & gear box manufacturers, pneumatic engineering and general ventilation systems manufacturers, crane & hoist manufacturers and many more. INDO Engineering Corporation is also equipped to provide complete technical assistance through Schaeffler technical services for resolving any bearing application issues. In a bid to meet the training requirements of customers, the company also conducts technical seminars for plant personnel. The company also provides various mechanical maintenance products manufactured by FAG, a division of the Schaeffler Group, under their value-added services
programme. Its services include mounting and dismounting toolkits & equipment, application specific greases, condition monitoring devices and services of condition monitoring for critical machinery or the complete plant. (for more information please visit website – www.fag.com) The company’s focus on on-time and quality service is central to its business success. “We have the capability to meet client’s service needs at a short notice. We maintain sufficient stocks of bearings required for various industries to meet client’s requirements in time,” shares Jignesh Vora, Director, INDO Engineering Corporation. Looking ahead, with its wideranging experience and expertise, the company is all set to continue its growth trajectory.
For more information E-mail: indobrgs@gmail.com indobrgs@vsnl.com www.engmag.in
COMPANY PROFILE
CHEMP International: Ensuring business success with customer satisfaction
E
stablished in 1985, Chemp International is a one-stop provider of bearing solutions, meeting requirements of diverse range of industries. Over the years, the company has established itself as a reliable provider with world-class brands and services. Chemp International stocks a wide range of bearings from reputed brands around the world so that it can cater to various customer requirements on a timely basis. Some of the key brands in the company’s vast product portfolio include NSK, FAG, SKF, RHP, INA, Timken, Gamet, NTN, etc. Since the company’s inception, it has been specializing in the supply of spindle bearings, other super precision bearings, bearing accessories & speciality lubrications. Some of the industries the company serves include machine tools industry, auto industry, chemicals, textiles, steel rolling mills and oil industry. For Chemp International, timely solutions and customer satisfaction have been the two key pillars that have contributed towards its success and places it ahead of the pack in the fiercely competitive market. “For us all our customers stand equal and are a stepping stone towards new heights that we aspire to touch with each coming day. That is the reason we always aim to satisfy the requirements of our customers with timely supply of genuine and excellent quality bearings. Our aim to satisfy requirements of our customers by giving timely and economical solutions is what sets us apart from our competitors,” shares Bipin Shah, Director, CHEMP INTERNATIONAL. 46 ENGINEERING REVIEW
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(L-R- Mr. Keval Shah - Director & Mr. Bipin Shah - Director CHEMP INTERNATIONAL
For more information E-mail:- chempint@hotmail.com/ mechexcel@hotmail.com www.engmag.in
COMPANY PROFILE
SAROJ IMPEX : Expanding the horizon Central Part of Madhya Pradesh and Eastern Part mainly Orissa. Currently the Company has been in the process of expanding in the rest of India.
Locations: The company has 3 marketing offices at Ahmedabad, Bhubaneshwar & in Satna (MP) supported by more than 24 Employees working tirelessly to satisfy our Vision.
Vision: Mr. Chirag Shah- Director SAROJ IMPEX
T
he SAROJ group was founded in 1978, by Mr. Arvind Shah, the current Chairman and thereafter with the joining of 2 sons-Mr. Bhadresh Shah & Mr. Chirag Shah grew at a rapid rate from 2005 to become a leading Industrial Distribution House. By the year 2007, the company was well established in the Western part of India, specially in the states of Maharashtra, Gujarat, as well as in
The SAROJ group’s vision is to be the Market leader in Power transmission Products and Services, by earning customer confidence thru right quality products and services offering, at competitive pricing, vide a single window and to serve the society maintaining a sustained profitable growth for the organization.
Mr. Bhadresh Shah- Director SAROJ IMPEX • 2010: Crossed $3 M in Sales & Became the most preferred distributor • 2015: Became the First Timken distributor to start MILLTEC(SM) Service for Timken.
Major Achievements: • 2005: Enrolled as Timken Channel Partner • 2008: Became a Platinum Club distributor with Net sales > $1.2 M
For more information E-mail: Saroj.ent@gmail.com 48 ENGINEERING REVIEW
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Stronger. By Design. As the world changes, so do our customers’ needs. With more than 100 years of technological and industrial experience, we are continuously expending our capabilities in engineering, metallurgy and precision manufacturing to meet those needs. We are committed to solve technical problems of our customers, no matter how simple or complex. Because we succeed when they do. Timken engineers apply their know-how to improve the reliability and performance of machinery in diverse markets worldwide. The company designs, makes and markets industrial components, including, gears, chain and related mechanical power transmission products and services.
SAROJ IMPEX
218/220, Samuel Street, Kapurwala Building Room No-301 / 302, 3rd Floor, Mumbai-400003 Tel. : +022-23464654 / 67473533 / 23465119 Email: Saroj.ent@gmail.com
39-42, Electronic City, Phase I, Hosur Road, Bangalore-560100 Tel: +91 (80) 41362000 I Email: salesbangalore@timken.com
www.timken.com/en-in
COMPANY PROFILE
Hitech Rolling Balls Pvt. Ltd.: Growth with innovation
(L-R Mr. Saurabh Shah- Director , Mr. Yogesh Shah- Director & Mr. Rushabh Shah Director Hitech Rolling Balls Pvt. Ltd
T
he parent company of Hitech Rolling Balls Pvt. Ltd, Chetankumar & Brothers traces its beginnings to the year 1977. With Yogesh Shah at the helm, Chetankumar & Brothers introduced various brands like Nachi and IJK in 1978 for import and distribution. The company was also indenters for Nachi till 1985 and introduced Jay Bearings in 1985. Continuing its growth spree, it started distribution of INA in 1990. Since 1993, Chetan Bearings Pvt. Ltd. (CBPL), erstwhile known as Chetan Kumar & Brothers, has grown multi-fold due to its ethical business practices to various industries in Maharashtra. CBPL is the leading
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authorized distributor for Schaeffler India Ltd. (FAG & INA) and ABB (Baldor & Dodge - Mechanical Transmission Products) in Pune. CBPL has a wide client base in various sectors. The company continued to scale greater heights as the second generation of the family came to the forefront. Saurabh Shah, MBA in Finance, joined the group in 2013 and now heads the Trading Arm in the capacity of CEO. In 1994, Yogesh Shah identified an opportunity to diversify the business by entering into the manufacturing sector. He formed a new venture by the name of Hitech Rolling Balls Pvt. Ltd. (HRBPL), focused on driving growth through the opening of automotive sector. The first plant was established in Pune for supply of auto ancillary products, such as needle cage bearings, needle bush, needle and cylindrical rollers, axial thrust washers, crank pins, etc. The second plant was started in 2005 in Mysore by acquiring the Needle Roller Bearing plant of Jay Bearings (commissioned with Koyo Japan Technology). HRBPL is a 100% OEM supplier in India and exports to North America, Europe and Asia-Pacific. The team became stronger as Rushabh Shah, MS in Engineering Management (USA) joined the group in 2011. He now heads both the plants in the capacity of Director. Yogesh Shah is the past president of All India Ball Bearing Merchants Association, past Chairman of Nagdevi Action Committee and is currently the Vice-president of Federation of Associations of Maharashtra. For more information E-mail:info@chetanbearings.com www.engmag.in
COMPANY PROFILE
ISK BEARING : Technology expertise with precision
I
Mr. Vinod Patel ISK Bearings Industries
SK Bearings has done modest beginning in 2010. The parent company was established in 1991 and since then we are engaged with bearing industry. ISK is now one of the most specialized Bearing Manufacturer and Solution Provider for Automotive Bearings. We are located at Rajkot, Gujarat, India. ISK Bearings has its Excellency for developing Innovative products. We have acquired quality certification of IATF 16949:2016 & ISO 9001:2015 We manufacture best-in-class automobile bearings for Cars, SUV, MUV, LCV, Three wheelers vehicles as well as manufacturing of complete Electric Three vehicle and its components.
• Taper Roller Bearings • And for Three Wheeler • Steering Column Bearings • Wheel Hub Units • Disc Brake • Ball Bearings • Electric Vehicle Components Complete Kit. We manufacture 3.5 million bearings and components per annum. ISK Products are exported to USA, Latin America, Europe, Middle East and Asian Countries Our vision is to become the most leading quality based manufacturer of bearings & components in automobile segment across the globe.
Our widespread ranges of product portfolio for cars are: • Wheel Hub Units • Wheel Bearings, • Clutch Release Bearings
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For more information www.isk.in www.iskbearings.com
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COMPANY PROFILE
JEI BEARING : The synergy of quality & durability
J Mr. Haresh Hadvani, JEI Bearings
EI BEARINGS is an IATF 16949:2016 company and was established in the year 1999 and we are engaged in Manufacturing and Exporting Bearings components since then.
