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BEARING FAILURE Load/Contact Patterns

As bearings rotate, the raceways of the inner ring and outer ring make contact with the rolling elements. This results in a Wear path on both the rolling elements and raceways. Running traces are useful, because they indicate the load conditions. They should be carefully observed when bearings are disassembled. If the running traces are clearly defined, it is possible to determine whether the bearing is carrying a radial load, axial load or moment load. Additionally running traces can help determine the accuracy of bearing roundness, confirm whether unexpected loads or large mounting errors occurred, and shed light on probable causes of bearing damage. (R1) Typical Runnin Traces o! "eep Groo#e Ball Bearin s a! shows the most common running trace generated when the inner ring rotates under a radial load only. e! through h! show different running traces that result in a shortened life due to their adverse effect on bearings. (R2) a! b! c! d!

Inner ring rotation "uter ring rotation Inner ring or Inner ring rotation Radial load Radial load outer ring rotation Radial and axial Axial load in one loads direction e! f! g! h!

Inner ring rotation Inner ring rotation Inner ring rotation Axial load and #oment load $ousing bore is misalignment #isalignment! oval

Inner ring rotation %o radial internal clearance %egative operating clearance!

Typical Runnin Traces o! Roller Bearin s i! &hows the outer ring running trace when a radial load is properly applied to a cylindrical roller bearing which has a load on a rotating inner ring. '! &hows the running trace in the case of shaft bending or relative inclination between the inner and outer rings. This misalignment leads to the generation of slightly shaded dull! bands in the width direction. Traces are diagonal at the beginning and end of the loading (one. )or double*row tapered roller bearings where a single load is applied to the rotating inner ring, k! shows the running trace on the outer ring under radial load while I! shows the running trace on the outer ring under axial load. When misalignment exists between the inner and the outer rings, then the application of a radial load causes running traces to appear on the outer ring as shown in m!. (R3) i! '! k! l! m!

Inner ring Inner ring Inner ring rotation rotation rotation Radial load #oment load Radial load #isalignment!

Inner ring rotation Axial load

Inner ring rotation Radial and moment loads #isalignment!

"a$a e Types % Causes


In general, if rolling bearings are used correctly, they will survive to their predicted fatigue life. +earings, however, often fail prematurely due to avoidable mistakes. The causes of, this premature failure include improper mounting, mishandling, poor lubrication, entry of foreign matter or abnormal heat generation. )or example, one cause of premature failure is rib &coring which is due to insufficient lubrication, use of improper lubricant, faulty lubrication system, entry of foreign matter, bearing mounting error, excessive deflection of the shaft or some combination of these. If all conditions are known for the times both before and after the failure, including the application, the operating conditions, and environment, then

a countermeasure can be determined by studying the nature of the failure and its probable causes. A successful countermeasure will reduce similar failures or prevent them from happening again. ,xamples of bearing damage and countermeasures are presented in the following sections. -lease consult these sections when trying to determine the cause of bearing damage. (R4)

Fla&in

Peelin

'corin

'$earin

Fracture

Crac&s

Ca e "a$a e

"entin

Pittin

(ear

Frettin

False Brinellin

Creep

'ei)ure

Electrical Corrosion

Rust and Corrosion

*ountin Fla+s

"iscoloration

,- Fla&in (R5) "a$a e Condition Possi.le Causes Counter$easures )laking occurs when small ,xcessive load. -oor Reconfirm the bearing pieces of bearing material are mounting misalignment!. application and check the split off from the smooth #oment load. ,ntry of load conditions surface of the raceway or foreign debris, water Improve the mounting rolling elements due to rolling penetration. -oor lubrication, method fatigue, thereby creating improper lubricant. Improve the sealing regions having rough and /nsuitable bearing clearance. mechanism, prevent rusting coarse texture. Improper precision for shaft during non*running or housing, unevenness in /se a lubricant with a housing rigidity, large shaft proper viscosity, improve the bending. -rogression from lubrication method rust, corrosion pits, &mearing, 0heck the precision of dents brinelling! shaft and housing 0heck the bearing internal clearance

-hoto 1*1

-art 2 Inner ring of an angular contact ball bearing &ymptom 2 )laking around half of the circumference of the raceway surface 0ause 2 -oor lubrication due to entry of cutting coolant into bearing -art 2 Inner ring of an angular contact ball bearing &ymptom 2 )laking diagonally along raceway 0ause 2 -oor alignment between shaft and housing during mounting -art 2 Inner ring of deep groove ball bearing &ymptom 2 )laking of raceway at ball pitch 0ause 2 5ents due to shock load during mounting

-hoto 1*3

-hoto 1*4

-hoto 1*6

-art 2 Inner ring of an angular contact ball bearing &ymptom 2 )laking of raceway at ball pitch 0ause 2 5ents due to shock load while stationary -art 2 "uter ring of -hoto 1*6 &ymptom 2 )laking of raceway surface at ball pitch 0ause 2 5ents due to shock load while stationary

