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CERAMIC BALL BEARING

Abstract
A Ceramic Hybrid Ball Bearing is a precision bearing in which one or all of its components are made of ceramic elements from silicon nitride. Silicon nitride is a highly processed silica and ceramic material, similar to the heat absorbing, highly resilient tiles on the Space Shuttle. These tiles are used to line the heat shield of the Space Shuttle, as they protect it from the 2500 plus degrees F. extremes of reentry into the earth's atmosphere. The use of Ceramics for bearing components results in a far superior product over traditional all steel ball bearings.The execellent characteristic of the ceramic ball beraings are, Lightweight : As the density of the ceramic ball bearings is 40% lower than that of steel, which allows the centrifugal force from the rolling elements lower, thus extending the life of the bearing. Low Coefficient of Linear Expansion: In applications involving high speed operation, although the temperature of the bearing is high, this low coefficient results in lower preload and lower heat generation. Low Friction : The slip of the rolling element during operation is reduced, resulting in less heat being generated. The use of Ceramics for bearing components results in a far superior product over traditional all steel ball bearings Generation. Low Friction: The slip of the rolling element during operation is reduced, resulting in less heat being generated. The use of Ceramics for bearing components results in a far superior product overtraditional all steel ball bearings. hybrids could no longer be considered a "luxury", but a necessity. During evaluation periods, manufacturer's discovered that every single spindle tested showed vibration levels to be two to seven times lower when run with ceramic hybrids. With machine's that were using conventional steel ball bearings, tolerances were harder to maintain and tool life was shorter. Silicon Nitride ceramic balls are virtually indestructible, and survive in thermal and heavy load environments that will destroy steel balls. Advanced processing methods result in a uniform and stress free material that wont dent or rust and are virtually unbreakable. Ceramics are mirror finished and will not wear or degrade over time. Ceramic balls have demonstrated a 3 to 5 time life improvement over traditional steel designs!

Fig:1 Ceramic ball bearings

2. Ceramic Hybrid Ball Bearing

Ceramic hybrid bearings consist of a standard inner and outer race made from either AISI440C grade stainless steel or SAE52100 grade chrome steel, and balls made from ceramic usually silicon nitride (Si3N4). The races of these bearings are hardened to between 58 and 62 Rockwell C, the same as standard type ball bearings made from the same material. However, silicon nitride is even harder, equivalent to around 90 Rockwell C. Standard ball bearings dont really like vibratory applications, but ceramic hybrid bearings absolutely hate them. A standard ball bearing that has been subjected to high vibration will usually show signs of damage to balls and the cage, the weakest parts of the bearing. In a similar application, a ceramic hybrid bearing will usually develop wear and flaking of the raceways due to the repetitive pounding with a much harder object the ball. Ceramic hybrid bearings are much better suited to smooth running applications. 2

1. Introduction
Starting in 1963, Silicon Nitride was developed by NASA for Thermal Protection Systems for the space program at the University of Washington's Department of Material's, Science and Engineering. Eventually, manufacturers of various products, from the starting block of all machinery, the benefits and various use's of ball bearing, to manufacturer's of complete ceramic engine assemblies, have been slowly discovering the today's hi-tech ceramics. The machine tool industry has been a pioneer in the use of ceramic hybrid ball bearings. Many different types of hiperformance motor racing programs, like Formula 1, are also discovering the advantages to using ceramic hybrids. Ball bearing manufacturer's soon discovered that after refitting their own factory machinery with Ceramic Hybrid Ball Bearings, the increase in performance over conventional steel ball bearings was so dramatic, that the use of

4. Characteristics Of Hybrid Ceramic Ball

Hybrid ceramic ball bearing is a production gradually started, developed toward project application in recent 30 years. Although the SbN4 rolling ball and CCr15 ring have turned the steel ball into SbN4 ball, it not only reduces the centrifugal force, but also reduces the friction between rolling ball and raceway so as to get low heat and high speed performance. The specifications of ceramic ball bearing and steel bearing are listed below Fig 2: Hybrid ceramic ball bearing

3. Full Ceramic Ball Bearings

Ceramic hybrid bearings consist of a standard inner and outer race made from silicon nitride(Si3N4).