We export the following types of Rings: • Cylindrical Bearing Rings • Spherical Bearing Rings • Taper Bearing Rings • Ball Bearing Rings • Angular Contact Bearing Rings • Thrust Bearing Rings • Self Aligning Bearing Rings
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We produce Rings of any size from 24 mm upto 550 mm OD as per customer’s required quantity of SAE 52100, 100Cr6, 100CrMnSi6-4, SUJ15 or any other required material. We are exporting Turned Rings to reputed bearing manufacturers in European countries since 2011.
For more information www.jeibearings.com www.jei.in
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COMPANY PROFILE
Darshak Bearing : The blend of quality & strength
E Mr. Darshak Ghetiya- Director Darshak Bearing
stablished in theyear 1991, at Rajkot (Gujarat, India), we “Darshak Bearing Co.” is the distinguished manufacturer of high-quality and durable range of Spherical Roller Bearing and Cylindrical Roller Bearing. We have provide these products at reasonable prices and deliver it within the assured time-frame These products are widely demanded by our clients for their varied associated attributes. We are Manufacturing of high quality and durable range of Spherical Roller Bearing and Cylindrical Roller Bearing.
Also introduce the huge product of Bearing. • Spherical Roller Bearing
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Mr. Champakbhai Ghetiya- Founder Darshak Bearing • Cylindrical Roller Bearing • Tapper Roller Bearing • Deep Groove Ball Bearings • Angular contact ball bearings We are always believing in Service and continuously connected with our Reputed Client. We having well established workshop with CNC machines with advance technologies. We are suppliers of OEM and Overseas customer with high pericision bearings as global business.
For more information www.darshakbearing.com
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COMPANY PROFILE
Techno Overseas: Specialization in High-
Temperature Bearings, Ball Screw Bearings & Agriculture Pillow Block Bearings
E
Mr. Hiren Doshi - Director TECHNO OVERSEAS
High temperature bearings
FK Pillow Blocks 58 ENGINEERING REVIEW
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stablished in 1998 by Hiren Doshi, Techno Overseas has come a long way since its humble beginnings. Today, the company has established itself as a credible brand and an authorized distributor and stockiest for NACHI JAPAN Bearings, ENC Brand HighTemperature Bearing Made In Spain, FK Pillow Unit Bearings and Beco Brand Extreme Temperature Bearings Made In Italy. “Under the guidance and support of my father, Mr. Kirti Doshi and my uncle, Mr. Ashok Gandhi (Sunrise Corporation, Mumbai), I have been able to mark a name for the company,” says Hiren Doshi. In over 20 years of its existence, Techno Overseas has continuously scaled new milestones in the field of importing and supplying a host of industrial bearings. High temperature Bearings,w Ball Screw Bearings & Agriculture Pillow Block Bearings. The key characteristics of the company’s products include operational life, enhanced load rating, high temperature lasting, low noise and high accuracy. With its vast product portfolio, the company caters to various industries and is registered with public sectors as well
as private sectors. The company links its phenomenal success to its ability to deliver all its products anywhere within a short period of time. With a clear focus on dedication, commitment and quality, Techno Overseas has an impressive track record of customer satisfaction and requirement. The company’s bearing products are genuine and high quality as they are sourced directly from virtually all the major industrial bearing manufacturers. “The huge success of Techno Overseas is exemplary in the industry and we owe it to various parameters such as best quality products, and timely delivery of any quantity, which is possible because of our vast and wellorganized storage unit. All-inclusive commitment and dedication are another two pearls of our company, which have helped us make a mark and put us before the competition,” shares Hiren.
For more information Email. hiren.doshi@technooverseas. com Website: www.technooverseas.com www.engmag.in
COMPANY PROFILE
Insist on
Quality Bearings Insist on V M Traders
(L to R) Mr. Dagdu Jadhav - Sr. Manager Marketing, Mr. Maruti Padwal - CEO, Mr. Vinod Padwal Head - Business Co-ordination
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.M. Traders established by Mr. Maruti Padwal in the year 1982 is one of the largest importer & stockist of bearings. Situated in the business capital of India, Mumbai it carries very good name & goodwill in the market. V.M.Traders primarily deals in bearings of INA, FAG, TSUBAKI, OZAK, ABBA, IKO. We keep bearings in wide range useful for various industries & market. We also have a showroom to facilitates prompt service & to fulfill the requirements of the masses.
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Over the years, we at, V.M.Traders have maintained our leadership position in the trading industry of bearings, cam clutches & rod-ends adhering to the highest quality standards. Our superior, state of the art customer service ensures that all your requirements are met immediately. Our position of consistent excellence is maintained through continuous developments, streamlining of work operations & improvements to the line. V.M. Traders works closely with its
customers to serve the holistic needs of the industry with a complete series of roller bearing, linear bearings, precision bearings, cam clutches & rod-ends. Please contact us for the requirements of bearings such as needle roller bearings, linear bearings, rod end bearings, spherical bearings, cylindrical bearings, clutch bearings, ballbearings and many more.
For more information, Website: www.vmtraders.com
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TECH NEWS
NSK launches J-Line – a new range of JIS standard bearing units NSK is expanding its existing RHP branded Self-Lube® range of bearing units to include products made to the JIS standard. With this new J-Line series, NSK also introduces a new packaging design. The J-Line bearing units comprise six of the most popular housing types: pillow block with/without feet, square and round flange, two-hole flange, and take-up unit. Also available are three pressed-steel housings and five inserts (wide and narrow set screw, wide and narrow lock collar, and adaptor sleeve) covering bore diameters that range from 12 to 90mm. The units are built on demand, offering the highest flexibility for customers. J-Line bearing units will be easily identifiable in their new, fresh NSK packaging design for the European
NSK J-Line units comprise a wide selection of bearings and housings market. Ready to ship from April 2019, J-Line bearing units are suitable for use in sectors that include agriculture, cement, construction, food, material handling, packaging, paper, steel, textiles and many others. To help simplify selection, NSK has published a new Bearing Unit Cata-
logue containing both J-Line and Self-Lube ranges. An electronic version will be placed on the NSK website ready for download. About NSK Europe NSK Europe Ltd. is the European organisation of the Tokyo-based bearing manufacturer NSK, which was founded in Japan in
The new packaging for NSK J-Line bearings
1916 and today employs around 31,000 people in its worldwide operations. The products and solutions provided by the industrial and automotive supplier can be found wherever things move. In addition to nearly all types of rolling bearings, the company’s portfolio includes housed bearings, linear technology, wheel bearing units, transmission and engine bearings and steering systems. The company is oriented to perfection in all of its business activities. Its aim is quality leadership in its industry, which it strives for through a continuous process of improvement, excellent product development, optimised production processes and customer-oriented service processes.
For more information Web: www.nskeurope.com 62 ENGINEERING REVIEW
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TECH NEWS
Simple Exchange of Gearbox Data New version of the standardized REXS interface with increased usability and expanded scope A large number of different software tools are used in gearbox development. Up to now, no standard has been established for exchanging gearbox data. FVA (Forschungsvereinigung Antriebstechnik e.V., the German Research Association for Drive Technology) is changing this with the development of the REXS interface, an industry-wide standard for exchanging gearbox data between different CAE tools. The freely available standardized interface is being developed in close collaboration with industry and research and is intended to minimize maintenance requirements and data errors when communicating and exchanging data between different CAE tools. Version 1.1 of the interface was released on 26 October, 2018 and features greatly improved ease of use as well as an expanded specification scope. It also now offers users the ability to model planetary stages and FE assemblies as well as consideration of parameters from mechanical system calculations.
• Bevel gears and gear stages • Rolling bearings • FE assemblies • External loads • Shifting positions • Load spectra • Lubricants • Materials • Tools In addition to the expanded contents, the new REXS database at www.rexs. info simplifies working with the specifications with many new features (navigation through different versions, validation, machine-readable export in .xml format, ChangeLog) as well as additional and more detailed attribute descriptions. The REXS interface has developed
The specification now includes: • Shafts • Planetary gears • Cylindrical gears and gear stages 64 ENGINEERING REVIEW
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substantially in both content and usability since publication of the first version in November 2017. In 2019, the REXS specification will be further expanded to include modeling of flank modifications and notches as well as the parameters of various cylindrical and bevel gear standards. Interested parties can contribute their suggestions at any time via the freely accessible REXS Ticket System and follow their implementation in the REXS development process.
For more information visit www.rexs.info. REXS in the FVA-Workbench 5.0 FVA-Workbench 5.0, the FVA’s drive technology simulation platform, already supports the current version of the REXS interface, making a significant contribution to the efficient exchange of data. It
also serves as a reference to users of how the interface can be implemented in a software package. For more information www.fva-service.de
About the FVA The German FVA (Research Association for Drive Technology / Forschungsvereinigung Antriebstechnik e. V.) is the world’s leading research and innovation network in power transmission engineering. The FVA supervises around 220 ongoing projects at the best research institutions in Germany. This cooperative industrial research provides the foundation for product innovations from more than 200 FVA members. The FVA brings thousands of industry experts along the entire value chain together with the best research institutes and scientific institutions in the drive technology industry. The FVA is a globally unique network of experts that creates value for all involved. For more information Web:www.fva-net.de www.engmag.in
COMPANY PROFILE
VIPUL BEARING CO. : Endeavouring coherent accuracy
Mr. Vipul Shah , Director VIPUL BEARING CO.
