Bearing Basics

Egyptian Cement Company
Rolling Element Bearing

Inspection & Maintenance
Presented By:
Alaa Eldin M. Ragab
Agenda
Inspection of Bearings
Check of bearings in operation
Bearing Temperature
Operating Sound of Bearing
Vibration of Bearing
Lubricant Selection
Re-lubrication
Inspection of bearings after operation
Bearing failures and countermeasures
What is a rolling bearing?
A rolling bearing is generally composed of an inner ring, an

outer ring, a set of rolling elements and a cage. Bearings are
generally classified into radial bearings and thrust bearings
depending on direction of load. In addition, they can also be
classified into ball bearings and roller bearings depending on
the type of rolling elements and then further segregated by
their different designs or specific purpose. The following
tables show the various classifications and corresponding
series codes.
Why Bearings?
Low Friction--Particularly low starting friction.

The ability to support both radial and thrust load and high
speeds of rotation.
Accurate performance under changing load and speed.
High Load Carrying capacity
Operating ability under extreme conditions of speed and
performance.
Practically no wear in running.
Simple methods of Lubrication.
Inherently Precision Mechanisms.
Sliding or Rolling Bearings
Sliding bearings:
sliding friction
Rolling bearings:
rolling friction
Rolling bearings and sliding bearings
Rolling-element bearings
(Anti-friction bearings)
Sliding bearings
(1)Friction
Lower starting friction

(=0.001~0.002)
Higher (except for hydrostatic

bearings)
(1)Load capacity
Usually smaller in
operation, suitable for high
starting load
Able to tolerate impact and

momentary overloads
(1)Shaft speed
Lower (fatigue life involved

in consideration)
(1)Operation
More noisy, can be no

clearance more precise
(1)Dimensions
Greater in radial direction
Greater in axial direction
(1)Cost
Higher
Lower if without lubrication

accessory
Higher
Bearing History
The first known ball bearing was found

when excavating a vessel from the Nemi
lake outside Rome in the 1930s
The bearing washers were made of wood
and the upper washer, equipped with
bronze balls with stub shafts on each side,
rotated on the lower washer. The balls
were mounted in recesses and not freely
rotating as in modern bearings, but
constrained by the stub shafts and straps
over them.
History
Bearing Evolution
Bearing Evolution
3500 B.C.
1794 A.D.
1869
700 B.C.
40 A.D.
1995
Bearing Nomenclature
Bearings Components
Seal
Rolling elements
Outer ring
Cage
Inner ring
Seal
Bearing Types
Bearing Size
Bearing Size
Bearing Seals
Contact Area/Form
The ball has a smaller radius

than the groove
The load capacity of a
bearing is limited by the
contact stresses between the
rolling elements and the races
Roller and Ball Contact Area/Form
Rolling Elements
Ball
Spherical
Cylindrical
Asymmetrical
Taper
Needle
Bearing Assembly
Step 1: Move the inner race to one side of the out race
Step 2: Locate the largest gap between the two races and insert the balls in
the groove
Step 3: Distribute the balls evenly, thereby centering the inner race with
respect to the outer race
Step 4: Place the separator (retainer)
10
Bearing Fixation
Bearing Fixation
The tolerances (housing & shaft) must be held to

prevent excessive angular thrust & resulting shortened
life (0.0001 mm)
Press fit the rotating ring to maintain alignment. Let
the stationary ring creep in its mounting so that new
portion of the ring are brought into the load-bearing
zone and wear is equalized
Thermal expansion is to be considered when two
bearings support a shaft. The thrust in each direction
must be carried by one and only one bearing
11
Bearing Fixation
Bearing Fixation an Example
WARNING!!!!! Thermal expansion of the shaft creates thrust force,

possibly overloading the bearings.
12
Bearing Mounting an Example
RECOMMENDED!!!! The thrust force is provided by a single bearing. The

second bearing only takes radial loads because it is allowed to slide axially.
Bearing selection
Bearing selection is usually based on a variety of factors

such as:
life required
servicing requirements (maintained or maintenance free)
load type (constant, cyclic, shock etc)
RPM and/or oscillation rate
environment (contamination possibilities)
temperature ranges
installation requirements.
13
Bearing Characteristics
Why Bearings Fail?
Only a fraction of all bearings in service actually fail. The

