Alan Buchanan Chief Engineer - rail The Timken Company

Transcription

1 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads Alan Buchanan Chief Engineer - rail The Timken Company Bearing Shop Basics 12:30 1:00 PM Day 2 27th Annual 2015 Quality Auditors and Industry Conference TTCI/AAR, 1/10/2012. filename, p1

2 Scope of presentation Incoming Inspection Training In Process Inspection Inspection and testing Identification and Traceability Preservation and Packaging Quality records AAR rules for bearing reconditioning & remanufacture Manual H-II Defines re-conditioning Defines re-manufacture Defines interchange parts C TTCI/AAR, 1/11/2012, Filename p2

3 AP-2 type bearing nomenclature C TTCI/AAR, 1/11/2012, Filename p3

4 C TTCI/AAR, 1/11/2012, Filename p4

5 Roller Bearing Manual - Section H Bearings in spec. M-934 Seals in spec. M Lists all applicable manufacturing requirements for: Grease in spec. M-942 List of approved roller bearing grease & seal combinations in spec. M-942 Appendix E C Spacers (M-934A) Seal Wear Rings (M- 934B) End Caps (M-934C) Backing Rings (M-934D) Cap Screws (S-702) Locking Plate (S-701) TTCI/AAR, 1/11/2012, Filename p5

6 Typical product receipt C TTCI/AAR, 1/11/2012, Filename p6

7 Typical high volume bearing washer C TTCI/AAR, 1/11/2012, Filename p7

8 Typical inspection line with electronic data collection C TTCI/AAR, 1/11/2012, Filename p8

9 Training and standard work It is critical to quality to ensure each and every worker has been trained and tested in proficiency Works instructions should be available for every operation. As accurate measurement is essential there should be calibration schedules for gauging, and traceability to calibration and national standards. C TTCI/AAR, 1/11/2012, Filename p9

10 Cup Initial visual inspect Gross defect Verify brand is present Outside diameter measured Counterbore diameter & roundness measured Visual inspection of raceway Stain or heat discoloration Cracks or broken areas Spalls repair, polish & mark AAR Spec None bigger than 3/8 x 3/8 x 1/8 Max of 6 on either raceway Max of 2 in 2 circumferential section Min bridge between 2 is 3/16 Brinells width, length & number Mating cones always removed from process Water etching, corrosion & rust Electrical fluting, pitting or burns Smearing, peeling, nicks, indentations Scribe inspection date & shop code Apply appropriate labels Enter inspection results into data collection Nonconforming that can t be repaired Scrap or Sent to OEM to be remanufactured reground Inspection & Repair Timken Confidential TTCI/AAR, 1/11/2012, Filename p10

11 Cone Back face wear inspection Inspect for cleanliness Inspect for Brenco recall Actual depth inspected at 3 points AAR spec up to.005 Scrap & salvage rollers Remanufacture Regrind face - up to.010 Laser mark cone repair history Assembly Inspection Inner raceway inspection Visual inspect on backlit fixture Corrosion, rust, pitting Spalls - unrepaired Water Etching Brinell or flat spots Electrical arcing Fracture Secondary inspect with feeler probe Hidden spalls Nonconforming cones Scrapped if unable to be repaired Sent to OEM remanufacturing Timken Confidential TTCI/AAR, 1/11/2012, Filename p11

12 Cone Assembly Inspection Roller inspection Complete circumference (360 )of each rotating roller Visual inspection utilizing magnified inspection light Etching, corrosion, pitting & rust Fatigue Cracks, Fracture Fatigue spalling or Flaking Smearing, peeling Electrical burns, fluting Brinelling, flat spots, indentations Stain or heat discoloration Scoring, nicks, threading Nonconforming roller(s) Sent to OEM reman Timken Confidential TTCI/AAR, 1/11/2012, Filename p12

13 Cone Assembly Inspection Bore (ID) measurement Measure bores using digital two point gauge or gauge plate Thermal compensation Indicator lighting defines conformance Red oversize, out of round Yellow AAR service limit Green - OEM Oversize sent to chrome Spacer Inspection Visual inspect for nicks, cracks Go/NoGo gauge for acceptable face width & length Check to surface finish standard Parallelism < or =.0010 Spacers are sized and placed on racks Data collection Cup & cone data tied to each order Cone data Class, date manufactured, type of defect, number of times reconditioned Timken Confidential TTCI/AAR, 1/11/2012, Filename p13

