pr@tik 2k12

A Report on Benara Udyog Limited(Bearings, Bushing & Disc Brake Pads)Given toME DepartmentKCC ITM, Gr. Noida

Submitted to:Submitted by:Mr. Dushyant MishraPratik RawatMech. Department 1249240094 Batch 2K12 Acknowledgement

The training opportunity I had with Benara Udyog Limited was a great chance for learning and professional development. Therefor I consider myself as a lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me through this training period.I perceive as this opportunity as a milestone in my career development. I will strive to use gained skills and knowledge in the best possible way.

Pratik Rawat ME 4th year KCC Inst. Of Tech. & Mgmt. Gr. Noida

Preface

Benara Udyog Limited is one of the premier manufacturer of Engine Bearings, Bushes, and Bi-Metallic Strip for the automotive industry. Presently, Benara Udyog limited has emerged as one of the Indias largest manufacturer in technical collaboration with NTE-South Korea.

This is being undertaken by the quality and, covers major share of bearing industries and machining forward for capturing higher percentage share of Oems.

Contents: About Company Bi Metal 1. Requirements to Engine Bearing Materials 2. Selection of engine bearing materials 3. Preparation of Powder of the alloy 4. Manufacturing bi-metal strip Sintering process for copper/aluminum based bi-metal strips Re Sintering 5. Blanking 6. Stamping 7. Bending 8. Coining 9. Facing & chamfering 10. Oil grove 11. Oil hole 12. Visual inspection 13. Packing & dispatching Conclusion Picture SaysAbout Company Presently, Benara Udyog Limited has emerged as one of the India's largest manufacturer in Technical Collaboration with NTE-South Korea.

In addition, they have an In-House R&D center, where they design and validate the performance of products.

Company Profile Business Type : Exporter / Manufacturer / Supplier Year Established : 1970 No. Of Employees : 400* Annual Turnover : Rs. 38.9 Lakhs Products Exporter, Supplier and Manufacturer : Bi-Metallic stripes (cu, pb, al, sn) bi-MetallicEngine Bearing

, Bi-Metal bushes

Client List M/S. V.E. COMMERCIAL VEHICLES LIMITED, PITHAMPUR M/S. V.E. COMMERCIAL VEHICLES LIMITED, DEWAS M/S. YAMAHA MOTORS LIMITED, FARIDABAD M/S. GREAVES COTTON LTD., AURANGABAD M/s. GREAVES COTTON LTD., RANIPET M/S. TATA MOTORS LTD, LUCKNOW M/S. TATA MOTORS LTD, JAMSHEDPUR M/S. TATA MOTORS LTD, PUNE M/s. HINDUSTAN MOTORS LTD., HOOGHLY M/S. INTERNATIONAL TRACTOR LTD, HOSHIARPUR M/S. ASHOK LEYLAND, CHENNAI M/S. MAHINDRA & MAHINDRA LTD (TRACTOR DIVISION), MUMBAI

Bi Metal Bimetal refers to an object that is composed of two separate metals joined together. Instead of being a mixture of two or more metals, like alloys, bimetallic objects consist of layers of different metals. Two metals have different coefficient of thermal expansion & expands at different rates as they are heated.

1. REQUIREMENTS TO ENGINE BEARING MATERIALS

Fatigue strength Compatibility Wear resistance Conformability Embed ability Corrosion resistance Cavitation resistance

2. SELECTION OF ENGINE BEARING MATERIALS

Selection of bearing material suitable for a particular engine should be based on the following engine parameters:

Maximum specific load applied to engine bearing Crankshaft material Possible misalignments and distortions Minimum oil film thickness

3. PREPARATION OF POWDER OF THE ALLOY

4. MANUFACTURING OF BI METAL STRIPThe following processes are used for manufacturing bi-metal strips for engine bearings- Sintering process for copper/aluminum based bi-metal strips Casting process for copper/aluminum based bi-metal strips

However Binara udyog Ltd. uses only sintering process.

Sintering process for copper/aluminum based bi-metal strips The sintering process includes the following stages:

Uncoiling steel strip. Straightening the steel strip. Washing the stripby a hot alkaline solution andmechanical cleaningby rotating steel wire cylindrical brushes. Sanding the strip surfaceby an abrasive rotating endless belt. Spreading the powderof the copper alloy over the steel surface. The necessary powder alloy thickness is pre-calculated. Sintering the powder. The process is performed in a long (about 33ft/10m) sleeve-type continuous sintering furnace. The sintering temperature is within the range 1515-1615F(824-880C) depending on the alloy composition. The atmosphere in the furnace is reducing: it consists of a mixture ofHydrogen(H2) andNitrogen(N2)

2NH3= N2+ 3H2

CuO + H2= Cu + H2O Compaction.After sintering stage density of the alloy is higher than in the powder state but it is still 20-30% lower than in fully compact state. The pores between the joined particles are closed in the compaction stage when the strip passes aRollingmill.