vast majority outlive the machinery or equipment in which
they are installed. A bearing failure may occur for many
reasons, i.e., heavier loading than hand been originally
anticipated, ineffective seals or mountings which are too
tight resulting in too little bearing internal clearance, etc.
Each of these factors produces its own particular type of
damaged bearing, it is possible in a majority of cases to
determine the cause and take corrective action to prevent a
recurrence.
14
Why Bearings Fail?
Of the small fraction of bearings that actually do fail,

approximately one-third die from old age (e.g., fatigue of the
bearing surfaces), another third fail because of poor
lubrication, and the rest fail as a result of liquid or solid
contaminants entering the bearing or because of handling
damage or faulty mounting. The pattern of failure can vary
according to the specific industry where the bearing is used.
For example, in the pulp and paper industry, poor
lubrication and contamination are the major causes of
failure, not fatigue.
Inspection of Bearings
Check of bearings in operation

Included are the check of bearing temperature, noise, and
vibration, and the examination of the properties of lubricant
to determine when lubricant should be replenished or
exchanged.
Inspection of bearings after operation
Any change of the bearing is carefully examined after
operation and during periodic inspections so as to take
measures to prevent recurrence.
15
Bearing Noise

Sound
Features
Causes
Hiss
Small bearings
Raceway, ball or roller surfaces are rough.
Buzz to Roar

Loudness and pitch change

with speed.
Resonation
Poor fit (Poor shaft shape)
Bearing rings deformed.
Vibration of raceways, balls, or rollers
(For large bearings, if this sound is minor,
then this is considered normal).
Brinelling
Crunch
Felt when the bearing is

rotated by hand.
Scoring of raceway surface (regular).

Scoring of balls or rollers (irregular).
Dust/Contamination
Deformed bearing ring (partial interference
clearance).
16

Sound
Features
Causes
Hum
Disappears when power

supply is switched off.
Electromagnetic sound of motor.
Chatter
Noticeable at low speeds.

Continuous at high speeds.
Bumping in cage pockets (insufficient lubricant)-Eliminated by clearance reduction or pre-loading.

Rollers bumping into each other on full-roller
bearing.
Clang/Clatter
/
Metallic, loud bumping

sound.
Thin section large bearing
(TTB) at low speeds.
Bearing ring deformed.

Grating of key.
Sound
Features
Causes
Screech/Howl
/
Occurs mainly on cylindrical

roller bearings.
Sound changes with speed.
Loud metallic sound that
disappears temporarily
when grease is added.
Large radial clearance.

Poor lubrication/grease consistancy.
Squeak
Metal-to-metal spalling
sound.
High pitch
Spalling of roller and rib of roller bearing.

Small clearance
Poor lubrication
Squeal

Generated irregularly due to

grating.
Slip on fitting surfaces.

Grating on mounting seat, of key, etc.
17

Sound
Features
Causes
Faint tinkle

Irregular (not changing with

speed).
Primarily on small bearings.
Dust in bearing.
Rustle
Sound quality remains the

same even if speed
changes (Dirt).
Sound quality changes with
speed (Scoring).
Dirt
Raceway, ball, or roller surfaces are rough.
Rustle
Generated intermittently at
regular intervals.
Chafing at the labyrinth.

Contact of cage and seal.
Sound
Features
Causes
Rustle patter
Regular and continuous at

high speed.
Growl
Continuous at high speeds.
Generated by retainer.
Normal if sound is clear.
Grease is inadequate if sound is generated at low
temp
Wear of cage pockets.
Insufficient lubricant.
Low bearing load.
Scoring on raceway, balls, or rollers.
Quiet
Fizzing/Popping
Generated irregularly on small

bearings.
Bursting sound of bubbles in grease.
Large Sound
Pressure
Large Sound Pressure
Rough raceway, roller, or ball surfaces.