14 Lateral setting is key to bearing performance Powered lateral process Pressure applied on each cone ensuring rollers are seated Bench End Play set based on spacer length Production lateral master to calibrate machine Bearing loaded into machine Data loaded - cup serial #, month & year Lateral measured with base spacer Conforming lateral Spacer size and lateral value data entered Verification of cup serial # with second entry Print, apply and scan bar code label Release assembly Nonconforming lateral Repeat lateral measurement Fault in this process requires key to unlock Supervisor or QC intervention TTCI/AAR, 1/11/2012, Filename p14

15 Grease & Seal Installation are safety critical Machine/data acquisition integrated w/lateral Lateral bar code scanned Error proofing conforming lateral verified Input scale tares incoming components Error proofing detects incorrect cone Measures and logs ungreased bearing weight Grease & seal installation Grease seal insert flip-grease seal insert Grease fill tolerance +/- 1 ounce Seal insertion & ability to rotate the seal is checked 100% Grease fill fixtures must be designed to ensure grease distribution per AAR service limit charts Seal clearance charted SWR orientation verified 100% Backing ring is applied using press Output scale tares greased -sealed assembly Error proofing PLC computer locks machine if grease weight nonconforming Exit gate won t open if grease weight nonconforming Fault in this process requires key to unlock Supervisor or QC intervention TTCI/AAR, 1/11/2012, Filename p15

16 Remanufacturing vs. Reconditioning AAR approved scope of work matrix: Reconditioner Independent Remanufacturer Authorized Representative OE Bearing Manufacturer Cone bore stress relief Cone bore chrome plating X X X X X X Cone face turning X X X Cone de-caging X X Cone race repair X X Cone Race/rib regrind Cup regrind X X TTCI/AAR, 1/11/2012, Filename p16

17 Cone Remanufacturing Roller Buffing and Polishing Remove stains and other visual discoloration Roller Visual Inspection 360 degrees, nonconforming rollers marked De-caging Visual of cone race for gross defect Roller sets kept together by class Nonconforming rollers removed (4 or less) Roller gauging Required to replace nonconforming rollers Master made to class XXX tolerance Gauge indicator resolution to Same gauging used at roller producing plant Must use consistent roller end marking TTCI/AAR, 1/11/2012, Filename p17

18 Cone Remanufacturing Race repair Visual inspect of naked race Spall repairs per AAR spec Majority of nonconforming >6 spalls/race Notches added indicate repaired spall locations Nonconforming sent to race regrind, face grind, or scrap Conforming sent to chrome for bore gauging Face wear grind AAR allowed once per cone Grinder up to removal Within on parallel Surface finish held to <125 RMS History of cone repair must be maintained Laser marker used to add shop code & history Cone assembly Complete roller sets loaded by class only OEM can do this Cage close-in press used for assembly Error-proofing - missing roller detector 100% cage clearance measurement on steel cages TTCI/AAR, 1/11/2012, Filename p18

19 Cone Reclamation Stress relief of cone bore 100% of cones to be chromed Parts normalized 24 hours Buffed and prepped to be gauged Bores are gauged Conforming parts sent to cone assembly Nonconforming sizes are sorted through gauge gate system Nonconforming out of round/taper is scrapped Sorted parts are staged/grouped by size Chrome Plating Electrochemical hard chrome process Cycle time varies by plating depth and AMPs Buffed & polished Post plating stress relief Bore gauged to verify final conforming size TTCI/AAR, 1/11/2012, Filename p19

20 Cup/Cone Regrind REMANUFACTURE Cup Regrind AAR allowed once per cup OD Track grind ID cup grind one race per pass 100% gauged for ID size & taper, OD and Counterbores Raceway visually inspected & repaired Shop code, date & operator mark applied Cone Regrind Rib grind Ribs 100% checked for race relief & size Cone OD grind Checked 100% for size & taper Raceways are visually inspected & repaired R circled to indicate conforming Remanufacturing TTCI/AAR, 1/11/2012, Filename p20

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22 CEPM ensures full traceability of bearing assemblies TTCI/AAR, 1/11/2012, Filename p22

23 27th Annual 2015 Quality Auditors and Industry Conference Thank you for your attention.. TTCI/AAR, 1/11/2012, Filename p23