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From Materials Evaluation, Vol. 70, No. 1, pp: 7885.
Copyright 2011 The American Society for Nondestructive Testing, Inc.
ABSTRACT
78
N
B
F 1 + cos
2
P
BPFO =
(1)
N
B
F 1 cos
2
P
FTF =
F
B
1 cos
2
P
BSF =
2
B
P
F 1 cos
P
2B
where
BPFI = ball pass frequency inner race (Hz),
BPFO = ball pass frequency outer race (Hz),
FTF = fundamental train frequency (Hz),
BPF = ball pass frequency (Hz),
N = number of balls,
F = shaft frequency (Hz),
B = ball diameter (mm),
P = pitch diameter (mm),
= contact angle.
Pitch
diameter
79
ME TECHNICAL PAPER w
x bearing analysis
events will occur for an inner race fault. The main reason why
inner race problems are detected less frequently than outer
race problems is because transmission of high frequencies
generated by lubrication and/or wear is attenuated greatly
through multiple transitions and lubrication boundaries. The
poor transmission of vibratory energy results in more severe
wear by the time a problem is detected. Therefore, trending is
limited for inner raceway wear.
The rolling elements and cage are typically the last
components to fail though roller spin frequencies, and are
often observed in non-ball bearing configurations.
The indications associated with the four stages of bearing
wear are general and may not be all-inclusive for each bearing
wear event. The stages are provided as follows as a point of
reference used in the evaluation of bearing severity for an
estimate of wear in lieu of disassembly and inspection
(Woodward, 1995).
Stage 1
Stage 4
Assigning a bearing wear stage for high-frequency natural bearing resonance indicator (HFNBRI) amplitude versus revolutions per minute
(RPM)
HFNBRI
RPM
High-frequency detection
(gs peak)
50
100
300
500
600
900
1200
1800
3600
7200
0.225/0.45/0.90/1.8
0.335/0.67/1.34/2.7
0.45/0.9/1.8/3.6
0.5/1.0/2.0/4.0
0.95/1.9/3.8/7.6
1.1/2.2/4.4/8.8
1.3/2.6/5.2/10.4
1.5/3.0/6.0/12.0
1.75/3.5/7.0/14.0
3.0/6.0/12.0/24.0
0.21/0.42/0.84/1.7
0.32/0.64/1.3/2.6
0.425/0.85/1.7/3.4
0.475/0.95/1.89/3.8
0.9/1.8/3.7/7.4
1.05/2.1/4.2/8.4
1.2/2.4/4.8/9.6
1.4/2.8/5.6/11.2
1.6/3.2/6.5/13.0
2.8/5.6/11.3/22.6
Spike energy
(gs spike energy)
0.075/0.15/0.3/0.6
0.115/0.23/0.46/0.92
0.15/0.3/0.6/1.2
0.17/0.34/0.68/1.36
0.325/0.65/1.3/2.6
0.375/0.75/1.5/3.0
0.44/0.87/1.7/3.4
0.5/1.0/2.0/4.0
0.6/1.2/2.4/4.8
1.0/2.0/4.0/8.0
Shock pulse
(dB shock value)
16/22/28/34
21/27/33/39
27/33/39/45
32/38/44/50
34/40/46/52
36/42/48/54
39/45/51/57
42/48/54/60
50/56/62/68
52/58/64/70
TABLE 2
Bearing wear stage for single highest bearing fault frequency harmonic amplitude (mm/s peak) versus shaft rotational speed
Revolutions
per minute
Stage 1
50
100
200
300
450
600
900
1200
1800
3600
4000
0.254
0.381
0.508
0.572
0.635
0.762
0.826
0.889
1.016
1.270
1.524
1.016
1.524
2.032
2.286
2.540
3.048
3.429
3.556
4.064
5.080
6.096
2.032
3.048
4.064
4.572
5.080
6.096
6.858
7.112
8.128
10.160
12.192
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ME TECHNICAL PAPER w
x bearing analysis
TABLE 3
Bearing wear stage for maximum time-waveform peak-to-peak magnitude versus shaft rotational speed
Revolutions
per minute
Stage 1
50
100
200
300
450
600
900
1200
1800
3600
7200
0.16
0.26
0.50
0.75
0.88
1.00
1.70
2.40
4.10
10.20
20.00
(2)
16667
C
H=
L
RPM
where
H = hours,
C = rated capacity (kN),
L = dynamic load (kN),
RPM = machine speed (revolutions per minute).
