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Slide 1
UNEVEN RUNNING
Excessive Bearing Clearance Saw Mills: More Knocks and Blows in Connecting rods. REDUCED WORKING ACCURACY Wear due to contaminants or insufficient lubrication Damaged rings or rolling elements Change in adjustment (Clearance or Preload) FAG Bearings India Limited Lathe: Gradual development of chatter marks on work piece. Grinders :Waiviness of ground surfaces Cold rolling mills: Periodic surface defects on rolled material such as stretcher grains, ghost lines etc. Slide 2
Cause
Insufficient operating clearance
Application Examples
Changes in operating clearance caused by temperature . Damaged raceway [from Contamination / fatigue] Excessive Clearance. Damaged running surfaces. Contamination. Unsuitable lubricant.
Electric Motors, Gears. [The bearing noise is hard to identify since it is drowned by the noise of gears ].
Slide 3
D 20%
A B C D E
Aged Lubricant Unsuitable Lubricant Lack of Lubricant Solid Contaminants Liquid Contaminants
80%
F Problems caused by assembly G Unknown or secondary problems H Material or manufacturing problems I Wrong bearing selection, e.g. too small Rating Capacity
20%
Typical reasons for rolling bearing damages : Inexpert Mounting Inexpert mounting Abnormal conditions during operation Unfavourable environmental influences Inadequate lubrication Incorrect mounting method, wrong tools Contamination Too tight fit Too loose fit Misalignment
Slide 5
Unsuitable lubricant
Slide 6
Fretting Corrosion
CAUSES
Micro motion between fitted parts where fits are too lose in relation to the acting forces. Form disturbance of fitting surfaces. Shaft deflection or housing deformation. Floating bearing function at ring with circumferential load.
Fretting corrosion in bore of inner ring of Cylindrical roller bearing with seats too loose
Fretting corrosion reveals the size of the load zone at the stationary outer ring. ring.
Slide 7
Fretting Corrosion
Fretting corrosion in bore of inner ring of Cylindrical roller bearing with seats too loose
Fretting corrosion reveals the size of the load zone at the stationary outer ring. ring.
Slide 8
Seizure
CAUSES
Rotary motion between the ring and shaft/housing with loose fits under circumferrential load:with static load and unbalance also. Axial support of rings insufficient. Sluggish movement of floating ring.
Seizing marks in the inner ring bore as a result of inner ring creeping on the shaft.
REMEDIES
Use bearing seats which are as tight as possible. Extend axial mating surfaces. Keep fitting surfaces dry. Improve floating bearing function. FAG Bearings India Limited
Slide 9
CAUSES
Insufficient fixation of the bearing in the housing or on the shaft. Large amount of external contamination with narrow gap between the bearing and mating parts. Loose mating parts. Axial clearance too large.
Circumferential scoring and cold welding at the faces due to grazing by a mating part.
REMEDIES
Ensure proper adjustment of parts. Ensure proper cleanliness. Check and adjust correct axial clearance.
Seal damage due to lateral grazing
Slide 10
Radial load of a radial bearing e.g. deep groove ball bearing Under point load and with a sufficiently rigid housing, the track on the stationary ring is shorter than half the raceway circumference in so far as there is no radial preload. Under circumferential load, the track spreads over the entire raceway circumference. A.Point load for the outer ring, circumferential load for the inner ring. B.Point load for the inner ring, circumferential load for the outer ring.
A
FAG Bearings India Limited
B
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Tracks on bearings in working order. The locating bearing shows the characteristics of a bearing under combined load, the floating bearing those of a bearing under mainly/purely radial load.
Tracks on bearings under detrimental axial preload (outer ring of floating bearing does not move). Each bearing shows the characteristics of a combined load. The detrimental axial preload is clear from the symmetric tracks of both bearings.
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Tilting of the inner rings relative to the outer rings in the case of misaligned housing seats
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False Brinelling
CAUSES
Vibrations in stationary machines leading to micro motion between rolling elements and raceways. When the bearing isnt turning, an oil film cannot be formed to prevent raceway wear .
REMEDIES
Eliminate or absorb external vibration. Use lubricants containing antiwear additives.
