Author: Team NBC

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Industrial Applications of Bearings – A Comprehensive Guide

Industrial Applications Of Bearings

Do you know what “bearings,” a mechanical component, actually do? They are so essential to the machine sector that they have been dubbed the sector’s “bread and butter.” They are employed in a wide variety of machines. Still, because they operate in secrecy, most individuals not engaged in the machine sector probably have no idea what they mean when they hear the name.

Bearings come in a wide range of shapes and sizes and are an essential tribological part of many different types of machinery. In a system that may be under static or dynamic loading, they can be described as a machine element that supports/permits only a particular form of motion (limitation of degrees of freedom).

What are bearings?

Bearings are “components that aid in the rotation of objects.” Inside the equipment, they support the shaft that revolves.

Automobiles, aircraft, power generators, and other devices need bearings. Even common household items like refrigerators, vacuum cleaners, and air conditioners we use daily contain them.

The rotating shafts of the wheels, gears, turbines, rotors, etc., in those devices, are supported by bearings, enabling smoother rotation. Although bearings in industrial applications may appear straightforward mechanical components initially, they are essential to our survival.

Purpose of Bearings

Bearings primarily avoid direct metal-to-metal contact between two elements in relative motion. By doing this, friction, heat production, and, ultimately, part wear and tear are avoided. As low-friction rolling takes the place of sliding motion, it also lowers energy consumption.

Additionally, they transfer the rotating element’s load to the housing. This load could be either radial, axial, or both. A bearing, as previously mentioned, limits the freedom of motion of moving parts in specific directions.

Different Types of Bearings

There are various types of bearings, each used for a particular function and designed to support a specific type of load, like ball bearings.

Ball Bearings

A ball bearing is a specific kind of rolling-element bearing that uses balls to keep the bearings’ inner and outer moving components apart. A ball bearing’s main functions are to support radial and axial loads and lessen rotational friction. Ball bearings in industrial applications have a straightforward design, are reliable, and are simple to maintain. They come in open and sealed varieties and single and multiple-row styles. They are appropriate for high speeds since they have low frictional torque.

Ball bearings connect the shaft to the motor housing, for instance, in electrical motors when the shaft is free to rotate but the motor housing is not. They are further divided into

Applications of the ball bearings:

  • Household items: Bicycles, Washing machines, Hair dryers, Fishing rods, DVD players, and Food processors.
  • Office equipment: Fax machines, hard drives, fans, etc. 
  • Industries: Elevators, assembly lines, Chain saws, power pumps, toy manufacturing, etc.
  • Automotives: Engines, steerings, electric motors, gearboxes, etc.

Advantages of ball bearings:

  • Do not require much lubrication.
  • Long service life.
  • Low price.
  • Can handle thrust hold.
  • Good wear resistance.

Disadvantages of ball bearings:

  • Can break easily due to shock
  • Can be loud
  • Fail to handle heavyweight

Cylindrical Roller Bearing

The outer ring, inner ring, and cylindrical roller bearing roller all have a straight geometry. The cage may be made of brass, steel, or polyamide. You can separate the outer and inner rings. As the roller makes line contact with the raceway, these bearings can support significant radial loads. The bearings come in a variety of styles and dimensions.

Types of cylindrical roller bearing

  • Single row
  • Double row
  • Four rows
  • Full Complement
  • Thrust cylindrical roller

Application of cylinder roller bearings:

  • Mining,
  • petroleum production,
  • rubber mixing equipment,
  • electric motors,
  • rolling machines, etc.

Advantages of cylindrical roller bearings:

  • They offer excellent stiffness
  • These bearings can face challenges of heavy radials and high speed.
  • It comes in split and sealed variants
  • Low friction
  • Long service duration

Disadvantages of cylindrical roller bearings:

  • Not suitable for thrust loads
  • When the inner or outer rings have two ribs, cylindrical roller bearings can withstand some axial load in one direction.
  • Double-row cylindrical roller bearings are utilized largely in precision machine tools and have high radial stiffness.

Tapered Roller Bearings

In general, taper roller bearings application can be mounted independently from the cup because the cone assembly, which consists of the inner ring with roller and cage, is removable (outer ring). Mounting is made simpler by being detachable. The appropriate rolling motion of the roller on the track surfaces of the cone and cup is ensured by the projection lines of all the taper surfaces (Cup, Cone, and Roller) meeting at a single point on the bearing axis, known as the apex point. Single and double-row taper roller bearing applications in inch and metric series are produced by NBC.

Types of Tapered Roller Bearings

  • Single row
  • Double row
  • Four rows
  • Tapered roll thrust

Application of Tapered Roller Bearings

  • Agriculture
  • construction & mining industries
  • sports robot combat
  • propeller shaft
  • engine motors and reducers
  • wind turbines etc.

Advantages of Tapered Roller Bearings

  • Low friction
  • Long service life
  • Rigid bearing applications
  • Separable and interchangeable
  • Enhanced operational reliability

Disadvantages of Tapered Roller Bearings

  • Not suitable for high engine speed.
  • Increase heat due to large contact surfaces.

Spherical Roller Bearings

In general, spherical roller bearings in industrial applications are designed for high radial loads. They automatically make up for significant angular faults (shaft misalignments). They typically have a two-row arrangement, with shared spherical raceways in the outer ring between both rows of rollers.

Types of Spherical Roller Bearings

  • Spherical rollers.
  • Spherical roller thrust bearings.

