Project Report: Manufacturing of Bearings at HMT Bearings Limited

This project report details a student's experience with the manufacturing of bearings at HMT Bearings Limited. The report covers the project's background, objectives, and the student's role, which included documentation and assisting the project manager. It outlines the characteristics of bearings, emphasizing their importance in machinery, and details the raw materials used, such as SAE 52100 steel. The student applied mechanical engineering knowledge and problem-solving skills to address issues like low-quality steel and raw material availability, proposing solutions that involved testing steel quality and sourcing materials from alternative suppliers. The report also highlights the importance of teamwork, training, and innovative approaches to improve the manufacturing process. The project provided a practical understanding of bearing manufacturing, its components, and the challenges faced in the industry.

CE 1.1 Project Information
Name of the project: Manufacturing of Bearings
Location of the project: HMT Bearings Limited, Hyderabad, India
Project Duration: From February 18 of 2009 to March 17 of 2009
Organization: HMT Bearings Limited, Hyderabad, India
Role and Designation during the time: Team Member of the project
CE 1.2 Organizational Background
HMT Bearings Limited is one of the leading manufacturing companies in India. It is
complete subsidiary of HMT Ltd and it started its journey in the year 1964 as a private sector.
It was later taken by Andhra Pradesh Industrial Corporation Limited or APIDC. After 1968, a
new unit was set up with technical collaboration with M/s. KOYO SIEKO Co. Limited, the
leading manufacturer of bearings of Japan. Finally, I the year of 1981, HMT Bearings LTD.
was inaugurated. This organization facilitates the manufacture of several components and
tools that are solely required for bearings. The major and the most important components of
this organization are HMT multi spindle automats, mini chuckers, rings grindings, roller
grindings, special purpose machines and various general purpose machines.
CE 1.3 Project Background
CE 1.3.1 Characteristics of the project
The project of Manufacturing of Bearings was my first important and professional
project in engineering career. Bearings are certain devices that are utilized for overcoming the
frictional losses by simply converting the sliding motion into rolling motion. Huge and rapid

industrialization is taking place in all over the world. This has lead to invention and
adaptation of several machines and thus importance of bearing has increased. Bearings are
present in all machines as it helps to move.
CE 1.3.2 Objectives developed for the project
This project of Manufacturing of Bearings has various significant objectives. They are
as follows:
 To know about the raw materials of bearings.
 To manufacture a bearing.
 To understand the importance and requirement of bearing in any machine.
CE 1.3.3 My area of work
This was my first major project in engineering career. I was extra cautious and excited
about this project. Although, I was the part of this project for only 1 month, I explored as well
as learned various new things. We had a group of three people and our project manager
divided tasks amongst ourselves. My major area of work was documentation. I had to
document each and every activity and action of this project. I ensured that I fulfil my duty
properly. Moreover, I also assisted my project manager in his work.

CE 1.3.4 Project Group
Figure 1: Team Members Associated with the project
CE 1.3.5 My responsibilities throughout the project
I had various significant and important responsibilities in this project. My first
responsibility was to document the entire project. I was the part of this project for a very short
period of time as I was pursuing my bachelor’s degree. For this reason, I had to study the
entire project history and know about bearings properly. I documented all the processes of
bearing manufacture. I even made lists of raw materials that were required in the project
regularly. At the end of every working day, I reported to my project manager and gave him
the reports of regular routine. Moreover, I even arranged daily meetings with my other
project members and project manager for understanding the progress of our project. My next
responsibility in this project was to assist my project manager in his work. I noticed every
activity and tried to follow his instructions properly.