Raceway, rollers, or balls are deformed by wear.
Large clearance due to wear.
18
Bearing Abnormality Diagnosis AE System
AE (acoustic emission) is the phenomenon of acoustic pulse

generation due to the release of strain energy caused by structural
alteration in a solid material.
Koyo developed and commercialized a highly reliable abnormality
diagnosis system utilizing AE : this system realized diagnosis of
bearing abnormalities under high vibration, which was considered
impossible for conventional diagnosis methods.
Bearing Life Evaluation
Invented at Alex Univ. 1999
19
Bearing Temperature
Bearing temperature generally rises with start-up and stabilizes at a

temperature slightly lower than at start-up (normally 10 to 40 Chigher
than room temperature) in a certain time. The time before stabilizing
depends on the size, type, speed, and lubrication system of the bearing
and the heat dissipation condition around the bearing. It ranges from
about 20 minutes to as long as several hours.
If bearing temperature does not stabilize but continues to rise, the
causes shown in Table 1 are conceivable Operation should be stopped
and an appropriate corrective action should be taken.
High bearing temperature is not desirable in view of maintaining an
adequate service life and preventing lubricant deterioration. A
desirable bearing temperature is generally below 100 C.
Major causes of high bearing temperature
Extremely insufficient or excessive lubricant

Poor installation of the bearings
Extremely small bearing clearance or extremely heavy load
Extremely high friction between lip and seal groove
Improper lubricant type
Creep between the fitting surfaces
20
Bearing Vibration
Vibration of Bearing
Damage to the bearing can be detected early by

measuring the vibration of the machine. The
degree of damage is inferred from quantitative
analysis of the amplitude and frequency of the
vibration. However, values measured differ
depending on the measuring point and the
operating condition of the bearing.It is desirable
to accumulate measurement data and establish
evaluation criteria for each machine.
21
Excessive clearance
stages of sleeve
bearing wear will give a
large family of harmonics
of running speed
A minor unbalance or
misalignment will cause
high amplitudes when
excessive bearing
clearances are present
Later
Phase Relationship
Typical Spectrum
Rolling Element Bearings

o
o
o
o
Earliest indications of bearing problems

Slight bearing defects
Bearing defect frequencies
Failure Mode
22
Earliest indications
Earliest
indications in
the ultrasonic range
These frequencies
evaluated by Spike
EnergyTM gSE, HFD(g)
and Shock Pulse
Spike Energy may first
appear at about 0.25 gSE
for this first stage
Typical Spectrum
Slight bearing defects
Slight defects begin to

ring bearing
component natural
frequencies
These frequencies
occur in the range of
30k-120k CPM
At the end of Stage 2,
sideband frequencies
appear above and
below natural
frequency
Spike Energy grows
e.g. 0.25-0.50gSE
Typical Spectrum
23
Bearing defect frequencies
Bearing defect
frequencies and
harmonics appear
Many defect frequency
harmonics appear with
wear the number of
sidebands grow
Wear is now visible
and may extend
around the periphery
of the bearing
Spike Energy increases
to between 0.5 -1.0 gSE
Failure Mode
Discreet bearing defect

frequencies disappear
and are replaced by
random broad band
vibration in the form of
a noise floor
Towards the end, even
the amplitude at 1 X
RPM is effected
High frequency noise
floor amplitudes and
Spike Energy may in
fact decrease
Just prior to failure
gSE may rise to high
levels
Typical Spectrum
Typical Spectrum
24
Formulae to Calculate Specific Bearing defect Types:

BPFO =
N b 1 Bd COS(
2
Pd
BPFI =
N b 1 + Bd COS ( )
* RPM
2
Pd
)
* RPM
D0
DB
D1
1 1 Bd COS ( )
* RPM
FTF =
2
Pd
BSF =
Pd
2 Bd
B COS( ) 2
1 d
* RPM

Pd

Note : shaft turning

outer race fixed
Bearing Lubrication
25
Effect of Lubricant
Reduces friction and abrasion

Transports heat generated by friction
Prolongation of service life
Prevents rust (corrosion)
Keeps foreign objects (or contamination) away from rolling
elements and raceways
Friction in Roller Bearings
small portion of rolling friction

but considerable share of sliding friction at:
roller bearing rings
cages and / or
rolling elements against each other
26
friction value
Effect of lub. film Thickness