The characteristics of SI3N4 and steel Property Unit Steel SI3N4 density g/cm3 7.80 3.20 Modulus of elasticity Thermal conductivity Heat Poissons ratio Stiffness Magnetism CPa W/mk J/kgK 208 35 450 0.30 800 Y 320 3.5 800 0.26 1700 N

1) Low quality: the density is only 3.218x103kg/cm3,40% of steel ball. Especially to the high rotational speed bearing, which can inhibit the increasing roller load generated from centrifugal force and decrease contact stress ,friction ,heat ,long life. 2) High stiffness, the modulus of elasticity E=3.22 x 106N/mm2 is 1.5 times of steel bearing .So the relative elastic deformation is low and the stiffness is high. lf the ceramic is used in spindle, it will improve the stiffness of bearing and spindle system ,so does the border speed. Fig 3: Full Ceramic Ball Bearings Full Ceramic Angular Contact Bearings are designed such that there is an angle between the races and the balls when the bearing is in operation. An axial load passes in a straight line through the bearing, whereas a radial load takes an oblique path that tends to want to separate the races axially. So the angle of contact on the inner race is the same as that on the outer race. Full Ceramic Angular Contact Bearings are typically assembled with a thrust load or preload. The preload creates a contact angle between the inner race, the ball and the outer race. The preload can be done while manufacturing the bearing or it can be done when the bearing is inserted into an application. 3) The linear expansion coefficient a=3.2x 10-6 IOC, the SbN4 ceramic of heat expansion coefficient is 25% of steel bearing, which makes the deformation between ball and inner ring lower, improves the relability.and reduces the preload and move because of heat. 4) High stiffness, which comes to HVI600~1700, is 2.3 times of steel ball. This characteristic decide them owing wear Resistance, long life. 5) Wear heat, still keeping high stiffness, strength and ant-heat shock at high temperature.

6) Insulation, the crucial factors for shedding damage and increasing noise are the powder from bearing itself absorbed into the rolling ball and raceway on the condition of high magnetism. Whereas, the ceramic ball bearing can work on this condition for their wear corrosion, no magnetism, and insulation.

than, that of bearing steels. Some tests have shown life 3 to 5 times that of M-50 steel. Low Coefficient of Thermal Expansion: This property has made it difficult to mount a ceramic bearing on a steel shaft (which expands 3 times faster than ceramic). The steel shaft may crack a ceramic bearing "ring", due to the thermally induced tension stresses created in the ceramic ring. To date, the most promising use is with bearings using ceramic balls only. Mounting difficulties and manufacturing intricacies, with their associated high costs, have slowed acceptance and potential usage of the all-ceramic bearing. Hybrid bearing applications from small high-speed turbines to larger grease lubricated machine tool spindles have achieved good results and have been very successful.

5. Features
Non-Conductive: Ceramic is a natural insulator, and is beneficial where electric motor design requires a high degree of electrical insulating properties between the armature and field windings. The service life of conventional steel ball bearings in electric motors is sometimes reduced, due to pitting and corrosion caused by trace discharging, between the rings and balls. Ceramic hybrids do not suffer from this, due to their natural insulating properties. Due to their inherent longer service life, it results in a more reliable, and longer lasting product. Less Maintenance: Due to a minimum level of Adhesive Wear, bearing components and lubricants last much longer, saving you expensive service and repair time. High Hot Strength: High compressive and flexural strength over a wide temperature range. Lends itself for use to 2200 degrees F. Low Density: Specific density of 3.2 compared to 7.8 for steel. At high bearing operating speeds, the bearing balls have a centrifugal force which may exceed the external loads on the bearing. The low density of ceramics can reduce this load considerably. High Hardness: While bearing steel is in the RC 58-64 hardness range, silicon nitride has a hardness of RC 75-80 and offers excellent wear resistance. Coefficient of Friction: Silicon nitride has a coefficient of friction which is significantly lower, especially under marginal lubrication conditions. It also exhibits better resistance to scuffing and seizing than bearing steel. Corrosion Resistance: Silicon nitride is unaffected by most common corrosive agents, and is well-suited for use in hot corrosive atmospheres, or where lubricants have been known to attack conventional bearing steels. Long Fatigue Life: Recent improvements in purity and grain structure have given silicon nitride a high stress fatigue life equal to, or better

6. Micro Weld
Micro Weld occurs when microscopic surface "peaks" on the ball and race make contact and actually weld together. This occurs even with light loading and adequate lubrication. This results in higher temperatures, higher friction, and decreased life. The ceramic hybrid bearing cannot micro-weld to steel, thus eliminating the problem entirely. One of the fundamental problems with conventional steel ball bearings is their tendency to "micro-weld". This is when microscopic surface "peaks" on the ball and race make contact and actually weld together. This occurs even with light loading and adequate lubrication, because the actual point load at these "peaks" is upwards of one million PSI. As the bearing rotates, the weld is pulled apart and the cycle continues. This "weldpull" cycle (technically called adhesive wear) results in higher temperatures, higher friction, and decreased life. Adhesive wear is not some laboratory-only phenomenon, but rather a normal process for a conventional steel ball bearing, especially when lubricated by grease. The ceramic hybrid bearing cannot microweld to steel, thus eliminating the problem entirely. Friction is drastically reduced, the bearing runs cooler, and therefore lasts many times longer. And because wear particles generated by adhesive wear are not present, the bearing and lubricant stays cleaner, and lasts even longer.