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ipul Bearing co has been in the field of bearing trade for the last 30 years. With its wide product range and unrelentless focus on quality and service, the company today has a well-established clientele across India. The company serves various types of customers from OEM segments.
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From OEM segment, the company serves steel, pharmaceutical process plants, paper mills, food processing plants, chemical plants, textile manufacturing plants. It offers products and services to cater to the requirements of electric motor manufacturers, pump manufacturers, machine tool manufacturers, construction machinery manufacturers, conveying & material handling , printing machinery manufacturers, textile machinery manufacturers, industrial transmission & gear box manufacturers, pneumatic engineering and general ventilation systems manufacturers, crane & hoist manufacturers and many more. Vipul Bearing Co is also equipped to provide complete technical assistance through Schaeffler technical services for resolving any bearing application issues. The company also provides various mechanical maintenance products
manufactured by FAG a division of the Schaeffler Group, & Skf India Limited under their value-added services programme. Its services include mounting and dismounting toolkits & equipment, application specific greases, condition monitoring devices and services of condition monitoring for critical machinery or the complete plant. The company’s focus on on-time and quality service is central to its business success. “We have the capability to meet client’s service needs at a short notice. We maintain sufficient stocks of bearings required for various industries to meet client’s requirements in time,” Looking ahead, with its wideranging experience and expertise, the company is all set to continue its growth trajectory.
For more information www.vipulbearingco.com
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TECH TRENDS
Indian Manufacturing Industry: Economic growth engine on track
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anufacturing has emerged as one of the prominent growth sectors in India and the nation is on track to become the fifth largest manufacturing country in the world by 2020. The ‘Make in India’ program aims to position India on the world map as a manufacturing hub and give global recognition to the economy. Various studies have estimated that every job created in manufacturing sector has a multiplier effect in creating 2–3 jobs in the services sector, this makes manufacturing critical to achieve inclusive growth in the country as India looks at transforming gradually from a service based economy to an economy with enhanced contribution from manufacturing sector. A globally competitive Indian manufacturing sector will be a key enabler in achieving the vision of a USD 5 trillion economy by 2025, creating 100 million new jobs by 2022. Business conditions in the India continue to remain positive and Foreign Direct Investment (FDI) is on the 70 ENGINEERING REVIEW
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rise as companies and economies try to capture Indian growth. Global competition and cost pressures are aiding the flow of organic investments in India. India is on the path of becoming the centre for hi-tech manufacturing as global giants such as GE, Siemens, HTC, Toshiba, and Boeing have either set up or are in process of setting up manufacturing plants in India, attracted by India’s market of more than a billion consumers and increasing purchasing power, cumulative Foreign Direct Investment (FDI) in India’s manufacturing sector reached USD 76 billion during April 2000-June 2018. While global manufacturing companies look at India for investments and capturing growth emanating from India, there are peculiarities in the market that makes India different from other markets. Indian markets are price sensitive. While the volumes could be interesting for the manufacturers, obtaining high prices for premium products could be challenging. The
global manufacturers need to evaluate each product with the “sufficient for application” Vs the “best in class” design philosophy. With price sensitive markets being more susceptible to counterfeit products, brand protection becomes more important than other geographies. Strong manufacturing process development and implementation to ensure consistency of quality across the globe could ensure companies gain customer brand confidence in long term. Quality perception of products manufactured in developing countries should be countered by delivery of equivalent quality products manufactured in India. India is on the path of reforms in policy framework to accelerate process of ease of doing business. While implementation of these reforms may bring some evident short term repercussions on the business performance, organizations tend to gain growth momentum with these policy changes in longer duration. There are more reforms www.engmag.in
TECH TRENDS of ecosystem for co-development and growth.
Author: Mr Vikas Manral - Global manufacturing expert
in pipeline and companies need to focus on the long term gains achieved through these reforms and not be flustered with the ripples of change. With the unprecedented growth in India, the pace of business is fast. Time to market new products requires organization agility & flexibility. New products (& designs) specific to the geography and market conditions (Madefor-India) need to be developed. Local R&D centres may help organizations to be more efficient in new product development. “Reverse Innovation” (product developed for the developing economies but marketed/ distributed globally) can be the mantra to obtain leverage in the global market. MSMEs (Micro, Medium and Small enterprises) in India have tremendous potential to grow and contribute to the
Indian economy. Long term partnerships with Indian MSMEs having good technical capabilities could not only provide a low cost advantage but also a source of “frugal innovation” for companies worldwide. An ecosystem with MSMEs could be a source of global competitive advantage for the companies investing in India. With changing geopolitical scenario expected to play a major role in coming time, having a global manufacturing base in India, could be a good strategy for companies. India’s relationship and acceptability in the world could help it in establishing itself as a hub of manufacturing for the world. Impetus on developing industrial corridors and smart cities, aims to ensure holistic development of the nation. The corridors would further assist in creation
Mr Manral is a senior management professional with 18+ years of experience in global manufacturing industry. He specialises in Business strategy and International marketing for Aerospace & Defence sector. He started his career as Management Trainee 27th batch from Hindustan Aeronautics Limited (biggest aerospace company in South East Asia owned by government of India) . In his last stint with SKF Aerospace, Mr Manral was managing business in multiple geographies with multi-national teams and global reporting structure. He graduated in Mechanical Engineering from GB Pant University Pantnagar- India in 1999 and completed his Post Graduate Diploma in General Management from XLRI JamshedpurIndia. Mr Manral has also done Executive Management Program from RMIT Melbourne Australia and Accelerated Development Program from Wharton School of Management. He is a keynote speaker and moderator in different global & domestic platforms like Knowledge@Wharton, NASSCOM, AIMA, PHD, FICCI, SIATI events. He has presented more than 15 white papers on Global Strategy, International Business, Leadership, Supply Chain Management etc. LinkedIn: https://www.linkedin.com/in/vikasmanral-a2b47a8/
Mr. Vikas Manral Global manufacturing expert www.engmag.in
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TECH TRENDS
Bearing Industry Special 2019 Q. Killing Bearings with Kindness? Having completed expert failure analysis for over 7 years, DASH Engineering is recognising the increased need for education and training amongst maintenance and engineering personnel who work with bearings and the associated rotating equipment. We’ve been lucky to have been exposed to many different industries and sites over the years and had the opportunity to share knowledge with many maintenance technicians and engineers. Often when discussing bearing lubrication requirements, there are many differing greasing theories, the most common being that if a little is good, more is definitely better!