Stribeck-Kurve
Stribeck
Diagram
number of revolutions/sliding speed
boundary friction
mixed friction
Grease lubrication
hydrodynamic friction
Grease is generally used for lubricating rolling-element bearings

because it is easy to handle and simplifies the sealing system.
Carefully examine the type and properties of the base oil,
thickener and additives of the grease, and select a grease
appropriate for the operating condition of the bearing.
The general relation between consistency of grease and the
application of the bearing is given in Table 1. The types and
properties of greases are given in the bearing section of the
Bearing general catalog.
27
Speed rates
r/min
Oil lub.
Grease lub
Bearing Lubrication
Oiling
Max rotating
speed
Greasing
28
Kinds of Lubrication of Roller Bearings
90% by greases
9,5% by oils
0,5% by solid lubricants only
The most important Parameters
revolution or DN - factor
D+d
DN =
n
2
D = external bearing diameter [mm]
d = internal bearing diameter [mm]
n = revolution per minute [rpm]
+d
dm= medium bearing diameter [mm] = D
2
temperature range
29
Lubrication by greases
Grease pump
Contamination may
cause bearing failures.
Seals protect to a large
extent from outside contaminations.
Contamination penetrating through

labyrinth channels.
Frequent relubrication is required when

the hazard of grease contamination exists.
Same applies if the grease should seal also
against penetrating moisture.
Newly supplied grease pushes out both

used up and contaminated grease
through the labyrinth packing seals.
Relubrication Intervals
Small bearings with lateral seals or cover plates do not need any
relubrication. They are already for - life lubricated.
For all other roller bearings relubrication intervals become valid.
30
Guidelines for Relubrication Intervalls
Lubrication interval,
given by service hours
tfc
10 000
tfb
6 000
20 000
4 000
tfa
15 000
3 000
20 000
10 000
2 000
15 000
7 500
1 500
10 000
5 000
1 000
5 000
2 500
500
3 000
1 500
300
2 000
1 000
200
1 500
750
150
1 000
500
100
500
250
50
tfa = radial ball bearing

200
tfb = cylindrical roller bearing / needle bearing 100
tfc = self aligning roller bearing / taper rolling bearing / axial roller bearing
massive cylindrical roller bearing (0,2 tfc), axial cylindrical roller
bearing (0,5 tfc)
Example: A deep-groove ball bearing with an internal diameter d=

100mm running at a speed of n = 1000 rpm. The operating
temperature lies between 60 and 70 C.
Which is the expected relubrication interval?
The vertical in point n= 1000 rpm on the abscissa
cuts the curve for d= 100mm. From there the horizontal leads to the
outer left-hand scale (deep- groove ball bearings)
indicating a relubrication interval of 10000 service hours
d=10
20
40
500 420 360
280 240 200
500
1 000
160
120 100
2 000
80
5 000
Correction of Relubrication Intervals
60
10 000
n [U/min]
The assessed intervals are valid only for:

bearings in stationary machines
normal load
ageing-proofed greases
temperature < + 70C at the outer ring
31
Effect Of Tempearture
Lubrication interval
C
100
z above 70C the factor 0,5 applies

for each temperature rise of 15C
85
i.e. with a temperature rise from e.g.

70C up to 85C the service life of
the grease is cut by half.
70
z below 70C the factor 2 applies
for each temperature drop of 15C
55
i.e. with a temperature drop from e.g.
70C down to 55 C the service life of the
grease is doubled.
40
Temperature at the outer ring
Consistency Grease
NLGL
consistency No.
ASTM consistency after 60

workings
Application
355 - 385
Centralized lubrication
310 - 340
Centralized lubrication
265 - 295
General, prelubricated
bearing
220 - 250
General, high temperature
175 - 205
Special applications
32
Oil lubrication
Oil lubrication is generally suitable for high speed or high

temperature operations. It is also suitable for carrying heat
away from the bearing.
Oil viscosities required for the operating temperatures of

bearings are given in Table 2.
Carefully study the viscosity, viscosity index, oxidation
resistance, corrosion resistance, foaming resistance, etc. to
select an oil. Table 3.5 gives a guide for selecting viscosity.
Oil lubrication
Oil bath lubrication