Application of Spherical Roller Bearings

  • Industrial gearboxes
  • conveyors
  • cement grinding rolls
  • passenger coach axle boxes of railways.

Advantages of Spherical Roller Bearings

  • High load-carrying capacities
  • Low friction
  • Self-aligning
  • Reduce noise and vibration levels
  • Extended service life

Disadvantages of Spherical Roller Bearings

  • Lower limit speed
  • Poor heat dissipation with compound material
  • Relatively high starting friction

Needle Roller Bearings

Typically, needle rollers and cages make up needle roller bearings. To facilitate flawless rolling action, several needle rollers are put between two hardened, smooth surfaces, and a cage prevents the needle rollers from touching one another. Needle roller bearings have relatively tiny roll bearing application diameters and great length-to-diameter ratios, which increases load-carrying capacity and makes them perfect for oscillation motion.

Types of Needle Roller Bearings

  • Needle roller and cage assembly
  • Shell-type needle roller bearings
  • Machined ring needle roller bearings
  • Thrust needle roller bearing

Application of Needle Roller Bearings

  • Industrial gearboxes
  • conveyors
  • cement grinding rolls
  • passenger coach axle boxes of railways.
  • Rocker Arm Pivot
  • Pumps
  • Gearboxes
  • Two or More Stroke engines, etc.

Advantages of Needle Roller Bearings

  • Convenient at high and low temperatures
  • Easy lubrication
  • International standards and specifications are uniform.
  • Easy to get interchangeable products
  • Fewer friction

Disadvantages of Needle Roller Bearings

  • Loud noise
  • Complex structure
  • Fatigue.

Conclusion:

We don’t frequently see these products immediately in our daily lives, such as machines that produce energy, materials, or machining equipment.However, as we’ve mentioned in this blog, a lot of bearings in industrial applications.These bearing applications help our daily life in addition to the force and rotation.Additionally, the functionality required of bearings is growing, and bearings suitable for many applications are in high demand. NBC, the leading bearing manufacturer, is acknowledged for its excellent quality and delivery.

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Press Release

National Engineering Industries Ltd (NBC Bearings) recognised amongst India’s Best Workplaces in Manufacturing 2023

Best Workplaces in Manufacturing 2023

The company has been Great place To Work® certified since 2018

Jaipur, 25 January 2023:: National Engineering Industries Ltd (NEI), part of USD 2.4 billion diversified CK Birla Group, once again, has been recognised as ‘India’s Best Workplaces in Manufacturing 2023’ by Great Place to Work® Institute. NEI featured in the top 25 out of 201 organizations considered through a rigorous evaluation and assessment demonstrating that NEI particularly excel on people practices that they have crafted for their employees and proactively act on the feedback to create a high trust culture. India's Best Workplaces in Manufacturing 2023

Every year, more than 10,000 organizations from over 60 countries partner with Great Place To Work® for assessment, benchmarking, and planning of actions to strengthen their workplace culture.

Sharing his views, Rohit Saboo, President & CEO, National Engineering Industries Ltd said, “I am thrilled that NEI has been recognized as one of India’s Best Workplaces in Manufacturing. This acknowledgement by GPTW is a testament of our focus towards the employees through our various people focused programs & practices we have in place. We believe that positive employee engagement is crucial for achieving our business goals and that the success of our company is directly tied to the happiness and satisfaction of our employees.”

Adding to this, Sandeep Gautam, CHRO, National Engineering Industries Ltd said “NEI’s reputation as an employer of choice is built on our strong people practices, which are continuously refined based on feedback from our employees. Our approach has enabled us to foster a culture of high trust and high performance which has propelled us towards our goal of being an employer of choice. Being named as one of the best manufacturing workplaces repeatedly is a significant achievement. We at NEI, highly value our talent and provide them with exceptional opportunities for learning and growth”

NEI offers best-in-class programs for its employees that foster a culture of continuous learning and equip employees with the necessary skills to navigate the rapidly changing business landscape. NEI has accelerated digital/virtual learning systems, leadership development and performance enhancement programs for its talented workforce. The company is dedicated to improving its people practices creating a positive and high-quality work environment.

About National Engineering Industries Ltd (NBC Bearings)
Founded in 1946, National Engineering Industries Ltd (NEI), is a part of the US$ 2.4 bn CK Birla group and manufacturer of NBC brand of bearings. Enabling sustainability by making movement more efficient, NEI is India’s largest manufacturer and exporter of bearings with production of 200 Mn bearings annually in over 2300+ variants for application across automotive, railways, aerospace and industrial segments to serve customers in more than 30 countries. It also serves the Indian aftermarket through a countrywide network of over 550 authorized stockists and thousands of retailers.

Headquartered in Jaipur, India NEI is the only bearings manufacturer in the world to win the prestigious Deming Grand Prize (2015). With an employee strength of over 2,800 and five manufacturing plants in Jaipur (2), Newai (Rajasthan), Manesar (Haryana) and Vadodara (Gujarat), NEI is equipped with global manufacturing and process technology and has one of the best R&D centres in India. Apart from being technologically advanced, the company practices methods of sustainability by using alternate sources of energy and increasing the efficiency of the manufacturing process by leveraging on the power of digitisation. NBC Bearings is committed to be carbon neutral by 2039.

