Minutes  of the IIT-Industry Meet  between NRB and IMG at IIT Bombay, November 20 , 1999

Partcipating Members

  • NRB
    Ms. H. S. Zaveri, Mr. N. S. Warrier, Mr. A. S. Kholi, Mr. P. K. Ray, Mr. B. C. Prashar, Mr. B. Venkatraman and Mr. V. C. John
  • IIT Bombay
    Prof. S. L. N. Murthy, Prof. M. C. Joshi, Prof. A. K. Pani, Prof. V. D. Sharma, Prof. R. K. Malik, Prof. Kannan Moudgalya, Prof. Jagdish Prakash, Prof. Sachin Patkar, Prof. A. Subramanyam, Prof. Ashok Srinivasan, Prof. Rekha Kulkarni, Prof. R. K. Pant, Prof. K. Narasimhan, Prof. Bharat  Seth, Prof. A. S. Deshpande, Prof. K. N. Gupta,  Prof. K. P. Karunakaran, Prof. V. G. Gurjar
  • Research Fellows
    Mr. Ashish Mishra , Mr. Ravi Shankar Gautam , Mr. Ramprasad M K , Mr. Vishwas S Jadhav , Mr. Shankar Dutt Bhatt
  • MS University Baroda
    Prof. D Vakaskar
        The Meeting started off with a welcome speech by the Dean of Resource Development, Prof. S. L. Narayanamurthy.  Prof. M. C. Joshi gave a brief summary of the activities of the Industrial Mathematics Group (IMG).  Ms. Zaveri talked about the Vision of NRB and how they intend to use R & D to help achieve this goal.

        Mr. Naresh Warrier began the technical talks on the role of noise in bearings.  A bearing that NRB had designed for Bajaj had some shortcomings.  They improved the design by introducing a logarithmic profile of the needle roller, by creating a wedge in the outerrace and by improving the cage design and manufacture.  Trials and error based on several years of experience in the bearings industry helped them achieve this new and satisfactory design.  He mentioned that some fundamental knowledege in bearing design will be most usefule to NRB.

        Mr. Prabir Ray gave a talk on Connecting Rod mechanism.  He said that that IIT could work on the topic of Force Balance of Crank Pin bearing in two and four stroke engines.  Detailed analysis of forces acting on each bearing could also be studied.

        Mr. A. S. Kholi talked about different ways of making a needle cage.  He talked about how if the heat treatment is not done properly, the geometry and the size could change.He mentioned that an optimal choice of parameters, such as, current, voltage, time and mandrel diameter would be important for good welding. He mentioned that IIT could work on building an online feedback controller that will help monitor the geometry during welding process on the sophisticated welding machine that NRB has.He also talked about phosphating vs. blackening and Zn vs. Mn. phosphating.These result in porous surface on the bearing which enables oil retention, so that there is no problems in cold start. Blackening will be the easiest process. If IIT can prove that it is sufficient from the cold start point of view, it will be most useful. Mr. Kholi also talked about corrosion during and after the manufacture of the bearings.He looked for a cyanide free plating process.   He also said that NRB will be interested in short term courses on the topics of failure analysis, Single Minute Exchange of Dyes, value Engg., stress analysis and corrosion.

        Subsequently , There was a detailed discussion of these points and the following points were accepted.  IMG will be the nodal agency for facilitating these projects from IIT side.  Eight  possible projects were identified.  The projects identified are:

  1. Optimising the manufacturing process with respect to plant layout
  2. Force balance
  3. Universal joints
  4. Vibration analysis
  5. Surface treatment
  6. Statistical analysis of welding parameters
  7. Production planning & Scheduling
  8. Consumer Perception of Product and Product Positioning and Selection of featutres
The IIT and Baroda group, after visiting NRB plants and after discussing the problem with appropriate staff at NRB, will produce a preliminary report by 22 December 1999.

Project Outcome

  1. Statistical Analysis of distortion of  shells due to heat treatment process
                           In this project, NRB shall be providing data on dimension of shells before heat treatment and dimension of shells after heat treatment. The main parameter involved are outside diameter at 3 different sections, ovality, thickness and concavity. Above data will be provided for 15 different sizes so that a mathematical algorithm can be worked out supported by necessary software. using this algorithm, evalution will be done for another 10 sizes. In case, algorithm does not give correct values, it will be corrected.
  2. Production planing and scheduling of  heat treatment operation
                           In thi project, NRB wants to arrive at a production plan and schedule for batch type furnaces with the objective to complete heat treatment on dates committed to costomers. The necessary input data for this will be dates on which various componentes will be ready for heat treatment, total quanty available for heat treatment, the minimum qualtity required to meet customer's requirment, the type of heat treatment process, constraints of upper basket, cycle time, heat treatment cycle. The output required is the production plan and schedule indication the dates on which material will be ready to ensure that delivery is done on committed dates. The mathematical algorithm design should also give 3 or 4 options.
  3. Bend Test of Needle Rollers
                            Needle Rollers ( material - SAE 52100, hardness - 60 to 64 HR'C') selected random are to be given a pre determined deflection on the Defection Test fixture. The facture of any rollers is cause of rejection. In this project NRB wants to estimate parameters (mechanical / matallurgical) of the product to pass the test with sacrifying the other properties such as fatigue streangth, hardness, dimensional stab

 
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