The question is: • Do we purge? • Use on-line systems • Re-lubricate at regular intervals • Install automated systems? • No matter the option, grease is always in plentiful supply! We were discussing these alternatives with a technician recently. His many re-lubrication regimes have been ‘engineered’ for the site applications. He had little input to these, but has a regular routine to follow. One story he shared was about one
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of the conveyor systems he maintains with some bearings on a monthly greasing regime and some, 6 weekly. He shared that although there was some ‘engineering’ behind the time intervals, he walks past the 6 weekly ones on his monthly route and adds grease to them. Why? He feels sorry for them! I understand where he’s coming from - if there is a grease nipple in sight, we feel obliged to grease it. Like feeding a Cocker Spaniel – they’ve had their dinner but the sad, starved look they give us makes us want to give them just a little bit more. Like over feeding the dog, we’re inadvertently overloving our bearings. This leads to internal friction, heat, sliding and contamination. The recognised global industry standard of filling the free space in the housing as a contamination barrier is, actually, a carrier. As leaders in our field of providing impartial advice and solutions, our research and practical experience has proven that this ‘over-loving’ is resulting in premature failures. Our reviewed lubrication regimes have proven excessive grease is unnecessary and wasteful. It offers little, if any, benefit to operational life. As impartial and independent
bearing experts, the knowledge that we have gained through practical, hands-on failure analysis allows us to deliver the specific training and knowledge that is truly beneficial to increasing bearing life. It’s time we stop killing our bearings with kindness. Article written by David Beattie – Principal Engineer, DASH Engineering Perth Australia - +618 6162 0990 www.dashengineering.com.au
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TECH TRENDS
Success of the Ukrainian bearing industry spreads around the world market
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harkov Bearing Plant (HARP), the largest manufacturer of bearing products in Ukraine and Eastern Europe, has been producing the bearings for 70 years. Roman Girshfeld, Vice President of the UPEC IG, told about the successes of Ukrainian bearing industry leader on the world market. HARP’s main priorities are
high quality and innovations. The company offers state-ofart, versatile and unique design solutions for various segments of industry such as automotive, agricultural, railway, mining and smelting and general engineering. In its proud history, HARP made its way from the pioneer of bearing manufacturing to the acknowledged
UPEC Industrial Group is an industrial holding which unites a number of leading design centers and engineering companies, including Kharkov Bearing Plant www.engmag.in
leader of the industry. Today dozens of companies in more than 20 countries of the world prefer the products of Kharkov Bearing Plant. As Roman Girshfeld points out, the export share was 65% in 2018. This year the company is going to hit 70-75%. HARP products are exported in EU countries (Germany, Poland, Italy etc), Russia, the Baltic states and Transcaucasia, Central Asia and North Africa. HARP also actively promotes the products to the North American market (in Canada) and going to enter the Turkish market. “Our main aim is the export activity expansion, so HARP presents its products at the largest international industry exhibitions. For example, we traditionally present our achievements at AGRITECHNICA and InnoTrans in Germany. In 2018 HARP made its debut at such large-scale exhibitions as China International Bearing Industry Exhibition, Canada’s Outdoor Farm Show and EIMA International in Italy”. HARP pursues a flexible OCTOBER 2019 | ENGINEERING REVIEW
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TECH TRENDS cooperation policy and cares about customers’ requirements and interests, offering traditional as well as individual design solutions. Such a business model allows the company to manufacture the original products in accordance with customer’s designs, embodying technical projects of any complexity, in addition to serial products. In such a way, the company builds a successful system of fruitful and long-term cooperation with its partners. Thus, the company prolonged an annual contract for bearing products supply with MetalAgro, the largest Bulgarian agricultural machinery producer, extended an annual contract with ArcelorMittal – leading world metallurgical company, and prolonged the contract of exclusive distribution with the company IGNERA (Latvia). “The 70-years production experience allows us to satisfy the demands of farmers and agricultural machinery producers around the world”, – Roman Girshfeld tells and adds that HARP products are demanded among such large machinery manufacturers as Rostselmash and Salford, Klever and MTZ. “Kharkov Bearing Plant doesn’t stay still. Annually the company adopts and produces over 100 modifications of bearings and bearing units of the top quality level. For the last several years, HARP developed the innovative solutions, implementing the patented
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HARP AGRO bearings with new seal systems of increased tightness X-SHIELD, providing additional protection in the harsh exploitation conditions
constructions of multi-sealing and cassette seals in the bearings and bearing units. New design boosted the productivity of agricultural machinery, increased time of the fault-free operation, eliminated the necessity of regular maintenance of spare parts in the heavy field conditions. The line, which includes six different designs of X-SHIELD seals, allows each producer of agricultural machinery and farmers to choose HARP reliable solution on the basis of their needs”, – Roman Girshfeld tells. In addition, HARP cooperates with the leading metallurgical
company and world producer of pipes and wheels for the railway vehicle Interpipe. The companies produce together set of wheels with increased run between repairs (up to 800 000 km or 8 years of service life), equipped with CRU Duplex bearings of HARP production. As for interesting novelties in 2018, HARP product range was supplemented by the new development – bearings 70-80315 with high-temperature lubrication of German company KLÜBER LUBRICATION, which were developed specially for application in the heavy industrial machines, and also bearing of European type WJ/WJP 130x240 mm for freight and passenger carriages of “space 1435”. HARP is keeping its continuous and dynamic development in the field of production modernization, adopting of new product types, improving quality control system corresponding to the international standard, what allows to keep the lead on domestic and the CIS markets and to establish lasting export relationships.
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TECH TRENDS
Understanding damage tolerance in hybrid bearings New research by SKF could make hybrid bearings more cost-effective and reliable, paving the way for their use in a wider range of applications.
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Mr. Junbiao Lai -Senior Scientist SKF’s Research & Technology Department in the Netherlands
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ybrid bearings, which combine hardened steel rings with rolling elements made of high-performance ceramic materials, are an increasingly popular option for demanding applications. Bearings of this type can outperform conventional designs where high speeds, high temperatures or poor lubrication conditions are experienced. Those characteristics have led to their use in jet engines and other critical aerospace equipment. Hybrid bearings also provide high levels of electrical resistance, making them useful in applications, such as electric motors and generators, where stray currents can damage steel bearing surfaces. Ceramic materials have many characteristics that make them ideal for bearing applications. Modern ceramics such as silicon nitride are hard, light and can be manufactured with an extremely smooth surface finish. Ceramic materials do have disadvantages, however. Despite
continued efforts to improve their toughness, these materials can have issues with damage tolerance in the form of sensitivity to imperfections that may pre-exist in the material or on the surface, which will potentially endanger the integrity of the ceramic rolling elements used in hybrid bearings. To reduce the occurrence of such problems in service, ceramic bearing components are manufactured under extremely tight quality control, handled with great care during production and assembly operations, and inspected rigorously prior to release. That approach has created products that perform very well in service. But it also drives up cost, limiting the wider adoption of hybrid bearing technology. One particular challenge for manufacturers is that they haven’t historically had good models for the damage-tolerance of ceramic bearings. Some surface imperfections are so small that they have no effect
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TECH TRENDS on the performance or longevity of a bearing, but without knowing exactly where the acceptable limits lie, manufacturers have had to take a conservative approach, rejecting components that might actually have performed perfectly in service. Now a team from SKF’s Research & Technology Department in the Netherlands is helping to take the guesswork out of ceramic product quality control. The group has developed a new predictive model of damage-tolerance for ceramic rolling elements used in hybrid bearings, allowing manufacturers to ascertain the precise threshold at which a microscopic imperfection should become a concern. The team based its research on an extensive series of tests using hybrid bearings or components with imperfections artificially introduced into the surfaces of ceramic rolling elements. The project studied a range of common imperfections. They included contact marks, such as surface scratches that can be introduced during polishing operations, ring or C cracks, which occur if the component experiences an impact, and surface voids, which can be the result of imperfections in the ceramic materials. The artificial imperfections were created using various methods,
including striking the ceramic ball surface in a controlled manner to create a crack, and laser machining to create a void of a precise size and shape. These bearings or ceramic components were then tested on a rolling contact fatigue test rig under a wide range of loading and lubrication conditions until failure or suspension. The team repeated its experiments with different types and sizes of imperfection. Some bearings were run
to failure, while others were removed from the rig before they failed and studied under the microscope so the team could see how cracks develop and propagate through the material. The SKF team used its findings to build a new model based on fracture mechanics to predict the damage tolerance of ceramic rolling elements. “We based our work on fracture mechanics, but we added some significant extra elements that account for the unique properties and failure mechanisms of ceramic materials under the relevant operation consitions of hybride bearings in applications,” explains Junbiao Lai, a senior scientist at SKF . “In particular, our new model accounts for interactions between the bearing material and the lubricant. Lubricant that enters a crack or void in a bearing becomes pressurised by the bearing loads. That can impart a tensile stress which are generally considered undesirable for lowering the fatigue resistance of a materials.” Junbiao Lai and his team are confident that their new model accurately reflects the behaviour of hybrid bearings in real operating conditions, and they are now working with SKF manufacturing engineers to apply their findings. “The model allows us to predict when a imperfection is stable, and when it is likely to cause cracks to develop and propagate.” He explains, “That knowledge could help our manufacturing colleagues to optimise the tolerances they use in production, reducing unnecessary scrap, and it could also help them to refine their manufacturing, assembly and handling procedures.” Ultimately, the work should make high performance hybrid bearings most cost-effective, allowing more applications to benefit from their unique and useful properties.
For more information https://www.skf.com/in/index.html 76 ENGINEERING REVIEW
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TECH TRENDS
4 critical technologies for your lubrication program Bearings are essential to any facility’s continued operation. That’s why lubrication is so critical for reliability maintenance engineering and physical asset management.
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any times overlooked, lubrication is far more complex than just buying oil or grease and throwing it into your equipment. Selecting the right type or types of lubricant, storing and filtering them correctly, monitoring bearing noise, and ensuring that over-lubrication and under-lubrication don’t occur all play an important role. Fortunately, there are more technologies than ever in the marketplace that allow you to manage your lubrication program effectively.
Oil Analysis The most precise lubrication in the world won’t help if the lubricants in question are poor quality, contaminated or breaking down under heat and pressure. Contracting with an oil analysis laboratory or investing in your own analytics kit will allow you to detect these kinds of issues before they result in machine failure. Many different factors can impact the quality of your lubricant. Improper storage or a blown seal on a component could allow dirt, water, or metal fragments to corrupt
your supplies. Even new oil should be tested – while your lubrication program might be top-notch, you’ve got little control over its handling before it’s delivered to your facility.
Proper Storage Facilities Industrial lubricants, despite their demanding conditions, can actually be some pretty sensitive materials. With the right combination of products and techniques, you can ensure that your investment isn’t eroded by neglect. There are many factors that can affect the storage of industrial lubricant, including using containers that already contain contaminants, storing them outside in harsh conditions, and not using color-coded containers to prevent accidentally mixing two different oils. Any auxiliary equipment, lines, and vessels should also be thoroughly cleaned and certified before being used with fresh lubricants.
