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Introduction

A Steel Mill customer was experiencing regular failures on bearings in their Pilger Mill. NSK investigated the application and found that severe operating conditions including high loads and inadequate lubrication were causing the failures. NSK proposed a special Spherical Roller Bearing with optimized internal design and Super Tough (STF) steel. A trial showed that the new bearings offerec a 20-30% longer life and a consequential reduction in maintenance costs.

Key Facts

  • Pilger Mill application
  • Bearings failure due to heavy and severe operating conditions
  • NSK solution: Special Spherical Roller Bearings made in STF steel
  • Bearings reached 2 times longer life than old bearings
  • Reduced maintenance and plant stoppage
  • Cost saving generated
  • Seamless Stainless Steel Pipe and Tubes
  • Bearings TF Series

Value Proposals

  • NSK application analysis
  • Proposal of Super TF steel
  • Bearings reached 200% longer life compared to old bearings
  • Reduced maintenance time
  • No unexpected bearing failures or unplanned downtime

Product Features

  • Innovative heat treatment technology
  • Outperforming standard bearing steel
  • Up to 10 times service life with contaminated lubrication
  • Up to twice the service life under clean lubrication
  • Up to 4 times the service life at 160°C/320°F
  • Less than one-third the rate of wear
  • 40% improvement in seizure resistance

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
Bearing replacement costs $23,357 Bearing replacement costs $9,433
Lost production:
2 hours x $2,412/hr x 52/year
$250,848 Lost production:
2 hours x $2,412/hr x 21/year
$101,304
Labour costs:
$33/hr x 2 hrs x 2 People x 52/year
$6,864 Labour costs:
$33/hr x 2 hrs x 2 People x 21/year
$2,772
Other material replacement $4,288 Other material replacement $429
Total Costs $285,357 $113,938

Reference:SS-E-4002

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