We import our Raw Material from the top manufacturers:
We import the steel in SAPP form & then do the wire drawing. All the Raw Material in checked with respect to its specification (Metallurgical, Chemical & Physical tests) & then used further. We plan for raw material in all range of diameters for the feasibility of any type of bearing rollers requirement. Raw material is key to final product so planning is very perfect and we are very good at it.
All our tooling is made in-house for forging as well as for any maintenance of our machines. We have CNC machine, VMC machine, Bore grinding, OD grinding & surface grinding machines for making good quality tools and dies. By this we can control the exact requirements of tools required for respective rollers.
We do wire drawing in-house for all the wires. This helps us in getting better control & defect free wire for our heading machine. We use carbide dies & we have a range of dies for different rollers & its wire size requirement. The wire drawing machines are from RMG – USA.
Cold forging process (called 'heading') is used to produce a near net shape so the scarp is also controlled. Ranging from 5mm to 22mm diameter can be forged on different machines. We have National –USA & Hatebur – Switzerland machines installed.
Rollers are the most critical component of a Bearing. The performance of the bearing highly depends on the rollers, its physical & metallurgical aspects are very critical. For all this we have 140 metric ton capacity per month in our Heat treatment plant which is equipped with continuous atmosphere control & SCADA monitoring. We have a good metallurgical & heat treatment team who insure routine activity & product analysis by making samples & doing microscopic examinations of each lot. We have cutting, polishing & moulding machines for making instant & perfect sample preparation for examination under Microscope.
There are several grinding procedures through which a roller passes. Various grinding processes are carried out on different grinding machines – Like Centerless grinding machine , Duplex grinding machine because it is the grinding process which transforms the mere input material into a precision roller. We have installed the world's best machinery like Cincinnati, WMW, Scarlo, BRD-TOS, SIM, Wickman , NSK-Seibu. Coolant filtration plays a major role in grinding efficiency. Vacuum filtration plant is installed to get the best output.
Super finish is final process which is carried out as per the customer's requirement of profile, roughness, Rt, Rz, cylindricty & roundness. Supfina & NSK machines are installed to get the best results. Various types of profiles can be achieved – Log Profile, ZB profile, End relieved profile, straight profile etc. All parameters are checked on high precision measuring instruments & calibrators.
What we do, we do well at Macwell. Checks for different types for rollers from grinding and super finish are done in-process as well as random checks are done. Checks like Profile, Roughness, Rt, Rz, Cylindricitry, Roundness etc. Lab is equipped with high precision instruments like Talysurf 50, TalyRond130, Taylor Hobson i120, Mahr MMQ200, Mahr CD120 etc. Metallurgical lab consists of Olympus Microscope, Hardness tester, Millipore check instruments, MPI for crack detection.
100% Visual inspection is carried to give zero defect quality. Visual team is trained & deployed for this process. Regular cross checks & verification of each team member is carried out to ensure the process capability.
As per the customer requirements of grade for Diameter and length we can do grading for all rollers. Grading machines are installed for the same. Grading in 1 micron for Diameter & 4 micron for length can also be achieved.
Washing, Cleaning & Oiling is done on a automatic machine. This helps to achieve the cleanliness level in Millipore check. MTO cleaning, drying & rust preventive oil is sprayed on rollers filled in Stainless Steel bins in a automatic continuous conveyer machine. Great care is taken while packing and dispatching of material to ensure perfect delivery. For large size rollers packing is done in individual isolated sponge type packing.