Success Story
Industry: Steel & Metals
Application: Continuous Casting Machine
Cost Savings: € 140 000
Introduction
An international steel manufacturer experienced regular failures on bearings in a continuous casting machine. This machine is used in the production of shaped sections and due to that, the bearings have to handle heavy loads. The problem was a short bearing life of the standard bearings due to wear and fatigue. The average bearing life was 124 weeks and they had experienced 3 failures to date. After an investigation, NSK suggested to apply a durability test with NSK’s SWR Spherical Roller Bearings. These bearings are made of specially developed bearing steel, which has a much better wear resistance and resistance against fatigue. With the NSK solution, the customer could achieve a significant cost saving.
- SWR Roller Bearing and Housing
- SWR Spherical Roller Bearings
Key Facts
- Steel & Metals
- Continuous Casting Machine
- Short bearing life because of wear and fatigue
- Heavy operation conditions
- Longer bearing lifetime & reduced maintenance costs requested
- Special Spherical Roller Bearings (SWR Steel)
- Bearing reached 60% longer life time
Value Proposals
- NSK engineers conducted an Application Review including a Bearing Condition Report
- This resulted in SWR Spherical Roller Bearing recommendation.
- Recommemded test with SWR Spherical Roller Bearing
- Bearing reached 60% longer life time
Product Features
- Improved material strength of outer ring
- Ability to use with or without seals
- Improved wear resistance - three times compared to AISI 52100 bearing steel
- Minimized outer-ring friction to extend bearing life
- Improved flaking life property - five times compared to AISI 52100 bearing steel
- Material strength improved to prevent breakage of the outer ring after the occurrence of flaking - five times compared to AISI 52100 bearing steel
- SWR can replace standard SRB without modifying the axle boxes
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Costs of lost production: Production loss due to bearing failures | € 100.000 | Costs of lost production: No production loss | € 0 | |
| Engineering Costs: Manpower costs for replacing the bearings | € 40.000 | Engineering Costs: No manpower costs | € 0 | |
| Total Costs | € 140 000 | € 0 | ||
Reference:SS-E-1019
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