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Introduction

A Steel Mill customer was experiencing regular failures on bearings in their Pilger Mill. NSK investigated this and found that the main problems were severe operating conditions with high loads and inadequate lubrication. NSK proposed a special Spherical Roller Bearing with optimised internal design and Super Tough (STF) steel. A trial showed that the new bearings gave 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 technical analysis
  • NSK proposed bearings with Super TF steel
  • Bearings reached 200% longer life than old bearings
  • Reduced maintenance time
  • No unexpected bearing failure and no 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
  • 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 € 21.788 Bearing replacement costs € 8.799
Lost production:
2 hours x 2250€/hr x 52/year
€ 234.000 Lost production:
2 hours x 2250€/hr x 21/year
€ 94.500
Labour costs:
31€/hr x 2 hrs x 2 People x 52/year
€ 6.448 Labour costs:
31€/hr x 2 hrs x 2 People x 21/year
€ 2.604
Other material replacement € 4.000 Other material replacement € 400
Total Costs € 266.236 € 106.303

Reference:SS-E-4002

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