Suitable only for bearings with low
speeds.
During standstand-stills the oil level should not
quite reach the middle of the rolling
element
at the bottom.
.
33
Oil injection lubrication
At high speed it becomes necessary,

that the air turbulence circulating with
the bearing is penetrated by the oil.
This is ensured by injecting oil under
high pressure (min.15 m/s) from the side
into the bearing.
Circulatory oil lubrication
Cooling
pump
With increasing speed the service

temperature
rises and accelerates the ageing of the
lubricating oil.
By circulatory lubrication the
oil can be cooled and consequently
the service temperature be reduced.
34
Oil Viscosity
Viscosities Require for Bearings Types

Bearing Type
Kinematic viscosity mm2/s
Ball, cylindrical roller and needle roller bearings
13
Self-aligning roller bearings, tapered roller

bearings and thrust needle roller bearings
20
SelfSelf-aligning thrust roller bearings
30
Lubrication Defects
35
Bearing checker
With its simple method and highly advanced features, the Bearing Checker (bearing
monitoring system) prognoses abnormalities in a bearing and monitors its operation.
Bearing Failures
36
Bearing Failures Causes
Normal fatigue
Improper mounting
Loose fits on shaft
Excessively tight fits
Misalignment
Electrical damages
Dirt
Inadequate lubrication
Vibration brinell
Bearing failures, Causes & Countermeasures
Flaking
Peeling
Spalling
Smearing
Wear
Speckles and
Discoloration
Indentations
Chipping
Cracking
Rust and Corrosion
Seizing
Fretting and Fretting
Corrosion
Electrical Pitting
Rolling Path Skewing
Damage to (Cage)
Creeping
37
Flaking
Flaking is a phenomenon when

material is removed in flakes from
a surface layer of the bearing
raceways or rolling elements due
to rolling fatigue.
This phenomenon is generally
attributed to the approaching end
of bearing service life.
life However, if
flaking occurs at early stages of
bearing service life, it is necessary
to determine causes and adopt
countermeasures.
Pitting ( )
Pitting is another type of

failure caused by rolling
fatigue, in which minute
holes of approx.0.1 mm in
depth are generated on
the raceway surface.
38
Flaking
Deep groove ball bearing

Inner ring, outer ring, and balls
are flaked.
The cause is excessive load.
Outer ring of angular contact ball
bearing
Making of raceway surface
spacing equal to distances
between balls.
The cause is improper handling.
Flaking
Inner ring of deep groove ball

bearing
Flaking on one side of the
raceway surface
The cause is an excessive axial
load.
Inner ring of spherical roller
bearing.
Flaking only on one side of the
raceway surface.
The cause is an excessive axial
load.
39
Flaking
Tapered roller bearing

Flaking on 1/4 circumference of
inner ring raceway with outer ring
and rollers discolored light brown.
The cause is excessive pre-load.
Outer ring of double row angular
contact ball bearing.
Flaking on 1/4 circumference of
outer ring raceway.
The cause is poor installation.
Flaking
Thrust ball bearing

Flaking on inner ring raceway
(bearing ring fastened to shaft)
and balls.
The cause is poor lubrication
Outer ring raceway of double row
tapered roller bearing (RCT
bearing)
Flaking originated from electric
pitting on the raceway surface
40
Cracking, Chipping /
Cylindrical roller bearing

Chipping of guide ribs of inner
and outer rings
The cause is excessive impact
load
Inner ring of spherical roller
bearing
Rib chipped
The cause is excessive impact
load.
Cracking, Chipping
Inner ring of tapered roller

bearing
Chipping of cone back face rib
The cause is impact due to poor
mounting.
Inner ring of double row
tapered roller bearing
Chipping of side face
The cause is impact due to
improper handling.
41
Cracking, Chipping
Inner ring of spherical roller bearing

Split of raceway surface in the axial
direction
The cause is excessive interference fit.
Fracture of inner ring shown in the
above
Originating point is observed at the
middle of the left raceway surface.
Cracking, Chipping
Outer ring of four-row cylindrical roller

bearing
Split of raceway surface in the
circumferential direction, originated from
large flaking.
The cause is large flaking.
Outer ring of angular contact ball
bearing
Split of raceway surface in the
circumferential direction
The cause is slipping of balls due to
poor lubricant
42
Brinelling, Nicks
Brinelling is a small surface indentation generated either on the

raceway through plastic deformation at the contact point between
the raceway and rolling elements, or on the rolling surfaces from
insertion of foreign matter, when heavy load is applied while the
bearing is stationary or rotating at a low rotation speed.
Brinelling, Nicks
Rollers of spherical roller bearing