-hoto 1*7 -art 2 +alls of -hoto 1*6 &ymptom 2 )laking of ball surface 0ause 2 5ents due to shock load while stationary -art 2 Inner ring of a spherical roller bearing &ymptom 2 )laking of only one raceway over its entire circumference 0ause 2 ,xcessive axial load -hoto 1*9 -art 2 "uter ring of -hoto 1*9 &ymptom 2 )laking of only one raceway over its entire circumference 0ause 2 ,xcessive axial load -hoto 1*: -art 2 Inner ring of a spherical roller bearing &ymptom 2 )laking of only one row of raceway 0ause 2 -oor lubrication -hoto 1*; -art 2 Rollers of a cylindrical roller bearing &ymptom 2 -remature )laking occurs axially on the rolling surfaces 0ause 2 &cratches caused during

-hoto 1*8

-hoto 1*1< /- Peelin (R6) "a$a e Condition Possi.le Causes

improper mounting

Counter$easures

"ull or cloudy spots appear Unsuita.le lu.ricant 'elect a proper lu.ricant on sur!ace alon +it0 li 0t Entry o! de.ris into I$pro#e t0e sealin (ear- Fro$ suc0 dull lu.rication $ec0anis$ spots1 tiny Crac&s are Rou 0 sur!ace due to poor I$pro#e t0e sur!ace !inis0 enerated do+n+ard to a lu.rication o! t0e rollin $atin parts dept0 o! 23,4 5$- '$all 'ur!ace rou 0ness o! particles !all o!! and $inor $atin rollin parts Fla&in occurs +idely-

-art 2 Inner ring of a spherical roller bearing &ymptom 2 Rounded areas of -eeling 0ause 2 -oor lubrication -hoto 3*1 -art 2 ,nlargement of -hoto 3*1

-hoto 3*3 -art 2 0onvex rollers of -hoto 3*1 &ymptom 2 Rounded areas of -eeling on the center of the rolling surfaces 0ause 2 -oor lubrication -hoto 3*4 -art 2 "uter ring of a spherical roller bearing &ymptom 2 -eeling occurs near the shoulder of the raceway over the entire circumference 0ause 2 -oor lubrication

-hoto 3*6

6- 'corin (R7) "a$a e Condition Possi.le Causes Counter$easures 'corin is sur!ace da$a e E7cessi#e load1 e7cessi#e C0ec& t0e si)e o! t0e load due to accu$ulated s$all preload Ad8ust t0e preload sei)ures caused .y slidin Poor lu.rication I$pro#e t0e lu.ricant and under i$proper lu.rication Particles are cau 0t in t0e t0e lu.rication $et0od or se#ere operatin sur!ace C0ec& t0e precision o! t0e conditions- Linear da$a e Inclination o! inner and s0a!t and 0ousin appears circu$!erentially outer rin s on t0e race+ay and roller '0a!t .endin sur!aces- Cycloidal s0aped Poor precision o! t0e s0a!t da$a e on t0e roller ends and 0ousin and 'corin on t0e ri. sur!ace contactin roller ends also occur-

-hoto 4*1

-art 2 Inner ring of a spherical roller bearing &ymptom 2 &coring on large rib face of inner ring 0ause 2 Roller slippage due to sudden acceleration and deceleration -art 2 Inner ring of a tapered roller thrust bearing &ymptom 2 &coring on the face of inner ring rib 0ause 2 Worn particles mixed with lubricant, and breakdown of oil film due to excessive load -art 2 Inner ring of a spherical thrust roller bearing &ymptom 2 &coring on the rib face of inner ring 0ause 2 5ebris caught in surface, and excessive axial load -art 2 0age of a deep groove ball bearing &ymptom 2 &coring on the pressed*steel cage pockets 0ause 2 ,ntry of debris

-hoto 4*1

-hoto 4*1

-hoto 4*1 -art 2 0onvex rollers of -hoto 4*1 &ymptom 2 &coring on roller end faces 0ause 2 Roller slippage due to sudden acceleration and deceleration -hoto 4*3 -art 2 Rollers of a double*row cylindrical roller bearing &ymptom 2 &coring. on the roller end faces 0ause 2 -oor lubrication and excessive axial load -art 2 0onvex rollers of -hoto 4*7 &ymptom 2 &coring. on the roller end faces 0ause 2 5ebris caught in surface, and excessive axial load -hoto 4*3

-hoto 4*3

9- '$earin (R8) "a$a e Condition Possi.le Causes Counter$easures I$pro#e t0e preload I$pro#e t0e .earin clearance Use a lu.ricant +it0 ood oil !il$ !or$ation a.ility I$pro#e t0e sealin $ec0anis$ '$earin is sur!ace :i 0 speed and li 0t load da$a e +0ic0 occurs !ro$ 'udden a collection o! s$all acceleration/deceleration sei)ures .et+een .earin I$proper lu.ricant co$ponents caused .y oil Entry o! +ater !il$ rupture and/or slidin 'ur!ace rou 0enin occurs alon +it0 $eltin -

-hoto 6*1

-hoto 6*4

-art 2 Inner ring of a cylindrical roller bearing &ymptom 2 &mearing around circumference of raceway surface 0ause 2 Roller slippage due to excessive grease =uantity -art 2 Inner ring of a spherical roller bearing &ymptom 2 &mearing around circumference of raceway surface 0ause 2 -oor lubrication -art 2 Inner ring of a spherical roller bearing &ymptom 2 -artial &mearing around circumference of raceway surface 0ause 2 -oor lubrication -art 2 0onvex rollers of -hoto 6*7 &ymptom 2 &mearing of rolling surfaces 0ause 2 -oor lubrication

