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The document discusses various reasons why bearings may fail prematurely, including fatigue from normal use (34% of failures), poor lubrication (36% of failures), contamination (14% of failures), and poor installation (16% of failures). It outlines common symptoms of bearing failure like noise, vibration, increased temperature, and jamming. Finally, it lists many specific contributing factors that can lead to bearing failure symptoms, such as improper lubrication, contamination, wrong mounting/preload, and housing/shaft tolerances.
The document discusses various reasons why bearings may fail prematurely, including fatigue from normal use (34% of failures), poor lubrication (36% of failures), contamination (14% of failures), and poor installation (16% of failures). It outlines common symptoms of bearing failure like noise, vibration, increased temperature, and jamming. Finally, it lists many specific contributing factors that can lead to bearing failure symptoms, such as improper lubrication, contamination, wrong mounting/preload, and housing/shaft tolerances.
The document discusses various reasons why bearings may fail prematurely, including fatigue from normal use (34% of failures), poor lubrication (36% of failures), contamination (14% of failures), and poor installation (16% of failures). It outlines common symptoms of bearing failure like noise, vibration, increased temperature, and jamming. Finally, it lists many specific contributing factors that can lead to bearing failure symptoms, such as improper lubrication, contamination, wrong mounting/preload, and housing/shaft tolerances.
Not always due to Natural Causes How do Bearings Fail? Not always due to Natural Causes Only
of bearings fail due to Fatigue, which is the basis of life calculation.
34 % How do Bearings Fail? Poor Lubrication is the reason for
of premature bearing failures
36 % How do Bearings Fail? Contamination is the reason for
of premature bearing failures
14 % How do Bearings Fail? Poor Installation is the reason for
of premature bearing failures
16 % Design Life of Bearing Depends on 4 Assumptions Good and clean Lubrication in adequate amount will always be available to the bearing
The bearing will be mounted without damage
Dimensions of parts related to the bearings will be correct
There are no defects inherent in the bearing
How do Bearings Fail? Fatigue of Bearing Material Spalling
Produced by normal end to useful life
Improper Lubrication
Mechanical Damage
Material Defect Design Life of Bearing Definition The life of a rolling bearing is defined as the number of revolutions ( or operating hours at a given constant speed) which the bearing is capable of enduring before the first sign of fatigue (Flaking ,spalling or crack )occurs on one of its rings or rolling elements
I n the vast majority of bearing applications it is sufficient when machine operators watch out for uneven running or unusual noise in the bearing system Bearing Failures & Their Causes Bearing Failures & Their Causes Unusual operating behaviour indicating damage : Subjective damage recognition Symptoms Sources of Trouble Examples Uneven running Damaged ring or rolling elements Motor vehicles: * More and more wheel wobbling * Increased tilting clearance * Vibration of steering system Contamination Fans: * Growing vibration Excessive bearing clearance Saw Mills : * More knocks and blows on connecting rods Bearing Failures & Their Causes Unusual operating behaviour indicating damage : Subjective damage recognition Symptoms Sources of Trouble Examples Reduced working accuracy Wear due to * Contamination or * Insufficient Lubrication Lathe: * Gradual development of chatter marks on work piece
Damaged rings or rolling elements Grinders: * Weavy ground surface Change in adjustment: * Clearance or * Preload Cold Rolling Mills : * Periodic surface defects on rolled material e.g., stretcher strains or ghost lines Bearing Failures & Their Causes Unusual operating behaviour indicating damage : Subjective damage recognition Symptoms Sources of Trouble Examples Unusual Running Noise Whinning or Squealing noise Insufficient operating clearance Electric Motors Gears Rumbling or Irregular noise Excessive Clearance Damaged contact areas Contamination Unsuitable Lubricant Gradual change in running noise Change in operating clearance due to temperature Damaged running track due to contamination or fatigue Why Bearings Fail? A. Overheated bearing B. Noisy bearing C. Vibration D. Shaft is jammed E. Bearing clearance has increased F. Lubricant has metallic debris G. Unsatisfactory equipment performance
Symptoms of Failures Contributing factors of Symptoms of Bearing Failures Sr. No Causes Symptoms A B C D E F G 1 Improper Lubrication X X X X X X X 2 Contamination X X X X X X X 3 Wrong Clearence / preload X X X X X X X 4 Wrong Shaft dimension / tolerance X X X X X 5 Wrong housing tolerance X X X X X X 6 Wrong mounting of bearing / seal X X X X X X 7 Unbalance / eccentricity / loose component X X X X 8 Misalignment X X X X X 9 Overspeed X X X X X 10 Overload X X X X X 11 Vibration / Heat from external source X X X X 12 Seal Friction / Malfunction / damage X X X X X X 13 Wrong selection of bearing /cage material / seal X X X X X X 14 Improper maintenance of seal X X X X 15 Passage of electric current X X X X 16 Improper Gear Mesh X X 17 Soft foot / loose foundation bolt X X 18 Spurious / Reconditioned Bearing X X X X X X X Why Bearings Fail? Improper lubrication
Wrong type lubricant for operating condition Low oil level. Lubricant being lost through seal Excessive lubrication causing churning Oil return hole too small Oil return hole blocked. Pumping action of seal causing leakage Lubrication starvation because of incorrect amount / relubrication interval
Contributing factors of Symptoms Why Bearings Fail? Seal friction / malfunction
Contact seals are dried out Radial lip seal has excessive spring tension Rotating seals / flingers are rubbing against stationary parts Contact seals are excessively worn causing lubricant loss or permitting dirt to enter bearing Labyrinth seal not greased
Contributing factors of Symptoms Why Bearings Fail? Wrong housing / shaft size / tolerance Housing bore is out of round / undersized Housing is warped / distorted Bore surface uneven Housing bore too large Housing material too soft. Resulting pounding enlarges bore allowing outer ring to spin. Shaft diameter is out of round / oversized Shaft shoulder diameter too large, rubbing against seal / cage Shaft is bending due to incorrect shoulder dia Shaft is distorted Shaft shoulder out-of-square Contributing factors of Symptoms Why Bearings Fail? Wrong mounting / preload
Bearings are axially preloaded Both bearings are located Adapter sleeve is tightened excessively Washer prong is rubbing against bearing Incorrect mounting method hammer blow Impact of roller edge on raceway Adapter sleeve is loose shaft undersized Contributing factors of Symptoms