7. Technical Chart
Lower operating Temperature: As running speed increases, ceramic balls run cooler than conventional steel balls. The reduced heat build-up prolongs lubricant life

Vibration

Fig 6: Vibration test Vibration test comparing spindles with steel ball bearings and the same spindle retrofit with ceramic hybrids. Vibration levels lowered than two to seven times with silicon nitride balls.

Fig 4: Lower operating Temperature

The heat generated in bearings is attributable to viscous friction from lubrication and load dependent friction between the balls and raceways. The source of the loading is external as well as internal. There is little that can be done to reduce the external loads. However, since ceramic balls have only 40% of the density of steel balls, the centrifugal load generated by the balls is less and the internal friction is lower. This provides cooler running for the same operating conditions or, if applicable, a higher rotational speed while maintaining the same temperature. Running Speed:

8. Reduction Of Friction
The reduction o f friction is one of the keys for a success full application of hybrid or full ceramic roller bearings under dry or nearly dry environmental conditions. In case of hybrid bearings diamond-like thin film coatings deposited on the raceway seem to be an appropriate method for improvement o f the performance. For full ceramics roller bearings, newly developed silicon nitride materials with self-lubricating phases promise to be the success full way. The main goals have been defined to be: a significant reduction of the friction co efficient (<< 0.6) and a load capacity o f more than 1 GPa, both under dry Conditions. Coating The optimization of diamond-like coatings (doped a C:H) deposited by a PA-CVD-process to steel raceways needs three steps: (a) optimization of the coating-substrate inter-face, (b) reduction of the friction coefficient, (c) improvement of life time.

Fig 5: running speed The running speed of a large diameter ceramic ball exceeds the same size steel ball by 40%. Converting to a small diameter ceramic ball will boost running speeds by an additional 15%. There is no high centrifugal force on the balls of bearing, due this significant reason the running speed of ceramic ball bearing increases.

Fig 7: Optimization of the adhesion of diamondlike coatings on different steel substrates by control of the residual stress states (micro-indenter 5

scratch tests, 10 m indenter tip radius)

Part Numbering System

The optimization of the coefficient of friction and the life time of coatings have to be related to the ball material (oscillating pin-on-disk sliding wear test, ball diameter = 10 mm, initial normal pressure = 1.4 GPa, frequency = 20Hz, amplitude = 1mm, dry) The results of scratch tests show that an improved control of the residual stress state o f the coating results in a significant gain of adhesion. Once the adhesion between substrate and coating is optimized, the friction coefficient and the thickness of the coating are the most relevant characteristics determining the performance of the hybrid bearing. An important detail in the subsequent optimization of the coating techniques is the configuration of the standard pin-on platetest with the relevant pin material.

Ceramic hybrid ball bearings are stocked in an open version in the sizes listed. In most cases, hybrid bearings can also be supplied with seals, shields, or low friction seals through the MRC Made-to-Order (MTO) program. In addition to those listed, other sizes of the 200S and 300S series as well as the 100KS series can be supplied through the MTO program. Most series of angular contact ball bearings can also be supplied through MTO.

9. Dimensions Of Ceramic Ball Bearing

10. Advantages Of Ceramic Ball Bearing

Lower Maintenance Costs: Maintenance costs can quickly add up if a bearing must be changed frequently. Anything that extends the service life of a bearing without increasing maintenance costs will reduce the operating cost of the equipment. Though the initial cost of a hybrid bearing is higher than a standard steel bearing, the difference is quickly recovered in maintenance savings. Less friction also results in lower energy costs. Extended Service Life: Most bearings are designed into applications based on loading conditions and do not take into account factors such as lubrication, contamination and maintenance. Without proper attention to these external factors, a steel bearing rarely reaches its design L10 life and therefore has a shortened service life. Because of the properties of ceramics, the service life of a hybrid bearing is up to 10 times that of a standard steel bearing. And longer service life reduces the need for maintenance on your machine as well as the costly interruptions in production.