In 2020, National Engineering Industries Ltd, acquired Kinex bearings in Europe through it’s subsidiary NBC Global Ag, to enhance, diversify and provide best-in-class products to its existing and potential customers. In 2022, NBC Global Ag opened it’s Global Technology Centre in Germany to support innovation and provide support to NEI’s global growth. For details, visit: https://nbcbearings.com
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Blog

Bearing Remanufacturing – The Basic Types Of Bearings Repairable

Bearing Remanufacturing
Bearing repair is not a new idea, nor has it evolved significantly over the years — which is good news. Repairing damaged bearings is a precise science that has been fine-tuned over time through gradual and careful improvements to provide superior results. As new designs and technologies improve bearings, growing expertise and technology in bearing repair continue to improve the reliability and performance of reconditioned bearings, making them a more cost-effective alternative to purchasing new bearings. Bearing remanufacturing can considerably reduce carbon emissions, using only about 10% of the energy required to manufacture a new one. By extending bearing service, remanufacturing prevents component scrapping and waste of natural resources. A remanufactured bearing will also have a shorter lead time than a new one.

Benefits Of Bearing Remanufacturing:

  • Lower life cycle costs
  • Improved service life
  • Machine downtime has been reduced.
  • Reduced environmental impact
  • Replacement bearings were kept on hand.
  • Increased overall asset dependability
Typical threats include wear, rust, solid particle contaminants, and sporadic metal-to-metal contact. Material fatigue may also occur as a result of shear stress appearing cyclically immediately beneath the load-carrying surface of a bearing’s rings and rolling elements. Such stresses cause micro-cracks beneath the surface to form over time, eventually extending to the surface itself. As the rolling elements of a bearing pass over the cracks, material fragments break away (this is known as “spalling”). For a bearing, this is usually the beginning of the end. When a bearing fails, it is certainly possible to replace the bearing. However, this standard approach can be costly and may involve lengthy delivery lead times. Using a controlled remanufacturing process for the bearing and then returning the bearing to full service, rather than outright replacement, offers a practical and cost-effective alternative.

Four Levels Of Bearing Repairs

Bearing repair is an exacting science that begins with an expert’s eye. A simple visual inspection kicks off a careful evaluation process that compares common types of bearing damage like scuffing and staining, to their repair potential. The extent of repair work can be determined once the type and extent of damage are determined. Serious damage may necessitate extensive rework, including the replacement of major components. Inspection and rework operations are classified into four levels. The following operations are listed in increasing order of repair time, difficulty, and cost:

Repair Type:

  1. Inspection, Cleaning, written report, and repack.
  2. Level I along with polishing all the components.
  3. Level I along with grinding rings plus manufacturing new rollers and cages.
  4. Level I + Level III + new inner and outer ring.
Bearing Repair
A detailed description of a typical Level III operation follows
  1. The complete cleaning of the bearing.
  2. Disassemble and inspect each component, etch the serial repair number, and record pertinent bearing information.
  3. Generate a written inspection report and formal quote.
  4. Launch a manufacturing order for regrinding races and producing new sets of rolls; generate routings and prints.
  5. Grind the raceways on the inner and outer rings until no surface damage remains.
  6. All other surfaces should be polished as well as possible without removing material from critical surfaces.
  7. Magnet Est and examine the inner and outer rings.
  8. The amount of material removed from the raceways, as well as the internal geometry, is used to size new rollers.
  9. Perform necessary cage maintenance.
  10. Grind rollers to the desired size.
  11. Rollers are magnets, inspected, and sized.
  12. Check clearances before assembling the bearing.
  13. Save, pack, and ship.
When to repair?
Despite its many advantages, reconditioning is not always the best option for a damaged bearing. The difficulty in properly utilizing bearing repair services is determining whether or not a bearing requires repair and deciding which options are the most cost-effective and long-term. Visual inspection is the first step in determining whether a bearing requires repair. A thorough examination of additional criteria, such as the following, aids in determining the need for repair:
  • Is the bearing beginning to reach or past its recommended life expectancy?
  • Have operating temperatures surpassed 200 degrees Fahrenheit?
  • Is the bearing subjected to excessive vibration?
  • Has the bearing been subjected to sudden lubrication or temperature changes?
  • Early detection of a problem via routine checks can save businesses unnecessary downtime and expense while also allowing them to capitalize on the capabilities and benefits of bearing repair.
Regardless of the manufacturer, type of bearing, or application, proper treatment can help to preserve and restore a bearing-to-like-new condition for continued use. Bearings with little or no damage can often be easily and cheaply reconditioned and recycled.