Peeling on rolling contact
surfaces
The cause is poor lubrication.
Tapered roller bearing
Development of peeling to
flaking on inner ring and rollers
43
Pear skin, Discoloration
Pear skin is a phenomenon in which minute brinell marks cover the

entire rolling surface, caused by the insertion of contaminants. This is
characterized by loss of luster and a rolling surface that is rough in
appearance. In extreme cases, this is accompanied by discoloration
due to heat generation.
Discoloration is a phenomenon in which the surface color changes
because of staining or heat generation during rotation.
Inner ring of double row tapered

roller bearing (RCT bearing)
Raceway surface is speckled
The cause is electric pitting.
Ball of deep groove ball bearing
Speckled all over
The cause is foreign objects and
poor lubrication
44
Outer ring of spherical roller

bearing
Partial oil deposition on
raceway surface
Spherical roller bearing

Discoloration of inner and
outer ring raceway surfaces
The cause is deterioration of
lubricant.
Scratch, Scuffing /
Scratches are relatively shallow marks generated by sliding contact, in

the same direction as the sliding. This is not accompanied by
apparent melting of material.
Scuffing refers to marks, the surfaces of which are partially melted
due to higher contact pressure and therefore a greater heat effect.
Generally, scuffing may be regarded as a serious case of scratches.
45
Scratch, Scuffing
A cylindrical roller with end

smearing caused by heavy axial
loading and improper
lubrication
Smearing
Smearing is a phenomenon in which clusters of minute seizures

cover the rolling contact surface. Since smearing is caused by high
temperature due to friction, the surface of the material usually
melts partially; and the smeared surfaces appear very rough in
many cases.
46
Smearing
Inner ring of cylindrical roller

bearing
Smearing on raceway surface
The cause is slippage of rollers due
to foreign objects trapped within.
Roller of same bearing as that of
the inner ring shown in Photo 1
Smearing on rolling contact
surface
The cause is slippage of rollers due
to foreign objects trapped within.
Smearing
Rollers of spherical thrust roller bearings

Smearing at middle of rolling contact
surfaces
The cause is slippage of rollers due to
foreign objects trapped within.
Inner ring of double row

tapered roller bearing (RCT
bearing)
Smearing on raceway surface.
47
Rust, Corrosion
Rust is a film of oxides, or hydroxides, or carbonates formed on a metal surface due

to chemical reaction.
Corrosion is a phenomenon in which a metal surface is eroded by acid or alkali
solutions through chemical reaction (electrochemical reaction such as chemical
combination and battery formation); resulting in oxidation or dissolution.
It often occurs when sulfur or chloride contained in the lubricant additives is
dissolved at high temperature
Rust, Corrosion
Inner ring of tapered roller bearing

Rusting on raceway surface spacing
equivalent to the distance between
rollers. The cause is water in
lubricant.
Outer ring of tapered roller bearing
Rusting on raceway surface spacing
equivalent to the distances between
rollers. The cause is water in lubricant.
Some points are corroded.
48
Rust, Corrosion
Roller of spherical roller bearing

Rust as well as corrosion on
rolling contact surface
Ingress of water
Inner ring (split type) of selfaligning roller bearing
Rust and corrosion of the raceway
surface
The cause is ingress of water.
Rust, Corrosion
Galvanic corrosion of the roller

outer race
49
Electric Pitting
When an electric current passes through a bearing

while in operation, it can generate sparks between the
raceway and rolling elements through a very thin oil
film, resulting in melting of the surface metal in this
area. This phenomenon appears to be pitting at first
sight.
Electric Pitting
Magnified (x400) pitting of

roller shown in the last photo
Nitaletchant develops a white
layer on the cross section
Explanation of magnified of the
last photo
50
Electric Pitting
Rollers of tapered roller

bearings
Electric pitting at middle
of rolling contact surfaces
bearing
Raceway surface is corrugated
by electric pitting
Wear
Normally, wear of bearing is observed on sliding contact

