Raw material used in production is 100 Cr 6 (SAE 52100 chrome steel) with highly improved micro cleanliness and low inclusion content. This raw material comes in form of bars, tubes or forged and cold rolled rings. Bar stock is up to 60 mm diameter, forged or cold rolled rings up to 160 mm and either tube or forged rings for larger size. The first stage of production starts with Hot Forging and Cold Roll Forming operations.
Hot Forging
By induction heating to above 1000ºC, bars are fed to high speed, automatic, Hot Forging Presses with max. loads of 200, 380 and 900 tons. Depending on material diameter, 1 to 2 pieces/second are formed.Forged rings are then heat treated to achieve a homogenous microstructure necessary properties for further processing.
Cold Roll Forming
Forged and heat treated rings are then enlarged by Cold Roll Forming. This operation expands the ring homogeneously in all sections, and improves the mechanical properties of the material.
Turning
CNC turning centers and automated lines of single spindle machines are set for continuous work, at this initial stage.
Heat Treatment
Rings are then heat treated in specifically designed and controlled atmospheric furnaces, ensuring material oriented for a long service life.
Grinding
Dimensional and working accuracy of bearing rings is achieved by grinding and super-finishing of the face, outer diameter, bore diameter and raceways.
Tolerances are measured in microns.
Super finishing provides very high tolerances as it removes micro-roughness on the raceways.
Washing
All components are thoroughly cleaned in fully automatic ultrasonic units equipped with ultra-filtration.
Pressing
Cages and shields are produced from deep drawn steel strip in multiple-station, fully automatic presses. Roto-finishing removes all the burrs.
Assembly
Bearing components are assembled in fully automatic lines with 100% control of the required parameters. After matching of inner and outer rings, balls are inserted, cage is placed and riveted, bearing greased, and finally shields and seals are placed. The produced bearing is 100% tested, final inspection checks prior to the final stage are performed, and at last, conservation oil is applied.
Packing
The last step in production is packing according to customer requirements. Standard and special packing is available, providing the most convenient form for the customer.
Tool and die fabrication
ORS produces all types of tools and dies for production machinery, automation equipment under engineering guidance, and utilization of precise machines.
Testing
Special function tests are performed at ORS. These tests help develop new and improved products. Examples of this program are testing of high speed performance, load, life, wear ratings on seals, water and dirt penetration, aging of cages and seals in greases and oils, noise behavior in electric motors etc.
ORS maintains a silent room for precise noise measurement.
Cogeneration
ORS is a large energy consumer and must maintain high quality electrical supply for its precision machinery. ORS's cogeneration presently has two 3.6 MW and two 6 MW units.
Environment
ORS accepts its role in protecting the environment. Disposals through refining, ultra filtration, and biological application produces water used in agriculture. Chimney outlets are filtered and tested.
ORS plants and offices are located among some 5000 fruit trees, and other vegetation. Our most treasured award, are the migratory birds that visit us each spring.