Bearing Restoration Best Practices

Rolling bearings are candidates for reprocessing (though small sizes may be economically unwise), and the nature and extent of restoration will hinge on the affliction of the bearing and the application requirements. In general, relevant functional surfaces of the bearing will be repaired during remanufacturing, including the replacement of bearing components as needed. Expert analysts should be consulted as a best practice. They will be well-equipped to evaluate the bearing and determine which remanufacturing method will be most effective in restoring the bearing. The recommendations and restoration work will then be guided by standard industry procedures and established criteria. Some bearings may require more attention than others. As a result, rework categories leading to remanufacturing have been developed. Inspection: This is the first step, whether for a used bearing or bearings that have been stored for a long time, and it involves comparing them to drawing and/or specification requirements. Cleaning, degreasing, and disassembling the bearing is typically followed by nondestructive testing, visual or microscopic inspection, and dimensional inspection, followed by a detailed bearing analysis report with recommendations for appropriate treatment and rework attention. Reclassification: This procedure includes all inspection operations as well as minor repair (buffing and minor polishing of inactive and active surfaces, as well as grinding of scratches and grooves), demagnetization, reassembly, dynamic testing, lubrication, preservation, and return to service packaging. Refurbishment: This service category is based on selected inspection and reclassification activities and includes one or more of the following tasks: replacing rolling elements, remanufacturing the bearing’s cage for the rolling elements or replacing it with an identical cage, exchanging used components (such as seals, snap rings, and others), grinding or polishing and/or plating of mounting surfaces to return the bearing’s outside surface and bore to original drawing dimensions. Remanufacturing: This set of tasks also included previous operations such as inspection, reclassification, and, if necessary, refurbishment. It will also include one or more of the following activities: grinding, ring installation, and changing or substituting components to create a different assembly identity (in effect, modifying in order to improve performance or properties). Deeper grinding of the inner and outer ring raceways of larger bearings is acceptable during remanufacturing. Furthermore, additional machining methods, such as hard turning, can be used. The surface damage is removed, and the stressed material volume is altered. The surface is finished in accordance with the original blueprint specifications. In some cases, new rolling elements with diameters greater than the original rolling element diameter may be designed. The increased size of the rolling elements may necessitate reworking or replacement of the cage pockets. Following completion of work, final inspection and measurements, cleaning and preservation, service reporting, and documentation archiving should be performed. NBC Bearings have many years of bearing remanufacturing experience A global network of specialists performs work at dedicated service centers that adhere to strict specifications. Bearings that are not irreparably damaged can be restored using suitable techniques such as polishing, grinding, and component replacement. In fact, any bearing that has more than 30% of its calculated service life left can be remanufactured. As a result, the cost savings that can be realized through remanufacturing are significant.
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How Does FEA (Fine Element Analysis) Play a Significant Role In Wheel Bearings Design?

Fine Element Analysis
Finite element analysis (FEA) is the process of reproducing a part or assembling it under specific conditions. To enable component optimization during a project’s design process, engineers use FEA to model physical phenomena and reduce the need for actual prototypes.

What is Finite Element Analysis (FEA)?

With Finite Element Analysis, materials and products can be predicted to respond to forces in the real world as well as other physical factors such as vibrations, heat, and fluid flow using statics. The FEA process helps to demonstrate whether the product will work or not. A product needs to be examined if it does not sustain the conditions under which it must function. Therefore, the advantage of FEA is that the company doesn’t have to manufacture the product at this stage.

How do FEA elements work?

For finite element analysis to function, an object must be divided into numerous smaller constituent parts, often known as “finite elements”. In other words, the more elements, the finer the mesh, which results in an accurate model. It is possible to exactly predict how the product will respond to various simultaneous inputs by using complicated mathematical equations. Thanks to modern software, and automated processes, with FE this mathematical calculation can be carried out easily and quickly.

How does FEA play a significant role in optimizing the design of wheel bearings?

Automobile wheels are critical parts, and their strength is essential for safety. The car’s wheels move in a circular motion as it travels; thus they bear both the vehicle’s radial load and its bending load. The standard design approach involves using FEM to analyze wheel forces. After creating the model and determining the load, the force division situation and dynamic response may be obtained, allowing the calculation of extreme failure position and dangerous point. During the driving time, wheels must be strong enough to run on rough roads. At the same time, it is important to meet the profit by minimizing the costs. Rotating wheels get two different impacts from radical and bending 0.  
What is the stiffness of the wheel bearing?
The relation between an element’s deformation and the application of external loads to the component is what gives the stiffness concept its name: F = k? Where F is, being force applied, k stiffness of the component, and ? the deformation. This link between force and deformation is normally created in the matrix form by: {F1} = [k -k] {F2} = [-k k] With F1 and F2, being the applied forces, ?1, and ? 2 result in deformation in nodes 1 and 2. Although the stiffness matrix of a double-row angular contact ball bearing is seemingly more difficult. There are numerous publications with various mathematical models and examined bearing design geometry. The nonlinear contact characteristics inside the roller bearing are the cause of major complexity, which makes the bearing stiffness nonlinear, and load-dependent. In the most recent publication, a 5*5 stiffness matrix is used to define bearing stiffness for a defined loading condition. For double-row bearings, the stiffness may either be identified by two matrices, or by one stiffness matrix for double-row units. Under dynamic operating conditions, the bearing must maintain a camber angle within relevant limits. Depending on the bearing rigidity or stiffness specified by the customer, under a specified bending moment. Bearing mounting flange, internal construction, etc., are designed. Following the evaluation of the bearing stiffness by FEA technology, the design is further improved. FEA Technology satisfies the stiffness requirements of the customer as well as the bearing weight, life, packing, etc. The bearing stiffness is tested using the Test Setup. Verified concerning the FEA calculation once the prototype is complete.

Why is bearing stiffness critical to vehicle dynamics?

