IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation ........ Email:editoriijme@ipasj.org
Volume 5, Issue 1, January 2017 ISSN 2321-6441

Review on prospect of rolling element bearings

failures, comparison of bearing life and its
estimation using on-line condition monitoring
techniques
Sheetal Gajjalwar1 , Surendra Pal Singh Matharu2
1
Research Scholar, Department of Mechanical Engineering, National Institute of Technology, Raipur (C.G.), India 492001;
2
Professor, Department of Mechanical Engineering, National Institute of Technology, Raipur (C.G.), India 492001;

ABSTRACT
The present work focuses on the condition monitoring techniques/methods used for the rolling element bearings to predict the
fault and its propagation sothat early bearing failure can be monitored. Because if the propagating failure is not monitored
then it can lead to the ruinous failure to the entire system, which can further lead to costs of unplanned repair and loss of
production. Several methods such as acoustic emission, vibration analysis, optical interferometry etc. have been compared and
relative analysis is done.

Keywords: Rolling Element Bearings, prospect, lubricant film thickness, EHD, online condition monitoring
techniques, remaining useful life.

1. INTRODUCTION
A rolling element bearing is a machine part whose function is to support a moving (rolling) element and to guide its
motion, while preventing motion in the direction of applied load. Rolling element bearings being one of the most
essential component of rotating machinery of any industry. And a machines performance could be seriously hampered
if during operation defects occurs in bearings. Hence early detection of the defects, therefore, is crucial for the
prevention of damage and a total failure of the associated large system. Over the last decades, condition based
maintenance by different methods and techniques have been used for detection and diagnosis of bearing failures and
estimating the remaining useful life of the bearings. Since the ball or roller surfaces is separated from the raceways of
the bearing by elastohydrodynamic (EHD) film thickness directly affects the bearing life and its estimation can help
predicting the useful remaining bearing life. Most often a frequent classic question is being asked by the maintenance
managers that when the bearing is going to fail, to the condition monitoring technicians. And this is one of the most
difficult question addressed in condition monitoring. And to gain the higher level of confidence needed, one has to use
more sophisticated diagnostic and signal processing techniques and being relatively expensive to apply, are normally
only used where the risk justifies it.

2. DEFINITION OF BEARING PROSPECT

In the present work, various condition monitoring methods/techniques used in the past for the measurements of
lubricant film thickness have been described and discussed, based on the authors tests and experiences. Since
measurement of lubricant film thickness, when reproducible and accurate, provide a very valuable insight into the
lubrication, which is necessary to test the validity of lubrication theories [1]. Bearing diagnostics and prediction refers
to the ability to acquire knowledge about events before they actually occurs, means, predicting remaining useful lifetime
of a bearing once an impending failure condition is detected, isolated, and identified. In order to illustrate the
surrounding fault propagation and failure prediction [2], examine the fig. no. 01 below, which shows how a fault might
propagate.

Volume 5, Issue 1, January 2017 Page 5

 IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm
A Publisher for Research Motivation ........ Email:editoriijme@ipasj.org
Volume 5, Issue 1, January 2017 ISSN 2321-6441

Fig. No. 01. Fault Propagation.

In context of engineering field, fault diagnosis has been approached via a variety of techniques which ranges from
Bayesian estimation and other probalistic/statistical methods to artificial intelligence tools and methodologies based on
notions from the computational intelligence arena.
Fig. no. 02 below, summarizes the range of possible diagnosis approaches as a function of the applicability to various
systems and their relative implementation cost.

Fig. No. 02 Fault trend and failure prediction.