-hoto 6*7

-hoto 6*9 -art 2 "uter ring of -hoto 6*1 &ymptom 2 &mearing around circumference of raceway surface 0ause 2 Roller slippage due to excessive grease =uantity -hoto 6*3 -art 2 "uter ring of -hoto 6*4 &ymptom 2 &mearing around circumference of raceway surface 0ause 2 -oor lubrication -hoto 6*6 -art 2 "uter ring of -hoto 6*7 &ymptom 2 -artial &mearing around circumference of raceway surface 0ause 2 -oor lubrication -hoto 6*8

2- Fracture (R9) "a$a e Condition Fracture re!ers to s$all pieces +0ic0 +ere .ro&en o!! due to e7cessi#e load or s0oc& load actin locally on a roller corner or ri. o! a race+ay rin Possi.le Causes I$pact durin $ountin E7cessi#e load Poor 0andlin suc0 as droppin Counter$easures I$pro#e t0e $ountin $et0od (s0rin& !it1 use o! proper tools) Reconsider t0e load conditions Pro#ide enou 0 .ac&3up and support !or t0e .earin ri.

-art 2 Inner ring of a double*row cylindrical roller bearing &ymptom 2 0hipping of the center rib 0ause 2 ,xcessive load during mounting -hoto 7*1 -art 2 Inner ring of a spherical thrust roller bearing &ymptom 2 )racture of the large rib 0ause 2 Repeated shock load -hoto 7*4 -art 2 Inner ring of a tapered roller bearing &ymptom 2 )racture of the cone back face rib 0ause 2 >arge shock during mounting -hoto 7*3 -art 2 "uter ring of a solid type needle roller bearing &ymptom 2 )racture of the outer ring rib 0ause 2 Roller inclination due to excessive loading %eedle rollers are long compared to their diameter. /nder excessive or uneven loading, rollers become inclined and push against the ribs.!

-hoto 7*6

;- Crac&s (R10) "a$a e Condition Crac&s in t0e race+ay rin and rollin ele$entsContinued use under t0is condition leads to lar er Crac&s or FracturesPossi.le Causes Counter$easures E7cessi#e inter!erence Correct t0e inter!erence E7cessi#e load1 s0oc& load C0ec& t0e load conditions Pro ression o! Fla&in I$pro#e t0e $ountin :eat eneration and $et0od Frettin caused .y contact Use an appropriate s0a!t .et+een $ountin parts s0ape and race+ay rin :eat eneration due to Creep Poor taper an le o! tapered s0a!t Poor cylindricality o! s0a!t Inter!erence +it0 .earin c0a$!er due to a lar e s0a!t corner radius

-art 2 Inner ring of a spherical roller bearing &ymptom 2 Rounded areas of -eeling 0ause 2 -oor lubrication -hoto 8*1 -art 2 "uter ring of a double*row cylindrical roller bearing &ymptoms 2 0racks propagated outward in the axial and circumferential directions from the )laking origin on the raceway surface 0ause 2 )laking from a flaw due to shock -art 2 Raceway surface of outer ring in -hoto 8*6 &ymptom 2 "utside surface crack propagating to the raceway -hoto 8*7

-hoto 8*4

-art 2 0ross section of cracked inner ring in -hoto 8*8 &ymptom 2 "rigin is directly beneath the raceway surface -hoto 8*9 -art 2 "uter ring of a double*row cylindrical roller bearing &ymptom 2 Thermal 0racks on the outer ring side face 0ause 2 Abnormal heat generation due to contact sliding between mating part and face of outer ring -art 2 "uter ring of a double*row cylindrical roller bearing used for outer ring rolling "uter ring rotation! &ymptom 2 0racks on outside surface 0ause 2 )lat Wear and heat generation due to non*rotation of the outer ring -art 2 Inner ring of a spherical roller bearing &ymptom 2 Axial 0racks on raceway surface 0ause 2 >arge fitting stress due to temperature difference between shaft and inner ring -art 2 Roller of a spherical roller bearing &ymptom 2 Axial 0racks on rolling surface -hoto 8*:

-hoto 8*3

-hoto 8*6

-hoto 8*8

<- Ca e "a$a e (R11) "a$a e Condition Ca e da$a e includes= Ca e de!or$ation1 Fracture and (ear Fracture o! ca e pillars "e!or$ation o! side !ace (ear o! poc&et sur!ace (ear o! uide sur!ace Possi.le Causes Counter$easures Poor $ountin (Bearin C0ec& t0e $ountin $et0od $isali n$ent) C0ec& t0e te$perature1 Poor 0andlin rotation and load conditions Lar e $o$ent load Reduce t0e #i.ration '0oc& and lar e #i.ration Use an appropriate s0a!t E7cessi#e rotation speed1 s0ape 'elect a di!!erent ca e sudden acceleration and type deceleration 'elect a di!!erent Poor lu.rication lu.rication $et0od and/or Te$perature rise lu.ricant

