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NSK Case Study

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Application

Cold Rolling Mill:
Steel Strip

Cost Savings: $28,288

A major steel producer was dissatisfied with the performance of their Four-Row Tapered Roller Bearings installed in their cold rolling mill. Steel shavings from the production process were entering the bearings resulting in a detrimental effect on bearing reliability. NSK performed a detailed on-site analysis of the bearings along with inspecting a failed bearing and lubrication analysis. After thorough review, a recommendation was made to adopt NSK Tough Steel technology which offers an excellent resistance to damage caused by the ingress of contamination.

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Cold Rolling of Steel

Key Facts

arrow-right-red Cold rolling mill
arrow-right-red Damage of the bearings due to ingress of steel shavings from the production process
arrow-right-red NSK solution: Bearings of Water Tough (WTF) steel
arrow-right-red More than 3X longer bearing life – reducing bearing consumption, downtime and maintenance costs

Value Proposals

arrow-right-red Analysis of the bearings, grease, structure and roll design
arrow-right-red NSK WTF steel bearings – designed for extreme operating conditions including solid and liquid contamination – were recommended
arrow-right-red Technical support including on-site engineering consultancy and lab-based bearing analysis

Product Features

arrow-right-red Advanced WTF (Water-Tough) material composition containing appropriate levels of chrome and molybdenum for increased hardness
arrow-right-red Innovative and patented heat treatment technology to optimize retained austenite and formation of finer carbide and carbonitride particles
arrow-right-red Significantly outperforms standard bearing steel in seizure resistance, rate of wear and service life
arrow-right-red Available for four-row cylindrical and four-row taper roller bearings
arrow-right-red Bearing life is 3 times longer than that of conventional bearing
arrow-right-red Grain boundaries have been strengthened to help prevent the propagation of cracks
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Four-Row WTF
(Water Tough)
Tapered Roller Bearing

Cost-Savings Breakdown

  Before Cost NSK Solution Cost  
  Cost_Saving_Downtime Bearing life of the previous bearings: 4 months, Lost production: $1,071/hr downtime X number of replacements X 4 unexpected downtimes per year $47,147 Bearing life of the new bearings: 12 months Lost production: $1,071/hr downtime X number of replacements X 1 unexpected downtime per year $18,859  
  Total Costs $47,147 Total Costs $18,859  
Before Cost
Cost_Saving_Downtime Bearing life of the previous bearings: 4 months, Lost production: $1,071/hr downtime X number of replacements X 4 unexpected downtimes per year $47,147
Total Costs $47,147
NSK Solution Cost
Cost_Saving_Downtime Bearing life of the new bearings: 12 months Lost production: $1,071/hr downtime X number of replacements X 1 unexpected downtime per year
 
$18,859
Total Costs $18,859

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.

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