Re-sintering

This stage is performed in order to set physical joining (welding) between the surfaces of the pores mechanically closed in the compaction stage. Re-sintering is conducted in a sintering furnace. As a result of re-sintering porosity is eliminated & sinter structure forms. The second phase(lead, bismuth) is homogeneously distributed throughout the surface in form of small particles (0.001-0.002/25-50 m) located between thegrains. Rolling.This stage is performed in order to strengthen (strain hardening) both the steel back and the sintered cooper alloy. Recoiling the bi-metal strip.

Dimensional Range and Tolerances Sintered Bimetal StripSteel Thickness (mm)Lining Thickness (mm)Usable Width(mm)Thickness Tolerance (mm)

0.50 to 5.00 0.25 to 1.50200.00 max 0.025

5. BLANKING

It is a metal fabricating process, during which A metal work piece is removed from the primary Bi-metal strip or sheet when it is punched. Material that is removed is the new metal work piece or blank.

6. STAMPING

It is a squeezing process in which the detail of the part to be produced is stamped on the blank i. e. Part number Loading Dimensions

7. BENDING

Bending is a forming process in which blank is deformed or bent into half round shape with the help of die and punch. When bending is done, the residual stresses cause the material to spring back towards its original Position, so the sheet must be over-bent to achieve the proper bend angle. Usually bending has to overcome both tensileStresses and compressive stresses

8. COINING

It is a process in which banded blank is compressed or squeezed into proper C shape. The forced applied in coining process is 5 to 30 times of the forced applied in bending process. It causes permanent deformation through the sheet. There is no or little, spring back.

9. FACING & CHAMFERING

Facing is an operation in which width or length of the bearing is reduced or to produced flat and smooth surface. Tool is moved perpendicular to the axis of the work piece

In chamfering process sharp edges of the bearing are beveled at 45 This is done to remove the burrs to protect the end of bearing from being damage and to have better look 10. OIL GROVE

Oil grove helps in distributing the lubricant very evenly around inner circumference of the bearing . Multiple groove bearings, in which the grooves are simply cut in a noncircular pattern, are used to provide a more general increase in lubrication.

12. VISUAL INSPECTION

In this process bearing is examine with eye in light By visual inspection standards of Surface finish are evaluated.

13. PACKING & DISPATCHING

CONCLUSION

OVERALL PROCESS IS :-

1 2 3 4 1 2 3 1 2 34 56 1

Picture Says

The first operations

there are two main types of 1st Operation:

removal of material (turning or bar turning)

deformation (pressing, forging or rolling)

1.Raw material

Bars or tubes of 100 Cr6 type steel.

2.Pressing

Cold working of the material (steel sheet) and cutting out (technique similar to forging).or Forging

Working a slug of previously heated material.

or 3.Rolling

Hot working of material by rotation.

or 4.Bar turning

Removal of material when cold, using a cutting tool (knurl or tip) on a multi-spindle turning machine.

or Turning

Technique similar to bar turning but performed on a single spindle turning machine.

Heat Treatment

Heat Treatment increases material hardness.

At each of the three steps, different processes are available, depending on the product.

1 - Heating 850 C

(Austenitizing) to alter the structure of the material.

2 - Quenching 40 C

Rapid cooling to fix the structure of the material and thus increase hardness.

3 - Tempering 170 C

"Reheating" to reduce the effects of thermal shock (quenching) inside the structure and stabilise the material.

Grinding

Grinding is used to give the ring blanks their "final" shape and improve surface condition (roughness).

Various mills are used to perform several operations:1. Surface grinding2. Outer ring outer diameter grinding3.Inner ring inner diameter grinding4.Inner ring outer diameter grinding (raceway)5.Outer ring inner diameter grinding (raceway)6.Superfinishing

Assembly End of process layout

Operations involving: assembly of various items,

Performing additional functions (greasing, marking, etc.)

1. During each of these steps, the bearing manufacturing process layout is carried out in compliance with total quality (self-inspection, SPC and TPM).

*************************************************************************************