High-quality Industrial Lubricants All the maintenance, storage and analysis technology in the world won’t serve you well if you’re not using both high-quality and properly www.engmag.in
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TECH TRENDS selected lubricants. Most, if not all technicians are comfortable with selecting the right grade of oil for a given application, but there are more complex factors than that to weigh. Considerations such as additives, duration of use and ambient conditions can all make for a significantly more complicated decision process. Often, a multipurpose lubricant won’t actually be the right selection for your applications. Multipurpose lubricants cannot provide satisfactory service in current demanding environments. Lubricant performance must be optimized to meet the increasing demands of modern industry. The first step in selecting the best lubricant for a given application is to define the tribological system. With a fully defined tribological system in place, the next step is theoretical analysis.
Ultrasonic Inspection Instruments An ultrasonic instrument designed specifically for lubrication, such as the UE Systems Ultraprobe 401 Grease Caddy can bring your facilities management game to the next level. The Ultraprobe 401 uses ultrasound technology to provide
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critical data about baseline dB levels, dB levels before and after applying grease, cost analysis of lubricants and other vital information. Over-lubrication is often a problem as big as or bigger than underlubrication – in fact, 70 percent of lubrication professionals believe it’s a problem at their plant. When excess grease gets into a bearing, it begins to churn and heat up. This churning causes the lubricant to solidify, blocking the entry of more, fresh grease and ultimately causing a bearing to fail. Another possible failure mode that can arise from over greasing is seal damage. Adding more than the
necessary amount of lubricant to a bearing under the high psi of a grease gun can crack the seal, allowing outside pollutants to infiltrate. This instrument uses ultrasonic technology so that lube technicians know when to stop adding grease which can prolong the life of your equipment. Its digital display allows the user to gauge friction levels through the dB levels. Even in high-noise environments, it can isolate the necessary ultrasonic waves and transmit them to the user.
Conclusion In all, the field of precision lubrication and maintenance has grown more complex and diverse than ever before. It’s easy to get lost in the minutiae of these processes and products, and sometimes the measures you think are helping may actually lead to failures down the line. With the right techniques and technologies, however, it’s possible to see real return on investment from your maintenance efforts.
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TECH TRENDS
T
he space industry thrives on the word “heritage”. Relying on historical designs, equipment, processes and suppliers results in known outcomes and reduced risks in the high stakes world of rocket launches. It’s hard to compete with that logic. But that hasn’t stopped Napoleon Engineering Services (NES) from going all in to support the commercial space industry with custom bearings for a wide variety of mission critical applications from turbo pumps, values, actuators and hydraulic power units to docking systems. The Olean, NY based custom bearing manufacturer has roots in the aircraft industry dating back to the 1990’s. That heritage has set the stage for Napoleon Engineering Services’ work in the space industry. “We started out providing bearing reverse engineering services to those looking to hold a PMA (Parts Manufacturer Approval) on type-certified aircraft and engine bearings,” explains NES President and Chief Engineer, Chris Napoleon. “Over the years, in support of our PMA and OEM customer base, we have made significant investments in manufacturing equipment, allowing NES to manufacture high precision aerospace bearings. We manufacture deep groove, angular contact and thrust ball bearings along with cylindrical, needle and thrust roller bearings for commercial and military jet engine, gearbox, auxiliary power units, and a variety of aircraft and helicopter applications.” Although the space community generally sees themselves as different than the aircraft industry, there are a lot of similarities that Napoleon picked up on and promoted to the rapidly developing commercial space industry. “Let www.engmag.in
Napoleon Conquers Commercial Space Market me first say that our modus operandi is picking up the phone in two rings. The new space market is moving fast and you can’t begin to listen to your customer’s problem, develop a solution and deliver quickly if you aren’t willing to answer the call,” states Napoleon. “It’s an area where global bearing manufacturing has hurt the design engineer. Today’s commercial space design engineers want to talk directly with people who are designing and manufacturing their bearing so they can quickly make design changes on their end. This can often make for a challenging and stressful manufacturing process since it’s common for material to be ordered, turned and heat treated ahead of final design signoff. However, the path of least resistance is not our path. We’re not afraid of obstacles. We know we are defined by the results we achieve.” Napoleon also notes that many of the large players in the commercial space market are developing their design reliability through full scale testing. Therefore, it’s extremely important to get to test on time. That means spacecraft companies are letting NES have a lot of control over the manufacturing quality and systems. “This is where our experience in aircraft bearing manufacturing has really helped us be successful with the space community,” emphasizes Napoleon. “You’ve got to be solid with your ability to maintain traceability of raw materials and control of the manufacturing processes. This includes knowing what level of inspection and non-destructive testing is required and establishing the correct standard for quality of workmanship in order to meet the rigors of launch and space travel. You need to know what
is right and then do it, even when the customer is not directly requiring you to do so.” Ultimately, delivery of the product needs to be expedient to allow the industry to take advantage of the fastpaced market opportunities for commercial launch services and satellite systems. This isn’t always easy when the bearing solution requires unique materials and configurations that challenge the conventional manufacturing process. “In order for us to meet the demands of our customers we need to be willing to change from machining one material to another to yet another, all in the same day. We aren’t afraid of setup changes and we understand that high mix, low volume production is what our customers need,” adds Napoleon. “We process our bearings differently than our predecessors did. We are revolutionizing the use of hard turning and milling because we are not boxed in by old equipment process constraints. We are able to design for manufacturing very difficult bearing configurations while minimizing distortion out of heat treatment and maximizing stock removal rates. This leaves us ready to finish grind in a fraction of the time it used to take. Bearing manufacturing can be tricky and challenging every step of the way but our new processes and attention to detail result in high yield rates and delivery that is very attractive to the new space community.” NES is poised to take custom bearing manufacturing where no man has gone before with the new commercial space market. That’s not too far of a stretch based on Napoleon’s heritage. OCTOBER 2019 | ENGINEERING REVIEW
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Turntable bearings in a C-arm x-ray machine Precision bearings for precise diagnosis
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recision bearings from Rodriguez are used in many medical applications – for exam-ple in a high precision x-ray machine with C-arm that is used for diagnostics purposes in oncology. In this extremely sensitive field of application installed components must meet highest standards. For this reason, the Dutch medical device manufacturer VDL Konings has decided on turntable bearings from Rodriguez for the bearing of the massive swivel arm. The Dutch company VDL Konings BV develops and produces medical devices, systems as well as modules which are used in radiology for diagnostic and therapeutic purposes. The C-arm is specially designed for oncology – where the success of a treatment largely depends on the radiotherapeutic planning, the simulation and the treatment evaluation. The C-arm is exclusively used for diagnostic purposes: In order to prepare 80 ENGINEERING REVIEW
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and perform treatments accord-ingly, the location of the tumor, the position and dose of the radiation must be determined prior to the procedure. The appropriate accuracy is imperative to keep a procedure as small as possible in the final treatment of the patient. Another advantage of the C-arm x-ray machine is the fact that prior positions are automatically and precisely approached again.
High precision positioning – with turntable bearings A number of factors have an influence on the accuracy in application.
This also include the mechanical components. The individual elements and assemblies form the base for meeting the high demands placed on the system: ¬¬The whole is only as good as the sum of its parts. For the high-precision positioning of the massive C-arm, the component for the bearing of this large system, is of great importance. VDL equips this rotation position with ball bearing slew-ing rings from Rodriguez. The high-performance precision bearings are part of the Precision Bearings business unit of the power transmission and bearing specialist from Eschweiler. They are suitable for applica-tions in which large tilting moments need to be supported or where large bearing diameters are required for design-related purposes. Thanks to their constructional design, they safely absorb radial, axial and tilting moment loads with one bearing point. Therefore, bearings with radial and axial bearing comwww.engmag.in
TECH TRENDS binations can often be realized with only one bearing point, and expenditure and costs for the design of the connection construction and the installation of the bearings can often be significantly reduced. Different sizes and versions – depending on the application requirements, without gear, with external or internal gear – are available as a standard in two types, with double-sided sealed raceway system.
An application-specific adapted solution Narrower tolerances for axial and radial runout and the technical specifications provided by the customer required a customized design with a customized internal gear for this applica-tion. For cases like these, Rodriguez has set up an in-house production facility with high-performance machinery; here, individual solutions are implemented without ifs and buts. For the turntable bearing for VDL, the material is first tempered. This heat treatment prevents the rings from warping in the subsequent processing; warping would result in functional inaccura-cies both in diagnostics and radiotherapy. The outer ring was slightly modified in order to meet the installation specifications, and the grease nipple was
counter sunk. This prevents anything from hooking to the arm in its rotary movement. To ensure the arm rotates in the same plane, has no range of motion and has a homogeneous rotation, the bearing is clearance-free and designed according to the specific rotation moment specifications. In addition, the shape and tolerances of the gear teeth were modified to ensure smooth running, reliable motion accura-cy and less wear. “The interplay of the technical components must be exactly coordinated,” says Sven Han-dels; the native Dutchman is Product Manager at Rodriguez and the sales executive for the customer VDL. The motor defines the drive pinion which in turn defines the requirements for the ball slewing connection. In accordance with the drive power, they are equipped with a gearing with head reduction and profile shift. This design allows for highest accuracy in the positioning and thus a corre-
sponding repeatability.