An angle made by the vertical axis of the wheel and the vertical axis of the vehicle is called a cambre angle. It is visible from the rearview mirror; it is an angle made by the vertical axis of the wheel and the vertical axis of the vehicle. Specifically designed for the steering and suspension. Cambre angle directly affects tire wear. Since improper camber angle adjustment could result in excessive inner or outer tread wear. Vehicle dynamics qualities can be further broken down into handling, steering, and ride comfort, which are important for the customer’s driving experience. It is important to understand stiffness in vehicle dynamics as this correlates with vehicle performance. The tests satisfactorily showed that the bearing could withstand the load and avoid making contact with the air gap, which was the primary goal. Furthermore, bearing deflection tests were conducted before and after fatigue tests. In the tests, no hub bearing damage was observed, which is essential for determining product longevity and maintenance intervals.
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Sensor Bearing – Everything You Need To Know About

sensor bearing for two wheelers
Want to know about sensor bearing and how it is used in place of conventional bearing? Here in this blog, we will look at everything that you need to know about sensor bearings. Sensor bearings are mechatronic bearings that feature a bearing and a sensor housed together. In these bearings, Harem Hall sensors are used to convert signals to electronically readable data. When the bearing rotates, the sensor in the sensor bearing measures the bearing speed and direction which is converted into electronic data to assist in optimized performance and results. NBC has developed the sensor bearing as an alternative standalone sensor to make the bearings smarter and optimized for high-performing applications. Sensors Bearings are a type of bearings integrated with Harem Hall sensors to convert signals from bearings into electronic data. 

Sensor Bearing and Their Function – How it is Different?

Most bearings consist of two parts: the inner race and the outer race. The inner race is the part that the shaft rotates on, while the outer race is the part that the housing or other support structure rotates on. Sensor bearings, however, have an additional third part which is the sensor. The sensor is typically a magnet, and its purpose is to detect the rotation of the inner race. This information can then be used for a variety of purposes, such as monitoring the speed of the shaft or detecting misalignment. Sensor bearings are therefore an important component in a wide range of applications. There are a few different types of sensor bearings, but the most common is the magnetic encoder. This type of sensor bearing uses a magnet to detect the position of the inner race. Optical encoders are also available, but they are less common. Sensor bearings are typically used in high-precision applications where reliability and accuracy are paramount. They are often used in medical devices, robotics, and aerospace applications.

What Are Sensor Bearings Used for?

Sensor bearings are used for numerous measurements like measuring the number of revolutions, speed measurement, direction of rotation, relative position or counting acceleration or deceleration, temperature, power/power shift, load, displacement, etc. NBC sensor bearings are designed to measure the speed and direction of rotation.

Market Trend of Sensor Bearing

The Asia Pacific is a growing market for Sensor bearings as the market is surging high with the huge demand for applications in two-wheelers and motors. Since it is a better solution than the conventional bearing options, it can be diversely used to increase performance, controllability, and reliability within mechanical systems.
End-Use Industries for Sensor Bearings
There are a variety of end-use industries for sensor bearings, including automotive, aerospace, and industrial applications. In the automotive industry, sensor bearings are used in a variety of sensors, including engine sensors, transmission sensors, and suspension sensors. In the aerospace industry, sensor bearings are used in aircraft engines and flight control systems. In the industrial sector, sensor bearings are used in a variety of machinery, including pumps, compressors, and turbines. NBC has also developed sensor bearings, especially for the automotive industry, such as Anti-Lock Braking systems in two-wheelers and electronic motors.
Conclusion
The current scenario of the bearing industry is growing at a very fast pace, giving birth to a lot of new and innovative products. These innovative products are in the market to cater to the needs of the consumers in the best and most efficient way possible to ensure mechanical advancements in the modern world. The Sensor Bearings designed by NBC also cater to such diverse needs to deliver optimum solutions.
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Medium Carbon Steel (MCS) Bearings – Everything You Need To Know About

Medium Carbon Steel
detail shot of Architectural blueprints.
Carbon steel is one of the most common types of steel used in manufacturing today, and bearings are among the specific tools which can take great advantage of it. While there are a variety of different carbon steel alloys, MCS or medium carbon steel works relatively better in industrial settings while offering a host of advantages compared to other materials. It has a higher tolerance to extreme heat and can withstand heavy loads in a wide range of applications. They are used in everything from automobiles, trains, or aeroplanes to construction equipment. In bearings, they also offer a set of unique benefits supporting mission-critical applications. Medium carbon steel is a versatile steel that is used in bearings to offer greater performance within the machinery. This makes bearings strong and durable which is ideal for use in a variety of industrial and engineering applications.

What is Carbon Steel, And What Are its Types?

Carbon steel is an alloy composed primarily of iron and carbon with a number of other elements. The main role of carbon in steel is to increase its yield strength, tensile strength, and hardness. Due to their excellent mechanical properties, we find carbon steel is used in almost every industrial and home application in some shape or form. There are three types of carbon steel used in bearings:
  1. High-Carbon Steel is the strongest and most durable option, making it ideal for heavy-duty applications. As the name suggests, the percentage of carbon in this type of steel is the highest – over 0.6%.
  2. Low-Carbon Steel is softer and easier to work with, making it a good choice for less demanding applications. With less than 0.30% carbon, this steel comes with minimal carbon content. 
  3. Medium-Carbon Steel strikes a balance between the two, offering good strength and durability while being easier to work with than high-carbon steel. Th1`is specific alloy uses anywhere from 0.30% to 0.60% of carbon as one of its integral materials.