3. SOME OF THE CONVENTIONAL DIAGNOSIS AND PREDICTION METHODS /

TECHNIQUES ARE AS FOLLOWS:

3.1 Model based diagnosis techniques

Model based diagnosis technique: In this approach, a mathematical model is often used to represent the systems
behavior. Several authors have proposed the concepts using a fatigue life model for rolling element bearings. The main
advantage associated with this type of technique is that it leads to a more accurate results. But on comparing the real
life situations, which are usually nonlinear and degradation mechanisms, and are difficult to be formulated into
analytical models, this makes the applicability of this technique limited in practice.
3.2 Probability/Experience based diagnosis techniques
The main text for your paragraphs should be 10pt font. All body paragraphs (except the beginning of a section/sub-
section) should have the first line indented about 3.6 mm (0.14").
3.3 Data driven prediction techniques
Data driven techniques: In this approach, online data is collected with the help of sensors and are converted into the
relevant information. Which is further used to study the degradation phenomenon based on different models and tools,
and the corresponding useful remaining life is predicted. Owing to the experience feedback data collection, this
approach comparatively leads to better results than other approaches.

Some of the condition monitoring techniques have been compared on the basis of pros and cons, in table no. 01 below:

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 IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm
A Publisher for Research Motivation ........ Email:editoriijme@ipasj.org
Volume 5, Issue 1, January 2017 ISSN 2321-6441

Table 1: condition monitoring techniques

4. SOME OF THE RESEARCH PAPERS PERTAINING TO THESE TECHNIQUES HAVE

BEEN DISCUSSED BELOW
Jie Zhang et. al. (2006) [3] described a lubricant-lm monitoring system for a conventional deep groove ball bearing
(type 6016, shaft diameter 80 mm, ball diameter 12.7 mm) is described. A high-frequency (50 MHz) ultrasonic
transducer is mounted on the static outer raceway of the bearing. The transducer is focused on the ball-raceway
interface and used to measure the reection coefcient of the lubricant in the contact ellipse between bearing
components. The reection coefcient characterizes the lubricant lm and can be used to calculate its thickness. An
accurate triggering system enables multiple reection measurements to be made as each lubricated contact moves past
the measurement location. Experiments are described in which bearings were deliberately caused to fail by the addition
of acetone, water, and sand to the lubricant. The ultrasonic reection coefcient was monitored as a function of time as
the failure occurred. Also monitored were the more standard parameters, temperature and vibration. The results
indicate that the ultrasonic measurements are able to detect the failures before seizure. It is also observed that, when
used in parallel, these monitoring techniques offer the potential to diagnose the failure mechanism and hence improve
predictions of remaining life.
Glovnea R, & Nagata. Y. et al [4] have presented a review paper describing the evaluation of lubricant film thickness
using the electrical methods. The methods are based on the measurement of electrical resistance and/or capacitance,
and are used to determine lubricant film thickness. Further the advantages and disadvantages of the electrical methods
have been discussed in the paper.
Dongchu Zhao [5] estimated the lubricant film thickness and condition monitoring was done employing the strain
gauges along with a micro-computer. The strain gauges were mounted on the inner side of outer race and the outer side
of inner race, and pressure change in the lubricant was recorded. The author developed an analytical formula to
estimate the lubricant film thickness. The strain gauges were connected and linked to a microcomputer thereby a
continuous recording of the lubricant parameter were done. Hence the online condition monitoring was performed.
Miettinen J. et al [6] used the acoustic emission technique for the bearing 6206, and has taken grease as the lubricant.
The author has performed experiment on the bearing considering the lubricant properties such as base oil viscosity,
thickner concentration etc and its influence on the acoustic emission signals. The author further described that the
starvation of lubrication increases with the increasing lubricant thickener content and decreases with lower base oil
viscosity. Results obtained with the grease lubrication were verified with pure oil lubrication. The analysis of grease
lubrication in his work was based on the relative differences in the pulse count rate of the acoustic emission generated
by the running of the bearing. The AE pulse count rate indicated the degree of starvation of the lubrication situation.
Kazuyuki Yagi et al [7] The author described in his paper an experimental study on dimple formation under
elastohydrodynamic lubrication (EHL) conditions. The author used white light optical Interferometry for the estimation
of lubricant film thickness within the contact area. The author estimated a circular EHD contact by applying a constant
normal load between a 10 mm thick glass (BK7) disk and a 25.4 mm diameter bearing steel ball. And Infrared
emission technique was deployed to measure the temperatures of both the surfaces and that of oil (lubricant) film. And