Flexible response – thanks to inhouse production Specially modified turntable bearings are also required in other fields of applications, for ex-ample as a hot version, which can be used in a temperature range of up to 150 °C. For such high temperatures, the turntable bearing must be fitted with a special seal that has high ther-mal and chemical resistance. The guiding of the rolling elements is implemented in a steel cage, because – just as in conventional rubber materials for bearing seals – synthetic material would reach its limits under such operating conditions. Here, the flexibility and know-how of technical special solutions are particular strengths of Rodriguez, but also the possibilities offered thanks to the broad orientation of the machinery: In the area of precision bearings, for example, large diameter slewing bearings with outside diameters of up to 1,400 millimeters, or even the increasingly popular rotary units with smaller diameters starting at 15 millimeters, can be manufactured. In linear technology, thanks to modern CNC machinery, it is possible to machine shafts and ball screw spindles with an outer diameter of up to 100 mm. Rodriguez always maintains its manufacturing facilities at the lat-est state of the art, with innovative equipment and advanced tools.
Author: Nicole Dahlen www.engmag.in
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TECH TRENDS
Air Bushings-Discover the Energy Savings Alternative to Ball Bearings Five Ways Air Bushings Outperform Ball Bearings Energy savings continues to be a focal point for consumers and companies alike.
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o remain competitive and cost-effective, companies today invest in energy initiatives to identify areas with potential energy savings. This type of thinking is what our world demands to not only preserve our future resources but to keep a company competitive for the long-haul. If you are serious about cutting energy costs, you need to make sure you’ve considered everything including questioning the efficiency of even the most fundamental of components including your bearing. But to justify changing something as fundamental as a bearing, you need hard data. Fortunately, New Way® Air Bearings did the homework for you. We’re on a mission to inform engineers, regardless of industry, of the benefits of air bearings in energy usage as well as operations efficiency.
Friction - Your Obstacle to Savings & Efficiency In use for centuries, ball bearings are tried and true. In fact, we have become accustomed to their often costly side-effects, such as: • Friction • Heat Generation • Maintenance Downtime • Wear • Noise • Speed Limitations Friction is the main culprit here as it is the trigger activating a cascade of the other disadvantages. Energy costs rise as more energy is required to power the moving parts with the friction-laden bearing. Ultimately, 82 ENGINEERING REVIEW
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Again, friction is the key component here, however, removal of friction creates a host of benefits. Energy costs decrease since there are no moving parts, and manufacturing operations see an increase in efficiency and production yield. A win-win for the bottom line!
So, why aren’t air bearings more prevalent? manufacturing operations feel the impact of this through decreased production and profit. While bearing technology has advanced to reduce friction through special coatings, friction is still nonetheless present. But what would happen to our energy costs and productivity if we could eliminate friction? Thankfully, companies no longer have to accept and mitigate the effects of friction on energy and production.
Air Bearing Technology - A Proven, Viable Option Air bearings offer an alternative to traditional lubrication-based bearings by providing a pressurized film of air to produce the necessary gap for operations. Friction is removed creating a domino-effect of advantages, such as: • No Contact • No Wear • No Moving Parts • Less Heat Generation • No Burdensome Lubrication Requirements • Less Maintenance Downtime • Higher Speeds
Despite being fairly new to mainstream use, air bearings are a proven technology, dating back more than a half-century. The removal of friction made them ideal for use in the metrology and hard drive industries where accuracy and control are paramount. At that time, air bearings were custom built so were out-ofreach for a typical manufacturing company. Standardized air bearings were first introduced in 1982 by New Way Air Bearings, then known as Aeolus Bearings. Air bearings became economically viable for a broad range of customers, particularly in light of the growing demand for micro and nano-level accuracies demanded during manufacturing and inspection. But, the benefits of removing friction go even further by increasing
Figure 1: Exploded View of Air Bushing Setup www.engmag.in
TECH TRENDS operational efficiencies, decreasing energy costs and thereby increasing production.
Investment
It’s All In the Numbers - Air Bushings vs. Ball Bearings New Way Air Bearings recently put these energy and efficiency claims to the test with one of its own products. A New Way Air Bushing was chosen for use in a side-by-side comparison test with a mechanical ball bearing. The air bushing was chosen because of its wide use across industries in linear and rotary motion, including applications where both motions are required concurrently. The air bushing, like all New Way products, is built on New Way’s Porous Media TechnologyTM. This unique design distributes the air evenly across millions of sub-micron holes inherent to the porous carbon face, providing a “zero friction” load bearing interface. Essentially, the air bushing is a tube of porous media which self-centers from the force of the air flow, allowing for true 360° non-contact motion on round shafting. Co-polymer O-rings are provided for ease of installation into a pillow block housing unit to compensate for parallelism errors of up to .002” over the length of the shaft. While not used in the demo, the air bushing design can also accommodate an axial constraint by adding on a porous media thrust face to the tube. A thrust bushing is thereby created, allowing for radial motion while constraining one end axially to prevent
Figure 2: Ball Bearing Unit www.engmag.in
Figure 3: Air Bushing Unit linear motion in one direction. Figure 1 above shows how air bushings are essentially interchangeable with existing ball bearings. The similarity in uses and setup made the air bushing a perfect candidate to compare with a ball bearing. For the demo, two different units were constructed, as seen in Figures 2 and 3.
As with any purchase, it’s important to understand more than just the initial cost. A wise decision-maker looks beyond and considers the overall return on investment (ROI.) Let’s look at several other reasons which make a compelling argument for the switch to air bushings.
1. Increased Operations Time Since there are no lubrication requirements or wear from moving parts, less downtime is required. This opens the door to more production time increasing production quantity.
2. Decreased Heat Generation Each demo unit consisted of: • Identical Rollers: 5” diameter, 26” wide, roll with shaft = 75 lbs. • Identical Direct Drive Motors and Couplings • Identical Drives and Motor Setup/ Tuning Files • Identical Testing speeds: 300, 900 and 1800 RPM Tests were conducted at each speed where the motor current to maintain the roll at speed was measured. Consistently, each test showed the air bushing required only 20% of the current the ball bearing needed to keep the roll spinning at speed. That’s an 80% savings in energy by the air bushing over the ball bearing! New Way engineers weren’t surprised by these findings based on the removal of friction. We realize it takes seeing real numbers to consider and justify changes to fundamental components like bearings. But there’s even more than energy savings. There are some natural extensions to the energy savings that make a switch to air bushings a prudent investment.
Five Ways to Realize Your
No friction or contact equates to less heat generated increasing component life. This also contributes to more operation time since less wear is experienced driving component failure/ replacement.
3. Improved Reliability Since there are no moving parts, there is less likelihood of failure, improving reliability over ball bearing operations. One of the advantages of New Way’s Porous Media Technology is the decreased chance of damage in the event of a loss in air supply. The porous material allows the air to slowly diffuse; when touchdown occurs, the soft carbon face minimizes chances of damage or scratching.
4. Increased Speed Since air bushings have no moving parts and are non-contact, higher speeds can be achieved. Similarly, the concern of heat generation due to high speeds is also eliminated, opening the door to increased production.
5. Decreased Operational Energy Costs This last benefit is a step beyond the energy savings demonstrated by the OCTOBER 2019 | ENGINEERING REVIEW
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TECH TRENDS air bushing over the ball bearing. We can take this a step further and note a savings in energy for time previously spent to perform maintenance of ball bearings whether for lubrication or part replacement. Additionally, less energy would be spent to offset friction-induced heat in operations.
Ready to Make the Switch? If you are ready to experience the benefits of Frictionless MotionTM, New Way stands at the ready! With
more than 30 years experience in air bearings, New Way can guide you through the process of use in either a new system or a retrofit to existing equipment. Our air bushings are designed to accommodate commonly-available shaft sizes and are available in a range of standard metric, English as well as custom sizes. We pride ourselves on working directly with customers to find solutions, either with one of our standard products or developing a custom solution.
Let us get you started on the road to efficient operations with a complimentary consultation to determine the right product for your operation!
To learn more about New Way Air Bearings, air bushings and our other products, please visit us online at www.newwayairbearings.com.
Author: Drew Devitt, CEO/CTO, Founder of New Way Air Bearings
Professional installation and removal of rolling bearings
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ver 16% of premature bearing failures are due to improper assembly. The lack of suitable installation tools and the necessary knowledge when replacing bearings often means that new bearings experience high forces incorrectly applied during installation and are thereby damaged. Early bearing failures are often the result. This can be prevented with the correct procedures and through the use of specialist professional tools. Only then will the new bearings reach their expected service life.
