NSK Case Study


Cold Form Saw
for Steel Tube

Cost Savings: $77,184

A global steel manufacturer was having problems with a cold form saw used to cut steel tube. The saw utilized a ball screw moving axially and was supported by a simple thrust ball bearing. This support bearing was failing every 6 weeks. Failures caused unplanned maintenance and downtime. NSK analysis of the saw design showed the ball screw arrangement was subjected to high axial impact loads and the original design was not robust enough to withstand these loads. An on-site bearing inspection was conducted and key dimensions measured. This allowed NSK to propose the WBK Ball Screw support unit which offers a much higher thrust load capacity.

Key Facts

arrow-right-red The bearing arrangement was supporting thrust loads as the cutting saw is applied to the steel tube
arrow-right-red High impact thrust loads were causing early failure of the original bearing arrangements
arrow-right-red Failure was catastrophic resulting in bearing collapse and seizure
arrow-right-red NSK engineers provided a full machine design upgrade including CAD drawings of the required housings
arrow-right-red NSK’s recommended bearing arrangement supported significantly higher thrust loads
arrow-right-red Bearing life was extended from just over 1 month to beyond 12 months

Value Proposals

arrow-right-red NSK engineers inspected the application and examined the operating conditions
arrow-right-red On-site failure analysis indicated that the existing bearing arrangement was not robust enough for the load of the application
arrow-right-red NSK proposed upgrading to an NSK ball screw support unit consisting of NSK super-precision ball screw support bearings, contained in a housing equipped with heavy duty lip seals
arrow-right-red NSK also provided a full machine design consultancy complete with CAD drawings showing the new bearing housing
arrow-right-red This combination of very high load capacity, ease of assembly and robust sealing resulted in no failures after 12 months of operation

Product Features

arrow-right-red High axial rigidity and load capacity
arrow-right-red Low friction torque
arrow-right-red Adjustable axial play
arrow-right-red Simple mounting arrangement
arrow-right-red Easy to handle bearing unit
arrow-right-red Several housing options
arrow-right-red Alternative bearing combinations
WBK Ball Screw
Support Bearing

Cost-Savings Breakdown

  Before Cost NSK Solution Cost  
  Cost_Saving_Downtime Downtime = 4 hours @ $2,144/hr x 9 breakdowns annually $77,184 No breakdowns in over 12 months $0  
  Total Costs $77,184 Total Costs $0  
Before Cost
Cost_Saving_Downtime Downtime = 4 hours @ $2,144/hr x 9 breakdowns annually $77,184
Total Costs $77,184
NSK Solution Cost
Cost_Saving_Downtime No breakdowns in over 12 months
Total Costs $0

Your Partner for Machine Optimization

Our AIP Added Value Program is based around a simple proposition: ‘improvement pays’. By working with you throughout the AIP Value Cycle, we will help you achieve improvements in machine reliability, productivity and performance, all of which carry a tangible and measurable cost benefit – and we have the tools to prove it! That’s what we mean by improvement pays.