Medium-Carbon Steel Bearing: Salient Features

Medium carbon steel bearings offer numerous benefits in applications where greater stability and endurance are required. Here’s a look at some of the significant ones – Higher Fracture Toughness: Carbon steel is highly resistant to fracture, which means it can handle long operating cycles of bearings without any problems. Its resistance to fatigue also provides significant durability. Greater Crack Propagation Resistance: Unlike lower grades of steel, medium carbon steel is more robust against cracking due to stress. This allows offering bearings a longer service life and reduces the need for frequent maintenance. Highly Resistant to Wear And Tear: These medium-carbon steel bearings are highly resistant to wear and tear, meaning they can withstand a lot of wear and tear over time in high-performance applications. Resistance to Corrosion: Medium-carbon steel bearings are also resistant to corrosion, meaning they won’t rust or corrode over time. Self-Lubricant: Another great feature of medium-carbon steel bearings is that they are self-lubricating. This means that they don’t require any external lubrication, making them very easy to maintain. Additionally, self-lubricating bearings also tend to have a much longer lifespan than other types of bearings. Impact Resistance:: Medium-carbon steel bearings are also very resistant to impact. This means that they can withstand high loads and shocks without damage. This makes them ideal for use in applications where there is a lot of vibration or impact. Greater Performance in a Contaminated Environment: Due to its ability to resist corrosion, medium carbon steel is suitable for use cases where they are installed in contaminated environments without any performance issues, such as oil fields and refineries. Conclusion All these benefits listed in this blog make Medium-Carbon Steel a popular choice for manufacturers who want high-performance bearings that are also cost-efficient. In terms of applications, medium-carbon steel is widely used across transmission bearings and pinion support bearings.
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Blog

Tungsten Carbide Carbon Coating in LDB

Deep Groove Ball Bearing
The tungsten carbide carbon coating on bearings is a very beneficial thing and can help various industries in terms of extending bearing life. Read this blog to know more.  Tungsten carbide carbon coating is becoming popular because of its efficiency at low cost and its increased use in bearings. Tungsten carbide is usually in a form of a greyish-colored fine powder and turns into a carbide coating for bearings when mixed with small portions of different metallic powders (cobalt, chrome, and/or nickel) according to the use. The TCC is a very hard, wear-resistant coating that can be applied to almost any type of bearing. It also has a low coefficient of friction, which means that it can handle high loads without slipping. Being very durable in nature, it has the capability to withstand high temperatures and harsh environments.

Current Industrial Challenges of Bearings

There are several industrial challenges that frequently occur in various applications and the bearings should be able to take the heat for the finest performance. Here are some of the current industrial challenges of bearings:
  1. Paper industry (calender machine): It has a very wide load range and zero load situations. It can create problems such as sliding, smearing damage, and micro-welding.
  2. Hydraulic application (pumps and motors): The motors and pumps may have varied challenges such as low viscosity lubrication which can result in conditions like wear-tear and friction. Without the proper coatings on bearings, the durability also diminishes. 
  3. Power plant (coal pulverizer): Coal pulverizers in power plants may face challenges due to contamination and vibration with low-viscosity lubrication. In different levels of production where coal is required, problems like abrasions, micro pitting, smearing, etc. can happen under these circumstances. 

Solution – Tungsten carbide carbon coating in Bearings

The challenges of bearings in a high-performing environment in the paper industry, hydraulic applications, power plants, etc. can be resolved using the tungsten carbide carbon coating to prevent wear and tear, abrasions, smearing, etc. Here are some of its features that make it ideal for the use of coating bearings:
  1. Increased resistance to wear and tear – The coating can help to protect the bearings from wear and tear, which can extend their lifespan.
  2. Reduced friction – The coating can help to reduce friction between the bearings and the surrounding components, which can improve performance.
  3. Protection against corrosion – The coating can help to protect the bearings from corrosion, which can also help to extend their lifespan.

Characteristics of Tungsten Carbide Coatings in Bearings

Here are some of the characteristics of tungsten carbide coatings in bearings:
  • Very thin coating: it has a very thin coating of 1-2 um. It helps in low friction and has great sliding properties. Even with the thin coating, its high melting point resists wearing effectively.
  • High adhesion strength (HF1 to HF2 grade): Tungsten carbide coatings applied with high-velocity oxygen fuel (HVOF) lead to stronger adhesion, corrosion resistance, and low porosity, which helps the bearings work very smoothly.
  • High hardness (1000-1500 HV): When tungsten carbide coating and detonation gun (d-gun) are applied together, there is a strong bond created, resulting in hardness, no wear-tear, and protection from erosion, which makes bearings more durable.
  • Lubrication: Hard coating on rolling elements polishes the race’s surface and the carbon layer provides lubrication for the traction-improving devices. This is the reason it is used in horseshoeing. Carbon-tipped hoof nails are also used to mount the shoes. 
  • Increased Life for Bearing: In thin oil or contaminated oil condition, the bearing life can be increased 3x as compared to the normal bearing.
Conclusion If you are looking for a way to improve the performance and lifespan of your bearings, then consider applying a tungsten carbide carbon coating. It is a very reliable solution offering low friction and eliminating smearing and other wear-tearing-related problems.
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High Precision Bearings Races for Spacecraft – A New Development At NEI

Angular Contact Ball Bearings
Space aeronautics is a diverse field and bearings manufactured for Spacecraft should withstand rigorous conditions of space travel and provide smooth operation of the spacecraft components. Bearing races being the critical component of a spacecraft, it should be designed for longevity and reliability to ensure that missions do not fail. At NEI, after continuous research and development, it has recently developed High Precision Bearings Races for Spacecraft that can empower indigenous organizations to use bearings manufactured in the country itself. 