Volume 5, Issue 1, January 2017 Page 7

 IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm
A Publisher for Research Motivation ........ Email:editoriijme@ipasj.org
Volume 5, Issue 1, January 2017 ISSN 2321-6441

it was found that the temperature profile across the oil film varies abruptly along the sliding direction. The lubricant
film thickness distribution varies with the slide to roll ratio. And the dimple formation was also sensitive to the slide to
roll ratio. The film thickness increases in the central area under moderate slide to roll ratios. Thus in his work, the
author estimated the lubricant film thickness by white light optical interferometry at various slide to roll ratios. From
pure rolling to an absolute value of the slide to roll ratio of 135% the film thicknes increases. Beyond 135% the thicker
feature moves from the central part of the contact towards the inlet zone while at the exit zone a thinner area expands.

5. CONCLUSION AND DISCUSSION

By using Condition monitoring techniques involves both equipment condition and bearing lubrication film thickness,
secondary damage and excessive operating costs can be avoided. Being able to measure the lubricant film thickness
including bearing conditions is predominant. Better assessment of the machine as a whole can be done by estimating
the lubricant film thickness while the machine is running. And this will enhance the bearing life as well as the total
machine life.
Measurements of lubricant film thickness have been performed by various methods over the last decades, but however,
the question of what really are good methods is still unanswered. Therefore, most methods are analyzed in this paper.
The most important point is that the measurements can be easily disturbed when they are not performed very carefully.
Proper interpretation of the results is often difficult, because of lack of information about important details &
assumptions.
An alternative method [9] and apparatus [8] was developed by Matharu et al. The method [9] was based on
determination of electrical resistance between the inner and outer races of the rolling element bearing by a simple
electrical circuit along with inexpensive instruments. An analytical formula derived was used, which involves multiple
parameters such as resistivity of lubricant, bearing parameters, resistance between ball and races. The method was used
for online condition monitoring of rolling element bearings. Lubricant film thickness determined by this method is
indicative in nature and does not represent actual film thickness. This method being simple and inexpensive needs
further investigation for its practical utility.

References
[1]. A. Cameron, ,1981, Basic Lubrication Theory, third edition, Wiley Eastern Ltd.
[2]. G. Vachtsevanos et al, 2006, Intelligent fault diagnosis and prognosis for engineering systems, John Wiley &
Sons, Inc. ISBN: 978-0-471-72999-0.
[3]. Jie Zhang et al, Feb. 2006, Acoustic measurement of lubricant film thickness distribution in ball bearings,
Acoustical Society of America, Vol 119, no. 02, page 863 871.
[4]. R. Glovnea & Y. Nagata, 2012, Electrical methods for the evaluation of lubrication in elastohydrodynamic
contacts., page 46 53, ISSN 1881 2198.
[5]. Zhao Dongchu, Jan 1990, Study of direct measuring of lubricant condition in Rolling Element Bearings with
microcomputer technique.,ASME, Journal of Tribology,Vol. 112, page 92 -97.
[6]. J. Miettenin et al, 2000, Analysis of Grease lubrication of Rolling Bearings using acoustic emission
measurement., Journal of Engineering Tribology.
[7]. Yagi Kazuyuki et al, July 2005, Film thickness changes in EHD sliding contacts lubricated by a fatty alcohol,
Vol. 127, transactions of ASME.
[8]. S.P.S. Matharu et al, 2010, Development of a Multipurpose, efficient and inexpensive bearing test rig, JETR,
page 44 49, Academic Journals, ISSN 2006 9790.
[9]. S.P.S. Matharu, August 2011, Indicative lubricant film thickness for online condition monitoring of rolling
element bearings, Vol. 4, No. III, page 1 8, IJERIA, ISSN 0974 1518.

AUTHOR
Sheetal Gajjalwar received the B.E. degree in Mechanical Engineering from Govt. Engg.College,
Raipur (C.G.) India, in 2001 and M.Tech (Hons.) in Design of Process Machines from M.N.N.I.T.,
Allahabad (U.P.). India, in 2003. He is a lifetime member of ISTE. He is pursuing Ph. D. from N.I.T.,
Raipur (C.G.).

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