-art 2 0age of a deep groove ball bearing &ymptom 2 )racture of pressed*steel cage pocket -hoto 9*1 -art 2 0age of an angular contact ball bearing &ymptom 2 )racture of machined high* tension brass cage -hoto 9*4 -art 2 0age of an angular contact ball bearing &ymptom 2 -ressed*steel cage deformation 0ause 2 &hock load due to poor handling -hoto 9*7 -art 2 0age of a cylindrical roller bearing &ymptom 2 5eformation and Wear of machined high*tension brass cage -hoto 9*9

-hoto 9*3

-art 2 0age of an angular contact ball bearing &ymptom 2 -ocket pillar )ractures of a cast iron machined cage 0ause 2 Abnormal load action on cage due to misaligned mounting between inner and outer rings -art 2 0age of a tapered roller bearing &ymptom 2 -illar )ractures of pressed* steel cage

-hoto 9*6 -art 2 0age of a cylindrical roller bearing &ymptom 2 5eformation of the side face of machined high*tension brass cage 0ause 2 >arge shock during mounting -hoto 9*8 -art 2 0age of an angular contact ball bearing &ymptom 2 &tepped Wear on the outside surface and pocket surface of machined high*tension brass cage -hoto 9*:

>- "entin (R12) "a$a e Condition Possi.le Causes Counter$easures

(0en de.ris suc0 as s$all "e.ris suc0 as $etallic Clean t0e 0ousin $etallic particles are particles are cau 0t in t0e I$pro#e t0e sealin cau 0t in t0e rollin sur!ace $ec0anis$ contact )one1 "entin E7cessi#e load Filter t0e lu.rication oil occurs on t0e race+ay '0oc& durin transport or I$pro#e t0e $ountin and sur!ace or rollin ele$ent $ountin 0andlin $et0ods sur!ace- "entin can occur at t0e rollin ele$ent pitc0 inter#al i! t0ere is a s0oc& durin t0e $ountin (.rinell dents)-art 2 Inner ring of a double*row tapered roller bearing &ymptom 2 )rosted raceway surface 0ause 2 5ebris caught in the surface -hoto :*1 -art 2 Inner ring of a tapered roller bearing &ymptom 2 &mall and large indentations occur over entire raceway surface 0ause 2 5ebris caught in the surface -art 2 "uter ring of a double*row tapered roller bearing &ymptom 2 Indentations on raceway surface 0ause 2 5ebris caught in the surface -hoto :*3 -art 2 Tapered rollers of -hoto :*4 &ymptom 2 &mall and large indentations occur over the rolling surface 0ause 2 5ebris caught in the surface -hoto :*6

-hoto :*4

?- Pittin (R13) "a$a e Condition Possi.le Causes Counter$easures I$pro#e t0e sealin $ec0anis$ Filter t0e lu.rication oil t0orou 0ly Use a proper lu.ricant Pittin 0as a dull luster and "e.ris .eco$es cau 0t in appears on t0e rollin t0e lu.ricant ele$ent sur!ace or race+ay E7posure to $oisture in sur!acePoor lu.rication

-art 2 "uter ring of a slewing bearing &ymptom 2 -itting on the raceway surface 0ause 2 Rust -hoto ;*1 -art 2 +all of -hoto ;*1 &ymptom 2 -itting on the rolling element surface -hoto ;*3

,4- (ear (R14) "a$a e Condition Possi.le Causes Counter$easures I$pro#e t0e sealin $ec0anis$ Clean t0e 0ousin Filter t0e lu.rication oil t0orou 0ly C0ec& t0e lu.ricant and lu.rication $et0od Pre#ent $isali n$ent (ear is sur!ace Entry o! de.ris deterioration due to slidin Pro ression !ro$ rust and !riction at t0e sur!ace o! t0e electrical corrosion race+ay1 rollin ele$ents1 Poor lu.rication roller end !aces1 ri. !ace1 'lidin due to irre ular ca e poc&ets1 etc$otion o! rollin ele$ents

-hoto 1<*1

-hoto 1<*4

-hoto 1<*3

-art 2 Inner ring of a cylindrical roller bearing &ymptom 2 #any pits occur due to electrical corrosion, and wave*shaped Wear on raceway surface 0ause 2 ,lectrical corrosion -art 2 Inner ring of a double*row tapered roller bearing &ymptom 2 )retting Wear of raceway and stepped Wear on the rib face 0ause 2 )retting progression due to excessive load while stationary -art 2 "uter ring of a spherical roller bearing &ymptom 2 Wear with a wavy or concave*convex texture on loaded side of raceway surface 0ause 2 ,ntry of debris under repeated vibration while stationary -art 2 Tapered rollers of -hoto 1<*4 &ymptom 2 &tepped Wear on the roller head end faces 0ause 2 )retting progression due to excessive load while stationary

-hoto 1<*4

,,- Frettin (R15) "a$a e Condition (ear occurs due to repeated slidin .et+een t0e t+o sur!acesFrettin occurs at !ittin sur!ace and also at contact area .et+een race+ay rin and rollin ele$entsFrettin corrosion is anot0er ter$ used to descri.e t0e reddis0 .ro+n or .lac& +orn particlesPossi.le Causes Poor lu.rication @i.ration +it0 a s$all a$plitude Insu!!icient inter!erence Counter$easures Use a proper lu.ricant Apply a preload C0ec& t0e inter!erence !it Apply a !il$ o! lu.ricant to t0e !ittin sur!ace

