Industrial Bearings Market in India

8/6/2019 Industrial Bearings Market in India

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Industrial Bearings Market inIndustrial Bearings Market inIndia :Issues and problemsIndia :Issues and problems

Ajay K Gupta

Managing Director

Kamtech Associates Pvt Ltd.

www.bearingsindustry.com


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Bearings of various types and sizesBearings of various types and sizes

are used for different sectorsare used for different sectorsThe major sectors are as follows:

Automobiles

Railways

Electrical Motors Electric Fans

Diesel Engines

Pumps

Machine Tools

Textile machinery and

Other heavy industries (Steel Plants , Sugar Plants, Process Plants, HeavyEngineering, Industries , Heavy Earth Moving Equipment , Cement Plants , Power

Generation Units


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Replacement MarketReplacement Market Replacement Demand is the after demand where as a part

of the maintenance of the machines or rotating machine ,the bearings are replaced by new bearings after it is failed

as natural life deterioration / wear or tear or due topremature failures and need replacement The replacementmarket represents the demand arising on account ofreplacing the used and worn-out bearings. The size ofreplacement market is dependent on equipment population

and frequency of maintenance. Replacement marketaccounts for 40% of total demand for bearing industry. Themargins in this market are relatively higher placed ascompared to OEM market.


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ContCont The replacement market is highly price sensitive and has

higher share of unorganized players and cheaper importedbearings. Exhibit4 represent the bearing demand per sector.

From the inception of the industry, bearing manufacturingin the country is dependent on foreign technology. Theorganised sector of the industry has imported know-how

from various internationally leading manufacturers ofbearings. The import of technology is generally restrictedto small and standard bearings. Technology borrowingspecifically for special bearings has not taken place so far.


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ImportsImports 30% of total demand for bearing industry is met by

imports. While a part of the imports come through officialchannels, there is also a huge volume of illegal imports.

Legal Imports generally represent the specialized bearingsnot manufactured in India. There are a large variants ofimported bearings, each holding a small market share inIndia.

Though, the quality of bearings manufactured by large players in India is comparable to world standards,domestic manufacture is not viable due to the small size ofthe market segment. It becomes uneconomical tomanufacture such type of bearings as it includes hugecapital expenditure.


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ContCont Illegal imports generally represent the entry of spurious

imports of bearings. In the past, the Indian bearingsindustry was highly protected on account of very high

import duties ranging from 150% to 240% ad- valorem. Asa result , illegal imports via smuggling and under invoicingof imports was the order of the day, accounting for a high45-50% of total imports. While duty rates have come downover the last few years, a few countries like China,Russia,

Eastern Europe dump their excess production at a very lowrate. This leads to a huge price differential betweendomestic and imported bearings (almost 40-50%),encouraging imports.


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Technological InterventionsTechnological Interventions The heavy dependence on borrowed technology indicates

that continuous efforts towards development have notyielded the desired results. Moreover, in spite of

collaborations the Indian industry generally has notachieved standards of quality close to international levels.Research and Development appears conspicuous more byits absence, in this industry.


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ContCont The industry undertakes routine development programmes

from time to time, in terms of additional bearing sizes orincreased production.

The various reasons that have been put forward forselection of a foreign collaborator are as follows :

The advantages associated with an internationally

renowned name.

Favourable terms and conditions of collaboration.

Quality of product. Assured access to latest developments at the

international level.


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COMPARISONOFTECHNICALCOMPARISONOFTECHNICAL

SPECIFICATIONSSPECIFICATIONS Since the product is standardized internationally, the

designs followed by the industry are more or less, thesame. Technical specifications are restricted to basic

parameters. Quality specifications adopted from thecollaborator's specifications, vary usually.

The bearing manufacturers have been adopting theequipment technology suitable for low volume production.

This was essentially due to the demand pattern of rolling bearings in the country being made up of a largediversified range of bearings in small quantities. In view ofthe very high cost of bearing equipment, most of the

bearing manufacturers did not venture to change theirequipment technology in favour of large batch production

or line production.


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THRUST AREASFORTHRUST AREASFOR

TECHNOLOGYTECHNOLOGYThe thrust areas for indigenous technology would include :

Development of indigenous machine tools and equipment fortesting, equivalent to international standards of precision.

The suitability of these machines in the Indian workingenvironment would be the critical factor.

Materials are available indigenously. However, the quality oftubes in particular, is not to the satisfaction of the industry.Moreover, consistency in supplies is also not experienced.

Cleanliness of material needs to be improved to a great extentto enable the industry to take basic advantage of quality rawmaterial. As regards forged rings, suppliers meeting sufficientquality standards need to be encouraged.


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ContCont Operational expertise of a very high calibre has to beachieved.

