the
MATERIAL
In majority of application of Bearings, a through hardening type
carbon-chrome steel is used. This steel is normally conforming
to SAE 52100 / 100Cr6 / SUJ2 specification which is popularly
known as Bearing Steel. The matching of chemistry only with the
specification is not adequate for its use in bearing application.
This qualifies to be used for Bearing application only when it
matches with chemistry and cleanliness both and to achieve both
of these depends upon steel making process and its casting technique
and methods of drawing it into the shape of wire.
We make sure to use the steel in which microinclusions,
microcleanliness and microstructure is maintained
and controlled as the fatigue life of bearings depends on it.
We source our material from the world renowned producers like
Diado-Japan, Ascometal-France, Nippon Koshua-Japan, Sanyo Steel-Japan,
Villares-Brazil, Nedstall-Holland etc. We have strong inward inspection
with in house facility for quick & accurate analysis.
the
Manufacturing
The first step in manufacturing is to design tooling. As soon
as we receive customer's order our tool room equipped with the
facility of computer aided design and world class machinery comes
into action. In order to ensure consistency in the geometry, the
data generated by computer in design goes to the machine directly
for tool production.
Steel
wire made out of selected source of steel is cold forged into
the shape of Taper roller for correct grain orientation.
These rollers are then tumbled and heat-treated in rotary retort
and steel belt conveyor furnaces.
These furnaces are controlled by temperature controller of One
Degree Celsius accuracy which is verified every day by quality
assurance department. Rollers in rotary furnace are heated indirectly
in the presence of a preventive atmosphere of controlled dew point
for zero decarburisation. Then the rollers are quenched in a tank
of mechanically agitated oil bath whose temperature is maintained
by controllers and heat exchangers for proper microstructure and
to achieve hardness of 62 + 2 HRC. Thereafter it is cleaned
by shot blasting and grinded by high performances Grinding line
capable of automatic size control which can read and control in
increment of 0.1 micron.
the
Microgeometry
Our Taper Rollers have correct and consistent profile on
OD to eliminate edge loading and to achieve proper load distribution;
correct and consistent sphered end profile on big end for smooth
running and high surface finish for noise reduction.