-art 2 Inner ring of a deep groove ball bearing &ymptom 2 )retting on the bore surface 0ause 2 ?ibration -hoto 11*1 -art 2 "uter ring of a double*row cylindrical roller bearing &ymptom 2 )retting on the raceway surface at roller pitch intervals -hoto 11*4 -art 2 Inner ring of an angular contact ball bearing &ymptom 2 )retting over entire circumference of bore surface 0ause 2 Insufficient interference fit -hoto 11*3

,/- False Brinellin (R16) "a$a e Condition Possi.le Causes Counter$easures A$on t0e di!!erent types Ascillation and #i.ration o! 'ecure t0e s0a!t and o! Frettin 1 !alse .rinellin a stationary .earin durin 0ousin durin transportin is t0e occurrence o! 0ollo+ suc0 ti$es as transportin Transport +it0 t0e inner spots t0at rese$.le .rinell Ascillatin $otion +it0 a and outer rin s pac&ed dents and are due to (ear s$all a$plitude separately caused .y #i.ration and Poor lu.rication Reduce t0e #i.ration .y s+ayin at t0e contact preloadin points .et+een t0e rollin Use a proper lu.ricant ele$ents and race+ay-

-hoto 13*1

-art 2 Inner ring of a deep groove ball bearing &ymptom 2 )alse brinelling on the raceway 0ause 2 ?ibration from an external source while stationary -art 2 "uter ring of a thrust ball bearing &ymptom 2 )alse brinelling of raceway surface at ball pitch 0ause 2 Repeated vibration with a small oscillating angle

-hoto 13*4 -art 2 "uter ring of -hoto 13*1 &ymptom 2 )alse brinelling on the raceway 0ause 2 ?ibration from an external source while stationaryt -art 2 Rollers of a cylindrical roller bearing &ymptom 2 )alse brinelling on rolling surface 0ause 2 ?ibration from an external source while stationary

-hoto 13*3

-hoto 13*6

,6- Creep (R17) "a$a e Condition Possi.le Causes Counter$easures Creep is t0e p0eno$enon Insu!!icient inter!erence or C0ec& t0e inter!erence1 and in .earin s +0ere relati#e loose !it pre#ent rotation slippa e occurs .et+een Insu!!icient slee#e Correct t0e slee#e !ittin sur!aces and t0ere.y ti 0tenin ti 0tenin creates a clearance .et+een 'tudy t0e s0a!t and 0ousin t0e$ sur!ace- Creep causes precision a s0iny appearance1 Preload in t0e a7ial occasionally +it0 'corin direction or (earTi 0ten t0e race+ay rin side !ace Apply ad0esi#e to t0e !ittin sur!ace Apply a !il$ o! lu.ricant to t0e !ittin sur!ace

-art 2 Inner ring of a spherical roller bearing &ymptom 2 0reep accompanied by &coring of bore surface 0ause 2 Insufficient interference -hoto 14*1 -art 2 "uter ring of a spherical roller bearing &ymptom 2 0reep over entire circumference of outside surface 0ause 2 >oose fit between outer ring and housing

-hoto 14*3

,9- 'ei)ure (R18) 5amage 0ondition When sudden overheating occurs during rotation, the bearing becomes discolored. Then, the raceway rings, rolling elements, and cage will soften, melt and deform as damage accumulates. -ossible 0auses -oor lubrication ,xcessive load ,xcessive preload! ,xcessive rotational speed ,xcessively small internal clearance ,ntry of water and debris -oor precision of shaft and housing ,xcessive shaft bending 0ountermeasures &tudy the lubricant and lubrication method Reinvestigate the suitability of the bearing type selected &tudy the preload, bearing clearance, and fitting Improve the sealing mechanism 0heck the precision of the shaft and housing Improve the mounting method

-hoto 16*1

-art 2 Inner ring of a spherical roller bearing &ymptom 2 Raceway is discolored and melted. Worn particles from the cage were rolled and attached to the raceway. 0ause 2 Insufficient lubrication -art 2 Inner ring of an angular contact ball bearing &ymptom 2 Raceway 5iscoloration, melting at ball pitch intervals 0ause 2 ,xcessive preload

-hoto 16*4 -art 2 +alls and cage of -hoto 16*4 &ymptom 2 0age is damaged by melting, balls discolored and melted 0ause 2 ,xcessive preload -hoto 16*4

-art 2 0onvex rollers of -hoto 16*1 &ymptom 2 5iscoloration and melting of roller rolling surface, adhesion of worn particles from cage 0ause 2 Insufficient lubrication -hoto 16*3 -art 2 "uter ring in -hoto 16*4 &ymptom 2 Raceway 5iscoloration, melting at ball pitch intervals 0ause 2 ,xcessive preload -hoto 16*6

,2- Electrical Corrosion (R19) 5amage 0ondition When electric current passes through a bearing, arcing and burning occur through the thin oil film at points of contact between the raceway and rolling elements. The points of contact are melted locally to form @fluting@ or groove*like corrugations which can be seen by the naked eye. #agnification of these grooves reveals crater*like depressions which indicate melting by arcing. -ossible 0auses ,lectric current passing through a bearing 0ountermeasures 5esign electric circuits which prevent current flow through the bearings Insulate the bearing