CE 1.4 Distinctive Activity
CE 1.4.1 Comprehending the Theory of the Project
Bearings are the most important parts of any machine as it helps the machine to move
and does its function. The basic of bearing is very simple. They permit smoother law of
friction movement between two particular surfaces. These movements can be either linear or
rotating. Two types of actions are possible in bearings; viz. sliding and rolling actions. The
bearings that are solely based on rolling actions are known as rolling elements; whereas the
bearings that are based on sliding actions are known as plain bearings.
For understanding the entire process of bearings, the raw materials are needed to be
known. The major components of bearings are made in SAE 52100. The most interesting
feature of this organization is that it is extremely inexpensive and is utilized for the purpose
of making roll and ball as bearings. This particular steel is also known as ball bearings steel.
This steel is spheroidized for the purpose of improving the merchantability. Each component
except retainers, once they are machined are heat trotted for attaining the hardness of 62+3
HRC. For treatment of heat, these components are quenched in oil from the range of 830cc to
840cc. The temperature for this is around 150 degree C to 200 degree C. at this time it
achieves the hardness and then all the components are grounded for giving final touch. When
the steel is fully heat treated, it comprises of high compressive strength, high resistance to
abrasion, harden ability, high fatigue strength, toughness, corrosion resistance power and
dimensional stability.
The raw materials of bearings are as follows:
i) Forged rings
ii) Hot rolled bars

iii) Bright bars and steel wires
iv) Cold formed rings.
Following are the constituents required in bearing manufacturing with their weight.
Constituents Weight
1. Carbon 0.98 to 1.11%
2. Chromium 1.3 to 1.6%
3. Silicon 0.25 to 0.35% Maximum
4. Manganese 0.25 to 0.45%
5. Molybdenum 0.1% Maximum
6. Sulphur 0.025% Maximum
7. Copper 0.2% Maximum
8. Nickel 0.25% Maximum
9. Phosphorus 0.25% Maximum
Table 1: Constituents with Weights
CE 1.4.2 Engineering knowledge and skills applied in the project
I had utilized my mechanical engineering skills and knowledge in this particular
project for making it successful. I had applied my problem solving and critical thinking
power in this project for solving difficult situations and problems. In the beginning, I had
problems in understanding the scope of the project. However, soon I was able to understand
the entire scope and theory of the project with my intellect and professional ideas. I had also
applied my computer proficiency in documenting the entire project.
CE 1.4.3 Identified issues and their solutions
1.4.3.1 Issues

The project of Manufacturing of Bearings faced some of the most significant and
dangerous issues or problems. These problems or issues were becoming extremely dangerous
for the completion of the project. These issues were required to be solved as soon as possible.
The issues that are faced in the project are as follows:
i) The first major issue that we faced in this project was the lower quality of steel.
This was the most important raw material of bearing and due to the low quality of steel, the
bearing that was manufactured, was not meeting to the client’s satisfaction level. Moreover,
this was also incurring huge cost, as we had to change the steel repeatedly.
ii) The second issue that we faced in this particular project was availability of raw
materials due trade conflicts and high cost. As we were not getting the raw materials, we
were not being able to meet the client’s deadlines and thus our goodwill was getting affected.
1.4.3.2 Solutions
My project manager asked all of our team members to come up with ideas and
relevant solutions for the above mentioned problems. I was happy that I was able to provide
solutions for these problems. I provided relevant suggestions to my project manager and the
problems were solved. The solutions for the problems are as follows:
i) For the first issue, I suggested to utilize stainless steel and to test the steel as soon as
it is purchased. Once the steel was tested under various testing procedures, the best quality of
steel was selected finally. Thus, our problem was solved and I was appreciated by project
manager for my intellect.
ii) For the second issue, I contacted some of known dealers of raw materials and was
able to arrange the raw materials in time and with lower cost. These raw materials were of
good quality and thus we were able to meet the deadline and our goodwill was not affected.

CE 1.4.4 Plan to produce creative and innovative work
We made plan for producing innovative as well as creative work. We made sure that
every member of the project team performed well and fulfilled their responsibilities and
duties. Moreover, we attended training sessions for properly knowing and understanding the
project details.
CE 1.5 Project Review
CE 1.5.1 Project Overview
This project of Manufacturing of Bearings was the major help for understanding the
requirement and importance of bearings in any machine. These are the most important parts
of all machines and help to produce rolling motion. Various raw materials are required for
this and steel is one of them. The other constituents of bearing have certain weight range and
can be manufactured in a fixed temperature limit. The process of manufacturing a bearing
does not require huge time and cost.
CE 1.5.2 My contribution to work
My main contribution to this project was the documentation part. I made the project
report perfectly and made sure that greater importance is given to the quality of the products.
Moreover, I also ensured that all the employees are working in a safe environment and does
not have much risk to their physical health. I also gave relevant suggestions to the two
problems that were faced in the project.