surfaces such as roller end faces and rib faces, cage pockets,
the guide surface of cages and cage riding lands. Wear is not
directly related to material fatigue. Wear caused by foreign
matter and corrosion can affect not only sliding surfaces but
also rolling surfaces.
51
Wear
Outer ring of cylindrical roller

bearing
Stepped wear on raceway surface
Inner ring of cyl. roller bearing
Stepped wear on full
circumference of raceway
Wear
Outer ring of double row angular

contact ball bearing (hub unit
bearing)
Wear on one side of the raceway
Retainer of cylindrical roller

bearing
Wear of pockets of machined
high tensile brass casting
retainer
52
Fretting & Electric Fretting
Fretting occurs to bearings which are subject to

vibration while in stationary condition or which are
exposed to minute vibration. It is characterized by rustcolored wear particles. Since fretting on the raceways
often appears similar to brinelling, it is sometimes
called "false brinelling"

bearing.
Corrugated fretting along full
circumference of raceway.
The cause is vibration.
bearing.
Fretting along full circumference
of raceway.
53
Outer ring of cylindrical roller

bearing
Fretting rust on outside diameter
surface
Outer ring of tapered roller

bearing
Fretting rust on the outside
diameter surface
Creeping
Creeping is a phenomenon in which bearing rings

move relative to the shaft or housing during
operation.
54
Creeping

bearing
Bore wall glazed by creep
Insufficient interference

bearing
Spalling due to creep at the
middle of bore wall
Insufficient tightening of sleeve
Creeping
Inner ring of thrust ball bearing

Spalling and friction cracking
due to creep on bore wall.
Insufficient interference

Spalling and friction cracking on
width surface due to creep crack
developed into a split reaching bore
wall.
Insufficient tightening of sleeve
55
Damage to cage
Since cages are made of low

hardness materials, external
pressure and contact with other
parts can easily produce flaws
and distortion. In some causes,
these are aggravated and
become chipping and cracks.
Large chipping and cracks are
often accompanied by
deformation, which may reduce
the accuracy of the cage itself
and may hinder the smooth
movement of rolling elements.
Damage to cage
Retainer of angular contact ball

bearing
Breakage of machined high
1tension brass casting retainer L
.The cause is poor lubrication
Retainer of spherical roller
bearing
Breakage of partitions between
pockets of pressed steel retainer
56
Damage to cage
Retainer of angular contact

Retainer of tapered roller
bearing
Breakage of pockets of pressed
steel retainer
Retainer of cylindrical roller
bearing
Breakage of partitions between
pockets of machined highhightension brass casting retainer
Seizure
A phenomenon caused by abnormal

heating in bearings
57
Seizure
Retainer of angularInner ring of double

row tapered roller bearing
SeizingSeizing-up discolors and softens inner ring
producing stepped wear at spacing equal
to distances between the rollers.
Outer ring of spherical roller
bearing
Stepped wear due to seizing up
of raceway surface.
Seizure

Large end of the raceway surface and
cone back face rib surface are seized
up.
58
Rolling element contact path on raceway surface

strays or skews, Deformation or tilt of bearing
ring due to poor accuracy of shaft or housing
Poor rigidity of shaft or housing
Deflection of shaft due to excessive clearance
Spherical roller bearing

Contacts on inner ring, outer
ring, and rollers are not even.
The cause is poor mounting.
Outer ring of tapered roller

bearings
Contact path on raceway surface
strays.
The cause is poor mounting.
59
Rollers of tapered roller bearing

of which outer ring is shown in
the last Photo
Contact marks on rolling contact
surfaces are not even.
Indentations
Inner ring (cut off piece) of self-aligning roller

bearing
Dents on one side of the raceway
The cause is trapping of solid foreign objects.
60
Indentations
Inner ring (cut off piece) of selfselfaligning roller bearing

Dents on one side of the raceway
The cause is trapping of solid
foreign objects.
Rollers of tapered roller bearings
Dents all over rolling contact
surfaces. (Temper color at two
ends.)
The cause is foreign objects
carried by lubricating oil.
Indentations

bearing
Dents on raceway surface
The cause is trapping of foreign
.objects
Rollers of spherical roller bearing
Dents on rolling contact surfaces
The cause is trapping of solid
foreign objects.
61
Spalling
.Score accompanying seizing

.Mounting score in axial direction
cycloidal-Scores on roller end face and guide rib
Scratches in spinning direction on raceway .scores
.surface and rolling contact surfaces
Spalling

bearing
Spalling on rib
The cause is excessive load.

bearing
Spalling on raceway surface and
cone back face rib
62
Spalling
Rollers of tapered roller bearing

Cycloidal spalling on the end
faces (Scuffing)
Roller of cylindrical roller bearing.

