NSK Case Study
Application
Continuous Casting Machine:
Shaped Sections
Cost Savings: $150,086
An international steel manufacturer was experiencing regular failures on bearings in a continuous casting machine. The machine is used in the production of shaped sections and as a result the bearings have to accommodate extremely heavy loads. Wear and fatigue were resulting in premature bearing failure, with 3 failures to date. After an investigation of the application, NSK suggested a durability test with NSK’s SWR™ Spherical Roller Bearings. SWR bearings are made of specially developed bearing steel, which has much better wear resistance against fatigue.
PDF DownloadKey Facts
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Continuous Casting Machine |
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Wear and fatigue caused short bearing life |
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Heavy operation conditions |
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Longer bearing lifetime and reduced maintenance costs requested |
Value Proposals
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NSK engineers conducted an Application Review including a Bearing Condition Report |
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As a result, a trial utilizing Super Wear-Resistant (SWR) Spherical Roller Bearings was recommended |
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The SWR bearings achieved 60% longer life |
Product Features
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Optimized, high-capacity internal design |
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Outer rings manufactured with proprietary SWR steel composition and heat-treatment process |
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With wear-resistant surface treated pressed steel and heavy-duty machined brass cages |
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Superior wear resistance – 3 times that of conventional bearing steel |
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Improved flaking life property – 5 times that of conventional bearing steel |
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Higher toughness of material core (prevention of crack damage) – 5 times that of conventional bearing steel |
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Improved bearing durability extends segment roll operation, reducing maintenance costs and preventing unplanned downtime |
Roller Bearings
Cost-Savings Breakdown
| Before | Cost | NSK Solution | Cost | |||
|---|---|---|---|---|---|---|
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Loss of production due to bearing failures | $107,204 | No production loss | $0 | ||
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Maintenance | $42,882 | No maintenance | $0 | ||
| Total Costs | $150,086 | Total Costs | $0 | |||
| Before | Cost | |
|---|---|---|
|
Loss of production due to bearing failures | $107,204 |
|
Maintenance | $42,882 |
| Total Costs | $150,086 | |
| NSK Solution | Cost | |
|---|---|---|
|
No production loss |
$0 |
|
No maintenance | $0 |
| 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.
