Why Bearings Fail?

How do Bearings Fail?

Not always due to Natural Causes
How do Bearings Fail?
Not always due to Natural Causes
Only

of bearings fail
due to Fatigue,
which is the basis
of life calculation.

34
%
How do Bearings Fail?
Poor Lubrication
is the reason for


of premature
bearing failures



36
%
How do Bearings Fail?
Contamination
is the reason for


of premature
bearing failures



14
%
How do Bearings Fail?
Poor Installation
is the reason for


of premature
bearing failures



16
%
Design Life of Bearing
Depends on 4 Assumptions
Good and clean Lubrication in adequate amount will
always be available to the bearing

The bearing will be mounted without damage

Dimensions of parts related to the bearings will
be correct

There are no defects inherent in the bearing

How do Bearings Fail?
Fatigue of Bearing Material
Spalling

Produced by normal end to useful life

Improper Lubrication

Mechanical Damage

Material Defect
Design Life of Bearing
Definition
The life of a rolling bearing is defined as
the number of revolutions ( or operating
hours at a given constant speed) which
the bearing is capable of enduring before
the first sign of fatigue (Flaking ,spalling
or crack )occurs on one of its rings or
rolling elements


Electrical erosion
Wear
Corrosion
Fracture
Fatigue
Plastic deformation
Failure mode Classification
How do Bearings Fail?
Failure mode Classification
- Spalling
Why Bearings Fail?
Symptoms of Failures
Unusual operating behaviour indicating
damage :Subjective damage recognition

I n the vast majority of bearing applications it is
sufficient when machine operators watch out for
uneven running or unusual noise in the bearing
system
Bearing Failures & Their Causes
Bearing Failures & Their Causes
Unusual operating behaviour indicating damage :
Subjective damage recognition
Symptoms Sources of Trouble Examples
Uneven running Damaged ring or
rolling elements
Motor vehicles:
* More and more wheel wobbling
* Increased tilting clearance
* Vibration of steering system
Contamination Fans:
* Growing vibration
Excessive bearing
clearance
Saw Mills :
* More knocks and blows on
connecting rods
Bearing Failures & Their Causes
Unusual operating behaviour indicating damage :
Subjective damage recognition
Symptoms Sources of Trouble Examples
Reduced
working
accuracy
Wear due to
* Contamination
or
* Insufficient Lubrication
Lathe:
* Gradual development of chatter
marks on work piece

Damaged rings or
rolling elements
Grinders:
* Weavy ground surface
Change in adjustment:
* Clearance or
* Preload
Cold Rolling Mills :
* Periodic surface defects on
rolled material e.g., stretcher
strains or ghost lines
Bearing Failures & Their Causes
Unusual operating behaviour indicating damage :
Subjective damage recognition
Symptoms Sources of Trouble Examples
Unusual
Running
Noise
Whinning or
Squealing noise
Insufficient operating clearance Electric Motors
Gears
Rumbling or
Irregular noise
Excessive Clearance
Damaged contact areas
Contamination
Unsuitable Lubricant
Gradual change
in running noise
Change in operating clearance due
to temperature
Damaged running track due to
contamination or fatigue
Why Bearings Fail?
A. Overheated bearing
B. Noisy bearing
C. Vibration
D. Shaft is jammed
E. Bearing clearance has increased
F. Lubricant has metallic debris
G. Unsatisfactory equipment performance

Symptoms of Failures
Contributing factors of Symptoms of Bearing Failures
Sr.
No
Causes Symptoms
A B C D E F G
1 Improper Lubrication X X X X X X X
2 Contamination X X X X X X X
3 Wrong Clearence / preload X X X X X X X
4 Wrong Shaft dimension / tolerance X X X X X
5 Wrong housing tolerance X X X X X X
6 Wrong mounting of bearing / seal X X X X X X
7 Unbalance / eccentricity / loose component X X X X
8 Misalignment X X X X X
9 Overspeed X X X X X
10 Overload X X X X X
11 Vibration / Heat from external source X X X X
12 Seal Friction / Malfunction / damage X X X X X X
13 Wrong selection of bearing /cage material / seal X X X X X X
14 Improper maintenance of seal X X X X
15 Passage of electric current X X X X
16 Improper Gear Mesh X X
17 Soft foot / loose foundation bolt X X
18 Spurious / Reconditioned Bearing X X X X X X X
Why Bearings Fail?
Improper lubrication

Wrong type lubricant for operating condition
Low oil level. Lubricant being lost through seal
Excessive lubrication causing churning
Oil return hole too small
Oil return hole blocked. Pumping action of seal
causing leakage
Lubrication starvation because of incorrect
amount / relubrication interval



Contributing factors of Symptoms
Why Bearings Fail?
Seal friction / malfunction

Contact seals are dried out
Radial lip seal has excessive spring tension
Rotating seals / flingers are rubbing against
stationary parts
Contact seals are excessively worn causing
lubricant loss or permitting dirt to enter bearing
Labyrinth seal not greased

Contributing factors of Symptoms
Why Bearings Fail?
Wrong housing / shaft size / tolerance
Housing bore is out of round / undersized
Housing is warped / distorted
Bore surface uneven
Housing bore too large
Housing material too soft. Resulting pounding
enlarges bore allowing outer ring to spin.
Shaft diameter is out of round / oversized
Shaft shoulder diameter too large, rubbing
against seal / cage
Shaft is bending due to incorrect shoulder dia
Shaft is distorted
Shaft shoulder out-of-square
Contributing factors of Symptoms
Why Bearings Fail?
Wrong mounting / preload

Bearings are axially preloaded
Both bearings are located
Adapter sleeve is tightened excessively
Washer prong is rubbing against bearing
Incorrect mounting method
hammer blow
Impact of roller edge on raceway
Adapter sleeve is loose shaft undersized
Contributing factors of Symptoms