Slide 20
Over Heating
CAUSES
Heavy electrical heat loads Inadequate heat paths Insufficient cooling or lubrication when loads and speed are excessive
REMEDIES
Thermal or overload controls. Adequate heat paths Supplemental cooling FAG Bearings India Limited Slide 21
CAUSES
Poor support of the rings in the bearing housing
REMEDIES
Improvement in bearing mounting. Follow FAG mounting instructions for appropriate recommendations
Slide 22
Slippage
CAUSES
Rolling elements slide on the raceways when the load is low and lubrication is poor. Occasionally occurs if load zones are too short, causing rolling elements to brake in the unloaded zone and accelerate again when entering the load zone. Fast changes in speed
REMEDIES
Select Bearing with lower load carrying capacity. Preload Bearings, Reduce Bearing Clearance, Improve Lubrication. FAG Bearings India Limited Slide 23
Misalignment
CAUSES
Bent shafts. Burrs or dirt on shaft or housing shoulders. Shaft threads that are not square with shaft seats. Locking nuts with faces that are not square to the thread axis
REMEDIES
Inspect shafts and housings for runout of shoulders and bearing seats. Use single point- turned or ground threads on nonhardened shafts and ground threads only on hardened shafts. Use precision grade lock nuts. FAG Bearings India Limited Slide 24
Tight Fits
CAUSES
Excessive loading of the rolling elements when interference fits exceed the radial clearance at operating temperatures. Continued operation under such conditions leads to rapid wear and fatigue.
REMEDIES
Decrease total interference with better matching of bearings to shafts and housings. Consider operating temperatures Increased radial clearance in bearing selection
Slide 25
AXIAL CRACKS
CAUSES
Bearing slippage, Rotation of inner ring on the shaft. Too tight of fit to shaft. Grooved shaft, Out-of-roundness. Grazing against Surrounding parts. FAG Bearings India Limited Slide 26
AXIAL CRACKS
Slide 27
Normal Fatigue
CAUSES
Bearing has remained in operation beyond its calculated fatigue life
REMEDIES
Replace the bearing and/or consider redesigning to use a bearing with a greater calculated fatigue life FAG Bearings India Limited Slide 28
TRUE BRINELLING
CAUSES
Static overload of the bearing, Severe impact to the bearing Using a hammer to install the bearing. Dropping or striking assembled equipment. Pressing a bearing to the shaft by applying force to the outer ring.
REMEDIES
Observe static load ratings in making bearing selection. Install bearings using appropriate equipment and by applying force only to the ring being pressfitted FAG Bearings India Limited Slide 29
Lubricant Failure
CAUSES
Restricted lubricant flow. Excessive temperatures that degrade the lubricant.
REMEDIES
Use of the appropriate and correct amount of lubricant. Ensure proper bearing fit. Control Preload to reduce bearing temperatures. FAG Bearings India Limited Slide 30
Corrosion
CAUSES
Exposing bearings to corrosive fluids or atmospheres
REMEDIES
Divert corrosive fluids away from bearing areas Use integrally sealed bearings Consider external seals for particularly hostile environments
Slide 31
Fluting
CAUSES
Constant passage of alternating or direct current Even low currents
REMEDIES
Prevent currents from flowing through the bearing by means of grounding or insulating. Use current insulated bearings
Excessive Loads
CAUSES
Excessive loading of the bearing
REMEDIES
Reduce the load Redesign using a bearing with greater capacity.
Slide 33
Lip Fractures
CAUSES
Axial load unacceptably high. Lip insufficiently supported. Axial shock load. Mounting damage.
REMEDIES
Ensure good lip support design. Keep load within specified limits. Observe appropriate mounting instructions & procedures. FAG Bearings India Limited Slide 34
Seizure
CAUSES
Inadequate lubrication with high loads and high speeds (quantity or operating viscosity of lubricant too low) Inadequate lubrication with high loads and low speeds.(When there is no hydrodynamic lubricating film between the roller face and lip). Detrimental Preload due to heat expansion. Skewing of rollers due to raceway wear or ring tilting. Axial load too high on cylindrical roller bearings. Axial Preload too high for out-of-square mating surfaces. FAG Bearings India Limited Slide 35
Seizure
Slide 36
Reverse Loading
CAUSES
Angular contact ball bearings are designed to accept an axial load in one direction only. When loaded in the opposite direction, the elliptical contact area on the outer ring is truncated by the low shoulder on that side of the outer ring.Result is excessive stress and an increase in temperature followed by increased vibration and early failure.
REMEDIES
Ensure proper installation of angular contact bearings. FAG Bearings India Limited Slide 37
Craters
CAUSES
Sparking over current for example during welding or due to earth failure.
REMEDIES
Do not direct the current through the bearing during Electro welding
Slide 38
CAUSES
Excessive (Axial Load). Moment Load too High. Operating Clearance too high. Tilting.
Fig1
REMEDIES
Avoid Overloading. Use bearing with higher load carrying capacity. Reduce operating clearance. Avoid tilting. FAG Bearings India Limited
Fig2
Slide 39
Ring Fractures
CAUSES
Well advanced fatigue damage.
REMEDIES
Cleanliness and caution required when Mounting. Improve sealing. Use clean lubricant. Improve mounting procedure. Rigid surrounding parts.
Slide 40
Unusual Tracks
Fig 1
CAUSES
Insufficient lubricant quantity available in the bearing. Viscosity of the lubricant is insufficient for the operating temperature and speed.