Mechanical tools Without the right special tools, professional assembly and disassembly of rolling bearings is impossible. With its wide range of high-quality tools, simatec offers the best conditions for fast and safe working. With the proven impact tool simatool Fitting Tool FT 33, bearings can be quickly and precisely, cold-mounted onto the shaft or hammered into a housing. The design of the tool ensures that the installation forces are transmitted through the inner or outer ring and not via the rolling elements. The bearings will not be damaged during assembly. 84 ENGINEERING REVIEW
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It is also important, however, to ensure that the components are removed professionally. Thanks to the use of simatool removal tools, time is saved while ensuring that none of the adjacent components are damaged.
Heating with induction Another method for the professional installation of bearings is the heating of the components before assembly. The leading bearing manufacturers recommend heating bearings to a temperature of 110 °C for installation. As a result, the inner diameter grows and the bearings can be positioned without effort onto the shaft. When mounting into a housing, it is this that is heated and the cold bearing is pushed into the heated housing. With simatherm induction heaters rolling bearings and other annular metal parts can be heated efficiently. The devices allow quick and clean installation and replace conventional heating methods such as hotplates, hot oil baths, open flames or ovens. During the heating process, only the workpiece heats up
and the device itself remains at room temperature. simatherm induction heaters are available for rolling bearings with a mass of up to 1200 kg. The simatec tools and heating devices are constantly evolving to better meet changing requirements and to offer the customer the greatest possible benefits. New in the program is the simatool Fitting Tool FT-P. This tool is the ideal solution for installations with larger installation forces, since the tool can be used on presses. It thus enables mounting that would not be possible by using a hammer, making it the ideal complement to the FT 33 Fitting Tool. Simatec ag has more than 30 years of experience in the manufacture and sale of innovative products for the assembly and disassembly of rolling bearings. Using simatec products ensures that bearings are installed correctly and that they reach their full performance potential in terms of quality and service life.
For more information Web: www.simatec.com www.engmag.in
TECH TRENDS
How to build a World-Class BEARING lubrication program Is your lubrication program world-class?
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coustic Lubrication is just one of the 8 application pillars adopted by world-class ultrasound programs. And what an important one it is. Poor lubrication practices account for as much as 40% of all premature bearing failures. When ultrasound is utilized to assess lubrication needs and schedule grease replenishment intervals, that number drops below 10%. What would 30% fewer bearing related failures mean for your organization? Keeping up with the changes in on-condition bearing lubrication techniques is challenging. Technology advancements from SDT’s LUBExpert allows us to transform complex processes into simple, 5-step procedure.
How to Get Started Success is dependent on organization and commitment. Without these two structural elements, your ultrasound lubrication program will find difficulty getting traction. A well-organized strategy and carefully planned execution will get the project started properly. Getting the commitment from all levels becomes much easier when a program can demonstrate structure and cohesion. Results will prove the program faster which will trigger easier access to funding to grow and sustain the program. Clearly defining and communicating the objectives of your lubrication program is the best way to create a precision lubrication culture that benefits your entire organization. Start by asking “Why start an ultrasound lubrication program and what improvements do we expect?” There is no one easy answer to the question. Saving money is an obvious benefit that gets the attention of management, but it is not specific enough. How will an ultrasound lubrication program save money? www.engmag.in
• By reducing grease consumption • By raising awareness of the right types of grease to use • By making more effective use of lube tech’s time • By reducing unwanted machine breakdowns caused by lubrication failures • By extending bearing life expectancy A new beginning is the best opportunity to review what you have been doing previously. Identify what worked and improve or remove what did not. We will not go deeply into all aspects related to good lubrication practices. However, there are some basic and relevant points that should be noted. Lubricant management program: Keeping your bearings healthy requires a lubricant with the right quality for the application. By quality we refer not only to the quality of the grease manufacturer, but quality in a broader sense which involves all the processes from manufacturing to application. Some general recommendations are: • Keeping high standards of housekeeping for storage, handling, and application to prevent contamination that degrades the quality of
lubricants. • Keep a detailed list of products to use for each lubrication point. Selecting the right lubricant requires technical knowledge in several aspects. Using the wrong product will jeopardize the useful life of the component. Don’t change lubricants without solid reasons. Consider contracting a lubrication consultant to direct advice on this. • Provide training in every aspect relevant to lubrication practices and product knowledge to those responsible for lubrication. • Set objectives to reach so you have a clear path to follow. Application Guidelines: Delivering the lubricant to the right point requires some type of device; usually a grease gun. There’s lots of different types but they all have one thing in common; they deliver grease with high pressure; enough to overcome the backpressure in the grease fitting. Dirty grease and mixing grease types kills bearings. Therefore, it is necessary to extend the precautions for contamination and storage discussed above, to the application of lubricant OCTOBER 2019 | ENGINEERING REVIEW
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TECH TRENDS grease causing a degrading chemical reaction. • Always clean the grease fitting and grease gun before and after every application. • Some bearings have drain plugs for purging old grease. If you open the drain, remember to clean the drain hole; it may be clogged. Use a clean brush like a bottle washing brush to clear the port. • Apply grease slowly, one full stroke at a time (no more than 20% of the maximum designated quantity per injection) to avoid over greasing. This also avoids potential damage to the bearing as too much pressure can push the bearing cage into the roller elements.
through grease guns: • Wherever possible insist on using a dedicated grease gun for each grease type to avoid the risk of applying the wrong product through cross contamination. Label the grease gun with the associated grease to be used. LUBExpert manages multiple grease guns to prevent mixing of grease types • Standardize your grease guns so they all deliver the same quantity of grease per stroke • The same principle must be applied for your ultrasound device. If using SDT’s acoustic lubrication adaptor, assign a different lube adapter for each grease type. Grease remaining in the adaptor can mix with new
5-STEP ACOUSTIC LUBRICATION PROCEDURE
1
2
3
4
5
Visit Lube Room
Pre-Lubrication Checks
Initial Lubrication Check
Evaluate Bearing Condition
Grease The Bearing
Simple method for determining bearing failure stages using ultrasound: Select grease gun designated for asset.
Safety: Follow OEM safety protocols for grease gun.
Inspect equipment for cleanliness, especially coupler. Inspect lube delivery tube for damage.
Safety: Follow facility/equipment safety requirements.
Equipment Check: 1. Personal Protective Equipment (PPE) 2. Ultrasound instrument 3. Headphones 4. Contact sensor 5. Lube adapter 6. Defect log 7. Grease gun with flex hose 8. Lint free rags 9. Flashlight
Visually inspect asset and document any defects.
Select the Right Lubricant for each asset/lube point. Check condition of old grease in the gun, if applicable. Consider using a new grease tube.
Tip: Color coding grease containers and bearing fittings is highly recommended.
Quantitative: Based on historical trend.
Right Location: Measure the ultrasound signal from the same spot each time. Tip: Do not measure from the bell housing.
+8 dBµV Quantitative: Increase of 8 dBµV over trend line indicates a need for lubrication.
If measuring from grease tube extension (not recommended), inspect it for damage or obstruction.
Record initial ultrasound measurement (RMS dBμV and Crest Factor).
+16 dBµV Quantitative: Increase of 16 dBµV over trend line indicates warning stage.
Decreased Signal = Add one shot of grease; wait to stabilize; repeat if signal decreases.
Qualitative: Tech may note louder signal and small popping signal indicative of impacting.
Right Interval: Based on data, determine if the bearing requires grease replenishment.
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Caution: Do not exceed calculated grease replenishment quantity.
+24 dBµV
Qualitative: Tech may note significant increase in signal, and rough, growling sound with loud popping.
Type of bearing inside: Don’t assume that a grease fitting installed on a bearing housing means a path to grease the bearing. Sometime motors are fitted with both grease fittings AND sealed for life bearings. You must identify every grease point to be managed within the ultrasound program. Identify the bearing inside to know the size for lubrication quantity, the particulars for defect diagnosis, and the type of grease used. Here are some helpful tips regarding the use of acoustic lubrication. • Friction produces ultrasound. Bearing friction is produced by the contact between race, rolling elements and seals or shields • Less contacts means less friction. A ball bearing produces less friction than a same size roller bearing under the same lubrication conditions, speed and load. • Plain bearings produce the lowest friction levels. Their ultrasound baseline often trends in the single digits or low teens. Typically, they remain consistent for their lifespan and only display sudden upward trend lines when the oil film becomes contaminated or the bearing is near failure.
Benefits of Ultrasound Right Indicators: Take a new ultrasound measurement (RMS dBμV and Crest Factor).
Increased Signal = Stop greasing!
© Copyright 2018 by SDT INTERNATIONAL. No copying or reproduction of this information, in any form whatsoever, may be undertaken without express written permission of SDT INTERNATIONAL. WARNING: The content of this graphic is a basic guide to lubrication. In practice, more details must be taken into account. SDT INTERNATIONAL is not responsible for any damage or injury arising out of the use of this document. This infographic is the result of a collaborative development project between SDT Ultrasound Solutions and LUDECA Inc - www.ludeca.com
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Churning Phase: Allow ultrasound readings to stabilize based on RPM: >1200 RPM = 5 seconds 500 - 1200 RPM = 10 seconds 300 - 500 RPM = 20 seconds. <300 RPM = 60 seconds
Qualitative: Tech may note elevated whirring sound typical of increased friction from metal to metal contact.