NEI Breaking the Long Legacy of Dependency for Spacecraft Bearings

The Indian organizations working on space aeronautics have to earlier rely on foreign players for manufacturing bearing races for spacecraft but now due to the latest development and research by NEI, the bearing races can be manufactured in the country itself. It will open new avenues for space research in the country and accelerate space missions in the coming years. The industry has greatly appreciated these efforts offering new opportunities for such developments.

Reaction Wheels for Spacecraft – How Critical it is in Space Missions

Reaction wheels are a crucial element of spacecraft that controls the altitude and x,y, and z axis of aircraft in space. In short, it deals with changing the orientation of a spacecraft. The bearings and associated components should be designed in a rigorous and reliable manner otherwise it can lead to critical failures. In the past, many mission failures have occurred due to faults in bearings which has resulted in severe losses for space agencies. One such case was the Kepler Telescope in which the bearing wasn’t able to overcome the friction due to which the reaction wheel failed and the mission failed way before its expected completion time.

Why High Precision Bearings Races for Spacecraft Needed?

Here are various reasons why bearings need to be high precision in a space environment where there is no scope to perform maintenance:
  • Offers Low Friction Interface: High precision bearings races for spacecraft are needed to provide a low friction interface between moving parts. This is especially important in environments where there is no atmosphere to provide lubrication, as friction can cause wear and generate heat that can damage sensitive components. 
  • Reduce Vibrations: Bearings also help to reduce vibration making them an important part of the overall design of a spacecraft. The vibration can also cause fatigue to some of the internal components which can result in part failure.
  • Optimal Design: The high-precision bearing races for spacecraft are designed with keeping reliability and rigorous conditions in consideration. They are perfect for high-speed and high-tolerance applications.
  • Works in Extreme Weather Conditions in Space: The weather conditions in space are quite different from what we face on earth. The major challenge is coronal mass ejection from the sun which can be hazardous to aircraft. The high precision bearing races can work well in such hazardous conditions too.
  • High Running Accuracy: The bearings are designed with a high degree of precision to ensure that they can maintain a high level of running accuracy. 
Benefits of High Precision Bearings Races for Spacecraft High-precision bearings races are used in spacecraft to provide a smooth, precise, and durable surface for the bearings to rotate on. The benefits of using high-precision bearings races in spacecraft are numerous, including:
  1. Reduced wear and tear on bearings: By providing a smooth surface for the bearings to rotate on, high precision bearings races help to reduce wear and tear on the bearings, lengthening their lifespan.
  2. Improved performance: The smooth, precise surface provided by high-precision bearings races leads to improved performance of the bearings, providing smoother and more efficient operation of the spacecraft.
  3. Enhanced durability: The increased durability of the bearings provided by high precision bearings races leads to enhanced durability of the spacecraft as a whole, providing longer life and increased reliability in difficult conditions.
  4. Reduced Heat Generation & Low Noise: The main advantage of using high-precision bearings in spacecraft is that they generate less heat and have low vibration levels. This is important as it helps to prolong the life of the spacecraft by reducing wear and tear and it also ensures that the spacecraft can operate at its highest level of efficiency.
Conclusion The development of High Precision Bearings Races for Spacecraft by NEI offers new avenues for space research and development in the country. The rigorous and highly precision-designed bearings can work well in extreme conditions to power a wide range of space research missions and can be widely used in spacecraft and satellites.  
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Why A Data Acquisition System Is Crucial For Plant Operations

Data Acquisition System
Data is critical for powering insights in a large-scale manufacturing plant. There are a number of machines that need to run with optimum efficiency, productivity, and power. The bearing manufacturing plant is one example. It is spread across huge areas with numerous machinery and equipment that power the plant operation. The Data Acquisition System can help in managing a plant better by ensuring that the machinery is operated with the right mechanism and efficiency. The DAQ system is a robust monitoring tool that not only monitors a wide variety of parameters but also keeps track of the status of all plant machinery and equipment. By continually keeping tabs on critical working areas, the DAQ helps to ensure that plant operations are running smoothly without any critical scenarios arising.

How does Data Acquisition System work?

A data acquisition system (DAS) is a device used to convert physical parameters into digital data that can be read by a computer. DAS systems are used in a variety of plant operations, including monitoring and controlling processes, managing assets, and optimizing performance. These systems typically consist of sensors, DAQ devices, and software. 

Components of DAQ :

Here are various components of the Data Acquisition System that facilitate plant operations:
  • Sensors
Sensors are devices that convert physical parameters into electrical signals that can be measured and recorded. They are used to measure physical parameters such as temperature, pressure, flow, and level.
  • Signal Conditioners
Signal conditioners amplify, filter, and convert the sensor signals into a form that can be read by the data acquisition hardware. These might not be required in all cases but if the signal from the transducer is not apt for DAQ hardware then a signal conditioner might be needed to make the information readable.
  • Hardware
Hardware is the physical platform on which the data acquisition system runs, including the sensors, signal conditioners, data acquisition cards, and any associated cabling. It is a connecting point between sensors and computers to offer input and output. 
  • Software
DAQ software provides a user interface for configuring and controlling the data acquisition devices, as well as for viewing and analyzing the data that has been acquired.

Why a DAQ System is Crucial for Plant Operations?