-art 2 Inner ring of a tapered roller bearing &ymptom 2 &triped pattern of corrosion occurs on the raceway surface -hoto 17*1 -art 2 Inner ring of a cylindrical roller bearing &ymptom 2 +elt pattern of electrical corrosion accompanied by pits on the raceway surface -art 2 Tapered rollers in -hoto 17*1 &ymptom 2 &triped pattern of corrosion occurs on the rolling surface -hoto 17*3 -art 2 +alls of a deep groove ball bearing &ymptom 2 5ark color covering the entire ball surfaces

-hoto 17*4

-hoto 17*6 ,;- Rust and Corrosion (R20) 5amage 0ondition -ossible 0auses 0ountermeasures +earing rust and corrosion ,ntry of corrosive gas or Improve the sealing are pits on the surface of water mechanism rings and rolling elements Improper lubricant &tudy the lubrication method and may occur at the rolling )ormation of water droplets Anti*rust treatment during element pitch on the rings or due to condensation of periods of non*running over the entire bearing moisture Improve the storage methods surfaces. $igh temperature and high Improve the handling method humidity while stationary -oor rust*preventive treatment during transporting Improper storage conditions Improper handling

-art 2 "uter ring of a cylindrical roller bearing &ymptom 2 Rust on the rib face and raceway surface 0ause 2 Water entry -hoto 18*1 -art 2 Inner ring of a spherical roller bearing &ymptom 2 Rust on raceway surface at roller pitch intervals 0ause 2 ,ntry of water into lubricant -hoto 18*4 -art 2 "uter ring of a slewing ring &ymptom 2 Rust on raceway surface at ball pitch intervals 0ause 2 #oisture condensation during stationary periods -art 2 Rollers of a spherical roller bearing &ymptom 2 -it*shaped rust on rolling contact surface. 0orroded portions. 0ause 2 #oisture condensation during

-hoto 18*3

-hoto 18*6 ,<- *ountin Fla+s (R21) 5amage 0ondition &traight line scratches on surface of raceways or rolling elements caused during mounting or dismounting of bearing. -ossible 0auses

storage

0ountermeasures

Inclination of inner and outer /se appropriate 'ig and tools rings during mounting or Avoid shock loads by using a dismounting press machine &hock load during mounting 0enter the relative mating or dismounting parts during mounting

-hoto 19*1

-art 2 Inner ring of a cylindrical roller bearing &ymptom 2 Axial scratches on raceway surface 0ause 2 Inclination of inner and outer rings during mounting -art 2 Rollers of a cylindrical roller bearing &ymptom 2 Axial scratches on rolling surface 0ause 2 Inclination of inner and outer rings during mounting -art 2 "uter ring of a double*row cylindrical roller bearing &ymptom 2 Axial scratches at roller pitch intervals on raceway surface 0ause 2 Inclination of inner and outer rings during mounting

-hoto 19*4

-hoto 19*3

,>- "iscoloration (R22) 5amage 0ondition 5iscoloration of cages, rolling elements and raceway rings occurs due to their reacting with lubricant at high temperature -ossible 0auses -oor lubrication "il stain due to a reaction with lubricant $igh temperature 0ountermeasures Improve the lubrication method

-hoto 1:*1

-art2 Inner ring of an angular contact ball bearing &ymptom2 +luish or purplish 5iscoloration on raceway surface 0ause2 $eat generation due to poor lubrication -art 2 Inner ring of a 6*point contact ball bearing &ymptom 2 +luish or purplish 5iscoloration on raceway surface 0ause 2 $eat generation due to poor lubrication

-hoto 1:*3

+earing )its (26)


,- Inter!erence )or rolling bearings the bearing rings are fixed on the shaft or in the housing so that slip or movement does not occur between the mated surface during operation or under load. This relative movement sometimes called creep! between the fitted surfaces of the bearing and the shaft or housing can occur in a radial direction, or in an axial direction, or in the direction of rotation. This creeping movement under load causes damage to the bearing rings, shaft or housing in the form of abrasive wear, fretting corrosion or friction crack. This, in turn, can also lead to abrasive particles getting into the bearing, which can cause vibration, excessive heat, and lowered rotational efficiency. To ensure that slip does not occur between the fitted surfaces of the bearing rings and the shaft or housing, the bearing is usually installed with an interference fit. The most effective interference fit is called a tight fit or shrink fit!. The advantage of this Atight fitB for thin walled bearings is that it provides uniform load support over the entire ring circumference without any loss in load carrying capacity. $owever, with a tight interference fit, ease of mounting and dismounting the bearings is lost. and when using a non*separable bearing as a non*fixing bearing, axial displacement is impossible. /- Calculation o! inter!erence 1! >oad and interference The minimum re=uired amount of interference for inner rings mounted on solid shafts when acted on by radial loads, is found by formula 9.1! and 9.3!.

3! Temperature rise and interference To prevent loosening of the inner ring on steel shafts due to temperature increases difference between bearing temperature and ambient temperature! caused by bearing rotation, an interference fit must be given. The re=uired amount of interference can be found by formula 9.4!. 4! ,ffective interference and apparent interference

The effective interference the actual interference after fitting! is different from the apparent interference derived from the dimensions measured value. This difference is due to the roughness or slight variations of the mating surfaces, and this slight flattening of the uneven surfaces at the time of fitting is taken into consideration. The relation between the effective and apparent interference, which varies according to the finish given to the mating surfaces, is expressed by formula 9.6!.