Quantitative: Increase of 24 dBµV over trend line indicates severe stage.
Inspect and clean grease fittings and color-coded caps with lint free rag. Confirm color codes of fittings and grease gun.
Right Quantity: Deliver a small amount of grease, no greater than 5% of the total bearing volume. Depending on grease gun calibration this could be equal to one shot.
Qualitative: Based on lube tech’s perception
Identify grease fittings e.g., Zerk, button head, etc.
Confirm bearings are greasable (not sealed).
Calibrate the grease gun’s output per stroke/shot and document accordingly.
Connect ultrasound sensor to grease fitting using lube adapter, or directly to clean bearing housing with magnetic base.
• Always allow for churning time – the time required for freshly injected grease to work its way into the bearing.
Document the results: • Number of strokes • Initial and final dBμV • Observations Tip: Replace the cap on the grease fitting to avoid contamination. If no cap, leave a small amount of grease on the tip.
sdtultrasound.com
Ultrasound performs well at sensing and measuring changing in friction levels. It’s the perfect technology to guide lube technicians during the lubrication-replenishment task. Ultrasound assisted lubrication of plant assets offers significant benefits that calendar based lubrication cannot. The days of relying on calendars and calculators are over. Use our 5-Step Acoustic Lubrication Procedure and start greasing bearings the right way! www.engmag.in
TECH TRENDS
Ceramic Rolling Elements for the Future New investments by Tsubaki Nakashima to enhance technology and expand production of ceramic material rolling elements.
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olling elements produced from high-performance speciality ceramic materials are increasing in demand to serve the growing market needs. From the early development of bearings using ceramic rolling elements in machine tool spindles, to the adoption of ceramic materials used in electric motors and fuel injectors, the market has demanded increasingly higher bearing performance in applications where low lubrication, high speeds, high temperatures, or electrical conductance are present. Major Automotive Tier 1 suppliers are developing, or have announced, plans for various electrification initiatives in the mobility segment. These companies are developing systems specifically designed for hybrid and electric vehicles, including powertrain products, drive products, and both high voltage and low voltage electric motors. These systems and products require an increasing need for specialty bearings using ceramic rolling elements. The material properties of ceramics, and silicon nitride in particular, are especially suited for these applications. The combination of fracture toughness, hardness, and corrosion resistance provide the optimal combination of properties to overcome the limitations of standard steel bearings. These mechanical properties make the rolling element manufacturing process a challenge. The high precision surface finish and diametrical tolerances can only be achieved through a process of successive fine grinding and lapping operations. Beginning with a ceramic blank a diamond grit slurry is used in successive operations for the process of stock removal and surface finish conwww.engmag.in
ditioning. The grinding and lapping processes are time intensive due to the hardness of the ceramic material and the relatively low pressure that must be used in the stock removal process. It is not uncommon for the process to take months from start to finish, especially if the application demands sub-micron dimensional tolerances. Minimal cost is achieved by efficient usage of resources and a high level of automation. Every step of the manufacturing process requires the highest precision, especially the initial blank where we partner with the blank suppliers to minimize the usage of resources including material. This has also a very positive influence on the Environmental Impact.
Tsubaki Nakashima has been producing products from ceramic material for more than twenty years and is now in the process of expanding production capability and production capacity at several make-sites worldwide. Investments are currently planned for the facilities in Japan, Thailand, and the United States. The driver for this expansion is not only the ever-increasing technical requirements, but also the increasing conversion in the market from standard bearings to speciality ceramic element bearings. Tsubaki Nakashima has seen a production output growth of more that 50% over the past three years, with continued growth projected into the mid-term. The full production range of rolling elements and components from Tsubaki Nakashima includes balls from steel, tungsten carbide, ceramics, glass, and plastic; as well as tapered rollers, cylindrical rollers, spherical rollers, stamped and welded bearing cages, sheet metal parts, ball screw, linear motion systems, and industrial air blowers. OCTOBER 2019 | ENGINEERING REVIEW
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TECH TRENDS
Complete Machining of Spherical Components Sphero – the innovative machine solution by Thielenhaus Microfinish
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he compact, high-precision tool machine Sphero, designed for machining workpieces with spherical forms, has been further developed by Thielenhaus Microfinish into a com-bination solution capable of handling the entire superfinishing process in just one clamp-ing operation. The world leader has designed an innovative trial machine that can ma-chine spherical workpieces with the highest demands, in terms of fine dimensional accu-racy and surface quality, into finished components. The workpiece unit is mounted vertically and easily accessible for fast changeover. Thanks to the integrated tool changer with a capacity for up to ten tools, even complex machining processes can be carried out in only one clamping process. The trial machine is based on one that was previously used for the manufacturer’s sub-contracting work. It is also equipped with QuattroClean CO2 snow-jet technology, which enables the workpieces to be cleaned using an environmentally friendly, dry and residue-free method. After cleaning, the machined component is subjected to a scattered light measurement procedure that allows, e.g., the shape or the gloss value to be pre-cisely determined. If a measurement value is not yet satisfactory, the component can then be put through another machining step in the same clamping procedure. Workpieces with diameters of up to 75 mm can be machined on the Sphero. The ma-chine’s construction is highly space-saving and is characterised by a modern, compact and ergonomic design. It is used for example in the automotive industry for machining
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the joint heads of wheel suspension and steering components that require a high level of freedom and movement for the associated assembly units. Metallically-sealing valve balls and seating rings for valves in the chemical industry, through which aggressive or very hot media travel, are able to be machined with a high degree of dimensional and surface accuracy. Another instance is the axial piston pump found in all fields of hydrau-lics: It has a spherical sliding surface at the end, and the dimensions of this component must be accurate to 1 µm or less in order to guarantee safe operation at great strain – such as in aviation. This machining concept enables machining of surface topography, spherical roundness, spherical diameter and sealing surfaces. Furthermore, defined contact rations that fulfil tribological requirements are possible. In just a few installation steps that take only a very short time, the operator can convert the machine from outer machining to inner machin-ing, i.e., from a sphere
The Sphero’s working area with tool changer, measurement control and high-performance tool spindle – shown here without the new in-process cleaning and measurement technology (Photo: Thielenhaus Technologies GmbH)
The new Sphero combination machining solution by Thielenhaus Microfinish makes it possible to machine spherical workpieces fully automatically to complete and controlled components with great precision. (Photo: Thielen-haus Technologies GmbH) to a sealing ring or a socket. Operator influence is reduced to a minimum and errors due to repeated handling and clamping are ruled out, since the workpiece remains in the clamp until it is completely finished. This drastically increases process reproducibility. Since this machining solution allows the implementation of several tool qualities, the machining process can, for example, be broken down into roughening and smoothing, fine finishing and pol-ishing. The tool change takes place in just a few seconds with the added benefit that the work-piece stays in the clamp. Since the process takes place on a self-correcting basis, truing cycles are done away with. This means that better end results can be achieved with short cycle times. Thanks to the MicroSens capacitive sensor with workpiece con-tact detection, the machine monitors the stipulated parameters itself on an on-going basis and makes any necessary adjustments. The integrated measure-ment and cleaning process ensures that the workpiece is quality-controlled prior to being unclamped. For more information www.thielenhaus.com www.engmag.in
AD INDEX COMPANY NAME
PG. NO.
A
COMPANY NAME
PG. NO.
I
ANTRIKSH METAL CORPORATION
33
B
INDO ENGINEERING CORPORATION
ISK BEARINGS INDUSTRIES
BEARING CLOUD
COMPANY NAME
PG. NO.
R
45
ROULEMENTS INC.
35
RULMENTI S.A.
BACK PAGE
53 S
16, 18 J
C JEI BEARINGS CHEMP INTERNATIONAL
47
CNZ BEARINGS PVT. LTD.
29
SAROJ IMPEX
49
SHREYANS ENTERPRISE
17
SUPERSLIDES & BALLSCREWS CO. INDIA PVT LTD
27
55
L
LAXMI BEARINGS PRIVATE LIMITED
GATEFOLD
D M DARSHAK BEARING CO.
57
DOSHI SONS
15
MANTRI BEARING HOUSE
T
11
N G N. GANDHI & CO. GARG INTERNATIONAL
INSIDE BACK COVER
TECHNO OVERSEAS
59
TOLIA GROUP OF COMPANIES
31, INSIDE FRONT COVER
23 V
NOZZLE AUTO ASSOCIATION PVT. LTD.
13
NS INDUSTRIES
37
VELY INTERNATIONAL
21
VIPUL BEARING CO.
69
VM TRADERS
61, 63, 65
H
HARSH BEARING CORPORATION
67 P
HENNIK IMPEX
HITECH ROLLING BALLS PVT. LTD
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41
51
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Y PRIMEROLL INTERNATIONAL PRIVATE LIMITED
43 YOGI HI-TECH (P) LTD.
39
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