Score in axial direction on rolling
contact surface caused during
mounting.
The cause is peer mounting practice.
Bearing Mounting
and Dismantle
63
Proper Handling of Bearings
Mounting
Shrink Fits
64
Dismounting
Dismounting of Outer Rings
Dismounting of Bearings with Cyl. Bores
65
Dismounting of Large-size Bearings
Removing the drive side bearing:

connect the nipple to the oil duct in the shaft
Bearing Do and Dont
66
Do and Dont
Do
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove all outside dirt from housing before exposing bearing.

Treat a used bearing as carefully as you would a new one.
Work with clean tools in clean surroundings.
Handling with clean, dry hands or better, clean canvas gloves.
Use clean solvents and flushing oils.
lay bearings out on clean newspaper.
Protect dissembled bearings from rust and dirt.
Use clean rags to wipe bearings.
Keep bearings wrapped in oil poof paper when not in use.
Clean inside of housing before replacing bearing.
Do and Dont
Dont
1.
2.
3.
4.
5.
Don't work in dirty surroundings.

Don't use dirty, brittle or chipped tools.
Dont use wooden mailers or work on wooden bench tops.
Dont handle with dirty, moist hands.
Don't use gasoline's containing tetra-ethyl lead, as they may
be injurious to health.
6. Don't spin unclean bearings.
7. Don't spin bearings with compressed air.
8. Don't use cotton waste or dirty cloth to wipe bearings.
9. Dont expose bearings to rust or dirt.
10. Don't nick or scratch bearing surfaces.
67
WARNING
Never spin a bearing with compressed air. The force of the

compressed air may cause the rollers to be expelled with great
velocity, creating a risk of serious bodily harm.
Proper bearing maintenance and handling practices are critical.
Failure to follow installation instructions and failure to maintain
proper lubrication can result in equipment failure, creating a risk
of serious bodily harm.
If a hammer and mild steel bar are used for bearing removal,
fragments from the hammer, bar or bearing can be released with
sufficient velocity to create a risk of serious bodily harm,
including damage to your eyes.
Bearing Summary
68
Bearing Failures Causes
Normal fatigue
Improper mounting
Loose fits on shaft
Excessively tight fits
Misalignment
Electrical damages
Dirt
Inadequate lubrication
Vibration brinell
Any Question ?
Thank You
Alaa Eldin M. Ragab

AlaaEldin.Ragab@eccAlaaEldin.Ragab@ecc-eg.net
+2012 521 6673
69

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Bearing Basics

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Egyptian Cement Company

Rolling Element Bearing

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Inspection of bearings after operation

Bearing failures and countermeasures

What is a rolling bearing?

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A rolling bearing is generally composed of an inner ring, an

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Low Friction--Particularly low starting friction.

Sliding or Rolling Bearings

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Rolling bearings and sliding bearings

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Lower starting friction

Higher (except for hydrostatic

Able to tolerate impact and

Lower (fatigue life involved

More noisy, can be no

Greater in radial direction

Greater in axial direction

Lower if without lubrication

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The first known ball bearing was found

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The ball has a smaller radius

Roller and Ball Contact Area/Form

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The tolerances (housing & shaft) must be held to

Bearing Fixation an Example

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WARNING!!!!! Thermal expansion of the shaft creates thrust force,

Bearing Mounting an Example

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RECOMMENDED!!!! The thrust force is provided by a single bearing. The

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Bearing selection is usually based on a variety of factors

Why Bearings Fail?

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Only a fraction of all bearings in service actually fail. The

Why Bearings Fail?

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Of the small fraction of bearings that actually do fail,

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Check of bearings in operation

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Operating Sound of Bearing

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