Fig 8: Dimension

 Prevents Electrical Arcing: When electrical current passes across bearings, a washboard or fluting pattern appears on the raceways, in addition to a darkened grey appearance. This damage usually results in excessive noise which requires that the bearing be removed. Besides the surface damage, premature aging of the lubricant also occurs. The natural insulating properties of ceramic material eliminate this type of damage. Extended Grease Life: In environments that place high demands on the bearing lubricant, standard bearings experience surface wear because of insufficient lubricant film. Bearings can fail if the initial grease charge is not replenished within an acceptable period of time. Hybrid bearings run cooler and can operate with thinner lubricant films, so there is less aging of the grease and the required re-lubrication interval will be longer. The result is increased service life compared to standard bearings in the same operating conditions. Reduced Wear from Vibration: In equipment exposed to static vibration, there is an inherent risk of false brinelling, (the wearing away of the surfaces within the ball and raceway contacts) which can eventually lead to spalling and premature failure. Because of the lighter weight ceramic balls and dissimilar materials, the risk of false brinelling damage is much less. Lower operating Temperature: The heat generated in bearings is attributable to viscous friction from lubrication and load dependent friction between the balls and raceways. The source of the loading is external as well as internal. There is little that can be done to reduce the external loads. However, since ceramic balls have only 40% of the density of steel balls, the centrifugal load generated by the balls is less and the internal friction is lower. This provides cooler running for the same operating conditions or, if applicable, a higher rotational speed while maintaining the same temperature. Reduced Wear from Contamination: In contaminated environments, solid particles create dents in the rolling surfaces and raised edges around those dents. This condition causes noise and premature wear as the steel balls roll over those surfaces. The harder ceramic ball material smooths the surface roughness with no material removal. Also, there is little evidence of adhesive wear as seen in steel bearings. This reduces the noise and wear, which extends the bearing service life.

11. Limitations Of Ceramic Ball Bearing

In some applications, we can see that the properties of the hybrid ceramic bearing would lead to an increased life compared to an all-steel bearing. However, this is not true of all cases. In normal-speed applications where true fatigue spalling of a raceway tends to be the failure mode, the hybrid ceramic design would not be expected to increase bearing life rather, a significant decrease in the life would be expected. (The higher stiffness of the ceramic balls reduces the size of the ball/raceway contact patch under load, thus raising the contact stress compared to the all-steel design.) Therefore, potential applications for hybrid bearings need to be carefully weighed on a caseby-case basis. Ceramic ball bearings have significant drawbacks and limitations. Like all ceramics, the silicon-nitride balls have a low tensile strength, which is a fundamental material property.

12. Applications
Motor Racing: All racing programs will benefit from the use of Ceramic Hybrids. Since people race anything from multi-million dollar Formula 1 cars, to John Deere lawn tractors, some of the programs that will see significant gains are; Go kart Formula 1 racing car MotoGP bikes Industry: Great advantages are achieved with machine tool applications like; Grinding Milling Drilling Boring Aircraft accessories/Aerospace: Turbo engines Gear box Radar Weapon systems Satellites Industrial machinery: Robotics Generators Electric motors Food processing equipment Heavy equipments

Medical equipments: Dental drills Centrifuges X-Ray tubes 7

13. Future Work

25% of all electrical energy produced is used to power some type of electric motor. Imagine the savings in resources if all motors were to run with ceramic hybrid ball bearings. Researchers are held to implement ceramic ball bearings in normal bikes and cars also in cycles. And also in industry to implement in low speed spindle.

[7] W.Pfei ffer, M. Rombach: Residual stresses and d amage inceramics due to contact loading. Proc. of the Fifth Int. Conf. on Resid. Stresses, Linkping Univ., Sweden, 2004, 1, 302-307 [8] www.bearingworks.com [9] www.cbrbearing.com [10] www.bearinghina.com

14. Conclusion
The stiffness of ceramic ball bearing is advantageous to steel ball bearing at the same working condition. Within the rotational speed, the larger preload is good to control heat and vibration. Compared to the steel bearing, the ceramic bearing is more suitable to electric spindle demand. We have studied dynamic characteristics of ceramic ball bearing and steel ball bearing, and also shown the properties of ceramic ball bearing. The paper also represents the technical charts based on studies like, vibrations, service life, speed.

15. References
[1] Wemhoner 1. Ceramics-A milestone on the way to the high-per-formance rolling bearing[l] CFI Ceramic Forum International, 2002, 79(4):2 1 - 24. [2] Cento P,Dareing D W. Ceramic materials in hybrid ball bearings[l]Tribology Transaction s,1999 ,42(4) 707 - 714. [3] Xu hao , Xu ying , Analys is on the dynamic characteristics of high speed machine tool with ceramic ball bearing , Feb. 2 , 28-29, 2005. [4] ZHOU Gui2xin, Development Status of Ceramic Bearings at Home and Abroad [1] Ceramic Research & Vocational Education No.4, 2003.T. [5] Hollstein, M. Rombach, W. Pfei ffer, M. Popp: Vollkeramische Wl zlager aus Siliciumnitrid: Anwendung, Auslegung und Optimierung. VDI Bericht e 2008, 1151, 3- 11. [6] M. Rombach: Experimental and theoretical investigations on plastic deformation and brittle cracking in a ball-on -plate cont act of ceramic m aterials. In Ceramics Charting the Future (Edit. P. Vincenzini, Techna Srl) 2006, 1055-1064.