Maximum precision in the process, minimum handling

damages, and maximum cleanliness should be observed to

get the desired quality of bearings.


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HANDLINGHANDLING ANDSTORAGEOFANDSTORAGEOF

BEARINGSBEARINGS If possible, determine when a bearing was manufactured and if it was

properly stored before being purchased. Ask the bearing distributorabout his storage and handling procedures. It might be prudent to havea representative from your company personally visit the bearingdistributor to confirm how bearings are being stored. For example, atapered roller bearing should be stored with the taper down and neverstacked, one on top of another.

Store bearings in an attitude angle that will reduce or eliminate the possibility of damage to rolling elements and raceway. It may beweeks or months before the bearing is called into service. Reducing therisk of startup damage begins with proper storage.

Bearings are manufactured with extremely tight tolerances andtherefore require special care when moving or handling. Consider them

fragile at all times and make the effort to treat them as such. Consider the proximity of the storeroom to areas of the plant that are

affected by vibration. Could a railroad main line affect the storeroom?Does the plant have equipment that vibrates nearby buildings?Bearings subjected to even minor daily vibrations can becomedamaged while in storage. Take the necessary steps to insulate stored bearings from any vibrations.

Always store bearings in a clean and sterile environment. Keep themfree of moisture, dust, and chemicals.


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Bearing installation andBearing installation and

handlinghandling Take care when removing old or damaged bearings from their shafts

and housings. Be careful to not damage holders or surfaces where thenew bearings will be installed.

Clean all housings, shafts, holders, keyways, etc., before attemptingto install a new bearing. Inspect the shafts and equipment for damage.Install new bearings in as clean and dry an environment as possible. Ifpossible, use sterile gloves to prevent contamination. Contamination atthis stage will ensure a shorter bearing life cycle.

Carefully inspect the new bearing for any obvious damage that mayhave occurred during shipping, storage, or manufacture. Inspectbearings to determine if all parts are present. Bearings have beenknown to ship from the factory missing roller elements and other parts.Also, check for factory lubricant. Lack of lubricant from the factory

can cause rust.


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Storage of BearingsStorage of Bearings a. Avoid storing bearings in

places with high humidity.

b. Store bearings in a coolplace.

c. If bearings come packed

in a wooden box, take themout of the wooden boximmediately, and store themon a shelf.

d. Do not take bearings outof the cardboard boxes or

protective wrappings. e. Do not stack bearings

because the protective anti-rust compound may besqueezed out of bottom

bearings.


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Temperatures Effects onTemperatures Effects on

Mounted BearingsMounted Bearings I cant lay my hand on the bearing because it's operating too hot!" While this is a commonly heard

complaint, most sleeve and rolling element bearings can operate successfully at temperatures well

above the pain threshold of a human hand. The stabilized operating temperature of a bearing is the

result of many factors. The key influences on operational temperature are bearing style, lubrication

type, operational factors, environmental conditions and level of maintenance

The particular bearing style (ball, roller, sleeve, etc.), the shaft mounting style (slip fit, adapter

mounted, press fit, etc.) and auxiliary items (housings, seals, shields, flingers, etc.) all contribute to a

final operating temperature. For a given set of application conditions, a particular bearing type will

generate friction given off as heat. A typical bearing temperature rise range would be 40 to 80F (4

to 27C) for most industrial applications. However, a bearing temperature rise over ambient of up to

a 120F (49C) can be observed at extreme conditions


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MOISTUREMOISTURE

Moisture is generally referred to as a chemical contaminantwhen suspended in lubricating oils. Its destructive effectsin bearing applications can reach or exceed that of particle

contamination, depending on various conditions. Likeparticles, vigilant control must be exercised over entry ofwater to minimize its accumulation in the lubricants and itsdamage to bearing surfaces

Once water enters the casing of a machine where bearingsare used, such as an engine, turbine, or gear box, it maymove through several chemical and physical states. Thesechanges are complex, but important to understanding howto control and analyze its movements. To begin with, waterwill enter an oil in generally one of the five following ways


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PRE LOADPRE LOAD Preload is the force that is applied to a

bearing assembly during installation to

remove the axial play and to furthercompress the bearing to provide both axialand radial stiffness. It is an important designparameter, affecting rotational performance

and lifetime of a bearing assembly. Afterpreload, the resulting ball contact angle must be considered


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Minimum LoadsMinimum Loads

Rolling element bearings require minimum loads to function

satisfactorily. This is because the balls or rollers must rotate

when carrying the load.

Skidding will occur if the load is not sufficient to overcome cage

friction and the resistance from the lubricant, especially during

periods of low temperature operation.

The consequent is damage to both raceways and rolling

elements. Usually the load from the shaft assembly is sufficient

to prevent this from happening. In cases where the load is not

sufficient, the bearings can be pre-loaded by the use of springs.