6! #aximum interference When bearing rings are installed with interference fit on shafts or housings, the tension or compression stress may occur. If the interference is too large, it may cause damage to the bearing rings and reduce the fatigue life of the bearing. )or these reasons, the maximum amount of interference should be less than 1C1<<< of the shaft diameter, or outside diameter.

6- Fit selection &election of the proper fit is generally based on the following factors2 1! the direction and nature of the bearing load, 3! whether the inner ring or outer ring rotates, 4! whether the load on the inner or outer ring rotates or not, 6! whether there is static load or direction indeterminate load or not. )or bearings under rotating loads or direction indeterminate loads, a tight fit is recommended. but for static loads, a transition fit or loose fit should be sufficient see Table 3!. The interference should be tighter for heavy bearing loads or vibration and shock load conditions. Also, a tighter than normal fit should be given when the bearing is installed on hollow shafts or in housings with thin walls, or housings made of light allows or plastic. In applications where high rotational accuracy must be maintained, high precision bearings and high tolerance shafts and housings should be employed instead of a tighter interference fit to ensure bearing stability. $igh interference fits should be avoided if possible as they cause shaft or housing deformities to be induced into the bearing rings, and thus reduce bearing rotational accuracy. +ecause mounting and dismounting become very difficult when both the inner ring and outer ring of a non*separable bearing for example a deep groove ball bearing! are given tight interference fits, one or the other rings should be given a loose fit. Table 3! Radial load and bearing fit

Lu.rication (R25)
Lu.rication o! rollin .earin s The purpose of bearing lubrication is to prevent direct metallic contact between the various rolling and sliding elements. This is accomplished through the formation of a thin oil or grease! film on the contact surfaces. $owever, for rolling bearings, lubrication has the following advantages. 1! )riction and wear reduction 3! )riction heat dissipation 4! -rolonged bearing life 6! -revention of rust 7! -rotection against harmful elements In order to achieve the above effects, the most effective lubrication method for the operating conditions must be selected. Also, a good =uality, reliable lubricant must be selected. In addition, an effectively designed sealing system prevents the intrusion of damaging elements dust, water, etc.! into the bearing interior, removes dust and other impurities from the lubricant, and prevents the lubricant from leaking from the bearing. Almost all rolling bearings use either grease or oil lubrication methods, but in some special applications, a solid lubricant such as molybdenum disulfide or graphite may be used. Grease lu.rication Drease type lubricants are relatively easy to handle and re=uire only the simplest sealing devicesEfor these reasons, grease is the most widely used lubricant for rolling bearings. Type and characteristics of grease >ubricating grease is composed of either a mineral oil base or a synthetic oil base. To this base a thickener and other additives are added. The properties of all greases are mainly determined by the kind of base oil used by the combination of thickening agent and various additives. &tandard greases and their characteristics are listed in (Ta.le 6). As performance characteristics of even the same type of grease will vary widely from brand to brand, it is best to check the manufacturersF data when selecting grease.

Replenishment As the lubricating efficiency of grease declines with the passage of time, fresh grease must be re*supplied at proper intervals. The replenishment time interval depends on the type of bearing, dimensions, bearingFs rotating speed, bearing temperature, and type of grease. An easy reference chart for calculating grease replenishment intervals is shown in )ig. 1 This chart indicates the replenishment interval for standard rolling bearing grease when used under normal operating conditions. As operating temperatures increase, the grease re*supply interval should be shortened accordingly. Denerally, for every 1<G0 increase in bearing temperature above :<G0, the relubrication period is reduced by exponent A1C1.7B. ,xample! )ind the grease relubrication time limit for deep groove ball bearing 83<8, with a radial load of 3.< k% operating at 4,8<< rCmin. 0rC-rH1;.7C3.< k%H;.:, from )ig. 3 the ad'usted load, f>, is <.;8. )rom the bearing tables, the allowable speed for bearing 83<8 is 11,<<< rCmin and the numbers of revolutions permissible at a radial load of 3.< I% are

therefore,

/sing the chart in )ig. 1, find the point corresponding to bore diameter dH4< from bearing table! on the vertical line for radial ball bearings. 5raw a straight hori(ontal line to vertical line I. Then, draw a straight line from that point A in example! to the point on line II which corresponds to the noCn value 3.;4 in example!. The point, 0, where this line intersects vertical line III indicates the relubrication interval h. In this case the life of the grease is approximately 7,7<< hours.