82
0.32
0.52
1.00
1.50
1.75
2.00
3.40
4.80
8.20
20.40
40.00
0.64
1.02
2.00
3.00
3.50
4.00
6.90
9.60
16.40
40.80
80.00
Stage 4
1.28
2.04
4.00
6.00
7.00
8.00
13.60
19.20
32.80
81.60
160.00
(3)
16667
C
H=
L + 4.14016 106 MVF
RPM
where
H = hours,
C = rated capacity (kN),
L = dynamic load (kN),
RPM = machine speed (revolutions per minute),
M = mass (kg),
V = velocity (mm/s),
F = frequency (Hz).
Machines with imbalance or misalignment will have
increased loads, thus reducing the life of the bearing
(Graney, 2008). Dynamic load calculations should use
8090% of overall vibration velocity alarm for turning speed
vibration and 5060% of overall vibration velocity alarm for
two to three times turning speed vibration. ISO 10816-1:1995
provides guidelines for overall vibration levels (ISO, 1995).
Review of Equation 3 for bearing life shows that bearing
lifetime is proportional to L3 and is also proportional to the
reciprocal of speed, RPM1. Therefore, it is possible to
evaluate the risk of failure with respect to increased speed
and/or load. Doubling only load will reduce the expected life
to 12.5%, whereas doubling only speed reduces the expected
life to 50%. Increasing the speed above the original design is
normally accomplished with an engineering process change.
Load may be increased above the original design in the same
manner. However, the dynamic load may increase due to
excess vibration (inertia loading). Velocity vibration amplitude is used to assign a dynamic force indicator, which will be
used to calculate a risk assessment value.
(4)
ARI = DFI 2 + B2
8.89
7.62
846.49
658.1
6.35
5.08
3.81
94.01
2.54
Alert
limit
1.27
0
0
333.3
(a)
666.6
1000
1333.3
1666.7
Frequency (Hz)
20
15
Acceleration (g)
Crest factor
10
5
0
Peak alarm
Peak alarm
5
10
15
20
25
Crest factor
(b)
Revolutions
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ME TECHNICAL PAPER w
x bearing analysis
Using the worst-case bearing wear stage for bearing indicator (Equation 4), ARI = 4.123. An ARI of 4.123 is considered a very high risk of catastrophic failure. The appropriate
recommendation should be to replace bearings immediately
(as can be scheduled).
Diagnosis (Crosscheck)
10.16
20.31
7.62
560.37
280.24
117.14
2.5
2.0
FTF
1.0
5.08
BPFI
BPFO
0.5
2.54
0
0
666.7
(a)
1333.3
2000
2666.7
3333.3
333.3
(a)
666.7
1000
Frequency (Hz)
Frequency (Hz)
Amplitude (mixed units)
Acceleration (g)
60
Crest factor
40
20
Peak alarm
Peak alarm
0
20
40
Crest factor
60
80
20.0 g
High-frequency
band 120 kHz
7.62
mm/s
2150 RPM
17.78
mm/s
520 RPM
400
Revolutions
84
3.0
1.5
0
0
(b)
3.5
128.83
BPFI
BPFI
BPFI
BPFI
BPFI
BPFI
BPFI
38.52
4.0
11231.4
12.70
BPFI
15.24
BPFI
BPFI
17.78
4.5
23.54
58.63
Root-mean-square (g)
5.0
(b)
600
800
1000
1200
1400
Days
ACKNOWLEDGMENTS
85