In some instances reduced bearing internal clearance may help

but great caution should be taken to avoid a high pre-load

condition, which can result in catastrophic failure


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Minimizing Bearing DamageMinimizing Bearing Damage

Inclusion-A fatigue crack starts just below the

raceway surface at a nonmetallic inclusion (micro

impurity) and propagates to the surface.

Geometric Stress Concentration-Damage occurs in

a localized region of high stress at the raceway

edges due to high rolling loads and misalignment.

Point Surface Origin-Damage originates at a

localized, high-stress point on the raceway surface,

typically caused by insufficient lubricant film

thickness separating the bearing surfaces.


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Degrees of Life enhancementDegrees of Life enhancement

Various degrees of power density can be applied to

enhance bearing life and durability,

Typically an enhanced bearing will provide a minimum of

1.5 times the life of a standard bearing, although in more

severe operating conditions, performance gains of 4-5times are not uncommon.

To clearly identify the design and life enhancement

potential of power dense bearings, the designer should

make a detailed application analysis of the many bearing

design variables as well as operating and environmental

factors. Bearing manufacturers can apply advanced

software to accurately quantify these effects.


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Fully-enhanced bearings increase life by

minimizing the three primary modes of

fatigue damage through the

incorporation of cleaner steel, super-

finished rolling contact areas (rollers and

raceways) and optimized geometry.Super-clean, air melt steel provides an

additional 30 percent increase in life to

fully enhanced bearings.


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Selectively-enhanced bearings offer the flexibility

of selecting or applying only those

enhancements needed to economically optimize

performance in specific applications. Service life

can increase within the range shown in Figure

and depends both on the specific enhancements

chosen as well as the specific operatingconditions.

Such bearings fill the performance gap between

standard and fully enhanced bearings. Selectively

enhanced bearings are especially cost-effectivein large bearings (8 to 84" OD), where fully-

enhanced features may not be readily feasible.


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Bearing selectionBearing selection Procure the correct bearing for the application. Often, the

replacement bearing is not compatible with the equipment where itis to be installed. Depending upon the age of the equipment,advances in bearing technologies may exist that make the OEM

bearing obsolete. Knowing the limits of the equipment and what bearing best suits the application will save time and money.

Determine the maximum load for the bearing. This is importantboth vertically and horizontally.

Determine the minimum and maximum running speeds for thebearing. This will help determine the correct lubricant and bearingfor the application.

Determine all possible environmental conditions to which thebearing will be exposed. Very hot or cold environments oftenrequire varied bearing specifications. This may, in turn, change thetype of lubricant and relubrication requirements as well.


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Materials -- Improved micro-cleanness, alloys and processing

techniques .

Design -- Improved internal geometry, such as roller/race profiles, to

carry higher loads and handle misalignment within a given envelope

Tribology -- Optimized interaction of bearing surface topography withlubricants, lubricant additives and debris .

Manufacturing -- Advances in processing techniques for surface

finish, plus precision tolerances, improved profiles, material

cleanness and heat treatment.

Application Analysis -- Advanced performance-prediction tools that

consider the effects of bearing design features as well as significant

bearing environmental influences such as load zone, misalignment,

lubrication,

temperature,

housing rigidity,

load and speed


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Bearing repair: An alternative toBearing repair: An alternative to

replacementreplacement


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Bearing repair is not a new concept, nor has it changed a

great deal over the years and that's good news.

Repairing damaged bearings is a precise science that

has been fine-tuned over time through careful and

gradual enhancements to provide superior results.

Just as new designs and technologies improve bearings,growing expertise and technology of bearing repair

continues to increase the reliability and performance of

reconditioned bearings, keeping it an economical

alternative to purchasing new bearings

Knowing and understanding the value of bearing repair

means knowing what repair can do, when to use it, and

where to get it done.


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Bearing LifeBearing LifeBearing life refers to the amount of time any bearing will perform in a

specified operation before failure. Bearing life is commonly defined interms ofL-10 life, which is sometimes referred to as B-10. This is the life

which 90% of identical bearings subjected to identical usage applications

and environments will attain (or surpass) before bearing material fails

from fatigue. The bearings calculated L-10 life is primarily a function of

the load supported by (and/or applied to) the bearing and its operating

speed.

Many factors have a profound affect on the actual life of the bearing.

Some of these factors are:

Temperature

Lubrication

Improper care in mounting resulting in: Contamination

Misalignment

Deformation

As a result of these factors, an estimated 95% of all failures are classified

as premature bearing failures.


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The Butterfly EffectThe Butterfly Effect

An event as small asa butterfly flappingits wings in Texascould set off a chainreaction of eventsculminating in asnow storm inTibet.

extraordinary results

can stem from attention to

the smallest details.

Industrial Bearings Market in India

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