)ig. 1 5iagram for relubrication interval of greasing

)ig. 3 ?alue of ad'ustment factor f> depends on bearing load (R27)

Ail lu.rication Denerally, oil lubrication is better suited for high speed and high temperature applications than grease lubrication. "il lubrication is especially effective for those application re=uiring the bearing generated heat or heat applied to the bearing from other sources! to be carried away from the bearing and dissipated to the outside. >ubricating oil /nder normal operating conditions, spindle oil, machine oil, turbine oil and other minerals are widely used for the lubrication of rolling bearings. $owever, for temperatures above 17<G0 or below J4<G0, synthetic oils such as diester, silicone and fluorosilicone are used. )or lubricating oils, viscosity of the oil is one of the most important properties and determines the oilFs lubricating efficiency. If the viscosity is too low, the oil film will not be sufficiently formed, and it will damage the load carrying surface of the bearing. "n the other hand, if the viscosity is too high, the viscosity resistance will also be high and cause temperature increases and friction loss. In general, for higher speed, lower viscosity oil should be used, and for heavy loads, higher viscosity oil should be used. In regard to operating temperature and bearing lubrication, Table 6 lists the minimum re=uired viscosity for various bearings. )ig. 4 is a lubricating oil viscosity*temperature comparison chart is used in the selection of lubricating oil. It shows which oil would have the appropriate viscosity at a given temperature. )or lubricating oil viscosity selection standards relating to bearing operating conditions, see Table 7. Table 6 #inimum viscosity of lubricating oil for bearings

)ig. 4 Relation between viscosity and temperature Table 7 &election standards for lubricating oils

"il =uality In forced oil lubrication systems, the heat radiated away by housing and surrounding parts plus the heat carried away by the lubricating oil is approximately e=ual to the amount of heat generated by the bearing and other sources. )or standard housing applications, the =uantity of oil re=uired can be found by formula 11.1!.

where, K 2 Kuantity of oil for one bearing cm4Cmin I 2 Allowable oil temperature rise factor Table 8! = 2 #inimum oil =uantity cm4Cmin )rom chart! +ecause the amount of heat radiated will vary according to the shape of the housing, for actual operation it is advisable that the =uantity of oil calculated by formula 11.1! be multiplied by a factor of 1.7 to 3.<. Then, the amount of oil can be ad'usted to correspond to the actual machine operating conditions. If it is assumed for calculation purposes that no heat is radiated by the housing and that all bearing heat is carried away by the oil, then the value for shaft diameter, d, second vertical line from right in )ig. 6! becomes (ero, regardless of the actual shaft diameter. Table 8 )actor I

,xample! )or tapered roller bearing 4<33</ mounted on a flywheel shaft with a radial load of ;.7 k%, operating at 1,:<< rpm. what is the amount of lubricating oil re=uired to keep the bearing temperature rise below 17G0L dH1<< mm, dnH1<<M1,:<<H1:M1<6 mm rCmin from )ig. 6!, =H1:< cm4Cmin. Assume the bearing temperature is approximately e=ual to the outlet oil temperature, from Table 8!, since IH1, KH1M1:<H1:< cm4Cmin.

)ig. 6 Duidance for oil =uantity

'ealin "e#ices (R24)


+earing seals have two main functions2 1! to prevent lubricant from leaking out and 3! to prevent dust, water and other contaminants from entering the bearing. When selecting a seal the following factors need to be taken into consideration2 the type of lubricant oil or grease!, seal sliding speed, shaft fitting errors, space limitations, seal friction and resultant heat, and cost. &ealing devices for rolling bearings fall into two main classifications2 contact and non*contact types. Non3contact seals %on*contact seals utili(e a small clearance between the seal and the sealing surface. therefore, there is no wear, and friction is negligible. 0onse=uently, very little frictional heat is generated making non* contact seals very suitable for high speed applications. As shown in )ig. 7!, non*contact seals can have the simplest of designs. With its small radial clearance, these types of seal are best suited for grease lubrication, and for use in dry, relatively dust free environments. When several concentric oil grooves )ig. 8! are provided on the shaft or housing, the sealing effect can be greatly improved. If grease is filled in the grooves, the intrusion of dust, etc. can be prevented. )or oil lubrication, if helical concentric oil grooves are provided in the direction opposite to the shaft rotation hori(ontal shafts only!, lubricating oil that flows out along the shaft can be returned to the inside of the housing see )ig. 9!. The same sealing effect can be achieved by providing helical grooves on the circumference of the shaft. >abyrinth seals employ a multistage labyrinth design which elongates the passage, thus improving the sealing effectiveness. >abyrinth seals are used mainly for grease lubrication, and if grease is filled in the labyrinth, protection efficiency or capacity! against the entrance of dust and water into the bearing can be enhanced. The axial labyrinth passage seal shown in )ig. :! is used on one* piece housings and the radial seal shown in )ig. ;! is for use with split housings. In applications where the shaft is set inclined, the labyrinth passage is slanted so as to prevent contact between the shaft and housing pro'ections of the seal )ig. 1<!.

)ig. 7 0learance seal

)ig. 8 "il groove seal

)ig. 9 $elical oil groove seal

)ig. : Axial labyrinth seal

)ig. ; Radial labyrinth seal

)ig. 1< Aligning labyrinth seal

Contact seals 0ontact seals accomplish their sealing action through the constant pressure of a resilient part of the seal on the sealing surface. 0ontact seals are generally far superior to non*contact seals in sealing efficiency, although their friction tor=ue and temperature rise coefficients are somewhat higher. The simplest of all contact seals are felt seals. /sed primarily for grease lubrication )ig. 11!, felt seals work very well for keeping out fine dust, but are sub'ect to oil permeation and leakage to some extent. Therefore, the N type rubber seal shown in )ig. 13! and D& type shown in )ig. 14!, have been used more widely.

)ig. 11 )elt seal

)ig. 13 )elt seal

)ig. 14 )elt seal

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