The Data Acquisition System is a boon to plant operations as it offers numerous benefits which will ensure smooth workflow and efficient operations while ensuring critical aspects that might help in better decision-making. Here are some of the points to give you more insights into why DAQ is crucial for plant operation:
  • Improved Efficiency: Data acquisition systems can improve efficiency in plant operations by providing accurate and timely data about the plant’s process and equipment. This information can be used to optimize production, identify and resolve issues, and improve safety and environmental performance.
  • Cost Optimisation: The data acquisition system can help reduce downtime, and improve quality and production while saving energy and resources. It can assist in identifying opportunities for cost savings and process improvements.
  • Monitor the Usage of Plant Machinery: The usage factor and time the machinery is running for is another critical metric that a plant might require in order to access the rate of utilization aligning with energy-related aspects.
  • DAQ can help in Identifying Areas of Improvement:  By collecting data on various aspects of plant operations, such as production rates, energy use, and equipment performance, data acquisition systems can help identify those areas where necessary improvements could be made.
  • Helps in Decision Making: The data collected by data acquisition systems can be used to make better decisions about future operations, such as when to schedule maintenance or make changes to the production process.
  • Helps in Process Automation: Using DAQ can help manufacturing plants get ready for industrial automation which can accelerate the profitability of the organization in varied ways.
  • Preventive Maintainance: Through Data Acquisition System, the machinery life can be subsequently increased while ensuring timely and preventive maintenance to make sure that machinery doesn’t break down.
Accelerating Plant Operations
The plant operations can be manually managed but shifting it to the digital system can have varied benefits and DAQ is exactly the right solution which eliminates all the hassles related to an error-prone process where manual inspection and checking was done. Since ensuring plant operations is a critical task, it should always happen within the bounds of safety norms to make sure the plant operations don’t get impacted keeping in mind both resources and costs. Due to DAQ, the plant performance can be highly optimized while tracking end to end process of manufacturing to make sure that plant operations happen without any red flags.
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Electric Motor Ball Bearings – Everything You Need To Know

Electric Motor Ball Bearings
As the name suggests, electric motor ball bearings are bearings that are used to support electric motors and make them function by transmitting the power between various elements of the machine or rotating the shaft. To help you understand more, This blog covers everything you need to know about electric motor bearings. The bearings are critical to support varied types of machinery and can work in any kind of environment within the mechanical systems. Electric motor bearings are designed to provide smooth, efficient operation of electric motors. The bearings are made of high-quality materials that can withstand the high speeds and loads exerted by electric motors making them apt for high-performance applications while ensuring an optimal operational life. These bearings are available in a variety of sizes and designs to meet the specific needs of different electric motors.

Electric Motor Ball Bearings: How they Power Electric Motors

Electric motors require reliable solutions to work in an optimum manner. In terms of mechanical characteristics, electric motors are powerful and versatile, making them useful to work in high-performing machinery. Be it machines at the factory or electric vehicles, these bearings can be used in any of the electrical motors to allow rotary motion and transmit the power to make various parts of the machinery function well. The bearings that support these motors need to allow for smooth, quiet operation while providing key features such as high load capacity, long life spans, and low running noise.  Electric motor ball bearings are subject to a variety of forces, including radial and thrust loads, as well as vibration and shock. To withstand these forces, bearings must be carefully designed and manufactured. The most common material used for electric motor ball bearings is steel, but other materials such as ceramic or plastic may be used in some applications.

Use Case in Real-Time Scenario

The main performance characteristics of electric motor bearings are high load capacity, high-speed operation, high precision positioning, low noise, etc. They are used in the load and speed requirements of the motor. In terms of general applications, they are widely used electronic appliances, large-scale machinery in factories, electric vehicles, railways, wind turbines, etc. Since these machines have different requirements, various types of bearings are used in different scenarios to power them:
  1. Ball Bearings: These are mostly used in non-belted and direct-coupled applications where the motor runs under 150 horsepower speed. Ball bearings are designed specifically to handle both axial and radial loads in varied conditions within the machinery systems. The most common application of these types of electric motor bearings is in AC motors.
  2. Standard Roller Bearings: These kinds of roller bearings are designed for belted applications and are perfect for radial loads. They are not used to handle axial loads. It also works with motors that operate at a minimum of 150 HP.
  3. Angular Contact Ball Bearings: These kinds of electric motor bearings are perfect for high-speed rotating applications with axial loads. It can be configured with different types of cage designs and rows.
  4. Cylindrical Roller Bearings: These roller bearings are perfect for handling extremely high axial loads. Cylindrical roller bearings work efficiently at both medium and high speeds and support several design alternatives as per the mechanical applications. These are mostly used for belt or gear-driven electric motors.
  5. Deep Groove Ball Bearings: These ball bearings are a perfect match for electrical motors as it is apt for high-speed applications supporting moderate-type axial and radial loads.
  6. Sealed Bearings: These are specially designed bearings that work in contaminant-prone environments. However, they have a limited life span as they cant be re-lubricated.
  7. Shielded Bearings: Shielded bearings are specially designed to protect electric motors from dust, dirt, and other debris. They are made with a metal shield that covers the bearing, preventing contaminants from entering and damaging the sensitive components.

Conclusion

This blog has covered various aspects related to electric motor bearing as these bearings are the perfect fit for all kinds of performance needs. Be it any kind of motor, there is always a type of bearing that exists to meet mechanical needs. While choosing a bearing, you should also consider checking out the design and specifications needed to make it work in the best way without compromising any performance issues or incurring functional damage. This is something that makes the machinery or motor work in a reliable manner.