REMEDIES
Improve lubricant supply. Use lubricant with a suitable viscosity & appropriate additives. Use bearing parts with surface coating. FAG Bearings India Limited
Fig 2
Slide 41
Overheating
CAUSES
Bearing clearance too low during operation, particularly with high speed bearings. Inadequate lubrication. Radial Preload due to external over heating. Over lubrication. Impeded running due to cage fracture.
REMEDIES
Increase bearing clearance, Avoid lubrication pile up- Improve lubrication. In the case of external heating ensure, sufficiently slow heating up and cooling down, that is to ensure uniform heating of the complete bearing. FAG Bearings India Limited Slide 42
Score Marks
CAUSES
During mounting,if the single ring and the ring with the rolling elements are not concentric and are forcefully shoved damages as shown in the photo are done to the inner ring. This can be particularly dangerous with large moving pass(large shaft is shoved with the bearing inner ring and rolling element into the outer ring which has already been pressed into the housing.
Slide 43
Score Marks
Slide 44
CAUSES
Insufficient lubricant supply to the contact areas,often inadequate drainage of the lubricant. Contaminated lubricant. Speed too high for the bearing. Excess tilting during assembly. Unexpectedly high temperatures in the case of outer ring guided brass cages(different coefficient of expansion between steel and brass). FAG Bearings India Limited Slide 45
Slide 46
CAUSES
Extreme amount of external dirt particularly in moist environment. Lip runs dry. Fig.- Corrosion in the area of the sealing track at the lip of an angular contact ball bearing.
REMEDIES
Use preseals e.g. flinger rings. Lubricate sealing lips. FAG Bearings India Limited Slide 47
Cage Wear
CAUSES
Lubricant contaminated with hard foreign particles. Too little or unsuitable lubricants.
REMEDIES
Ensure clean assembly conditions. Filter the lubricant that is recycled. Increase lubricant through and/or apply a different viscosity.
Fig Shows cage wear due to starved lubrication and contaminants
Slide 48
Cage Wear
CAUSES
Excessive speed. Unsuitable cage construction selected.
REMEDIES
Select suitable cage material as per the speed application.
Fig Shows cage wear due to grazing at the bearing outside diameter.* FAG Bearings India Limited Slide 49
Cage Wear
CAUSES
Unpermissible tilting of the bearings. Faulty adjustment of clearance in the bearings.
REMEDIES
Adjust bearing correctly. Use self aligning bearing , avoid misalignment.
Fig Shows cage wear due to roller skewing FAG Bearings India Limited Slide 50
Cage Wear
CAUSES
Excess tilting of the bearing rings to one another. Eg. Ball bearings with combined load.Varying circumferential velocity of balls as a result. Stress in cage area high, particularly with poor lubrication.
REMEDIES
Avoid tilting. Apply eventually self aligning bearing or bearing with polyamide cages. Special design long hole pockets can be used. Fig Shows cage wear due to rings tilting towards one another.
Slide 51
Cage Wear
CAUSES
Vibration or shocks which superimpose the normal cage stress. Tilting in the case of deep groove ball bearings.
REMEDIES
Use of solid cage instead of a pressed cage. Use of window type cage particularly when stress is great.
Fig Shows fractured cage rivet connections resulting From vibratory stresses.
Slide 52
Cage Wear
CAUSES
Mounting damage. Kinematically permissible speed exceeded. Moment load too high. As a result of wear due to poor lubrication. In case of tapered roller pairs when clearance is large and reversal of axial loading is quick.
REMEDIES
Mount carefully. Filter lubricant. Operate bearing pair preloaded if possible. Avoid tilting as much as possible.
Fig Shows disruptive fracture at the side edge of a spherical roller bearing.
Slide 53
Initial fusing in the case of plastic cages, grooves or warping in the case of metallic cages.
Cage Wear
CAUSES
Incorrect heating of the bearing for mounting. Unsuitable mounting aids.
REMEDIES
Mount the bearing as the manufacturers recommendation. Refer FAG publication WL 80 100 Mounting and Dismounting of rolling bearings
Fig Shows melted face of a plastic cage resulting from incorrect heating on heating plate.
Slide 54
Sealing Damage
Fig a
CAUSES
Operating temperature too high for sealing material. Extreme amount of dirt at the sealing lip. Sealing interference too high. Sealing lip is not lubricated.
REMEDIES
Use suitable sealing material. Use non rubbing preseal. Grease sealing lips. FAG Bearings India Limited
Fig b
Slide 55
Sealing Damage
CAUSES
Incorrect mounting aids. Bearing over heated. Sealing occasionally removed. Bearing blown off with compressed air.
Fig a
Fig a
REMEDIES
Ensure careful mounting with suitable mounting devices. Never open sealed bearings if they are to be subsequently used. FAG Bearings India Limited
Fig b
Slide 56
ABRASIVE WEAR
Slide 57
GROOVING
ETCHING
Slide 58
EXCESSIVE PRELOAD/OVERLOA D
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FALSE BRINELLING
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