Bearing Failure
Bearing Failure
(1) INTRODUCTION
P
AGE NO 1
ANALYSIS OF BEARING FAILURE
P
AGE NO 2
ANALYSIS OF BEARING FAILURE
Fig-1.1
Fig-1.2
→ EXAMPLES OF TRUE BRIINELLING CAUSES:
→ Using a hammer to install a bearing
→ Dropping a bearing
→ Pressing a bearing onto a shaft by applying force to the
Non-rotating ring
P
AGE NO 3
ANALYSIS OF BEARING FAILURE
(4) CONTAMINATION:
Contamination is one of the leading causes of
premature bearing failure. Symptoms of contamination are dents or
scratches embedded in the bearing raceways and balls/rollers,
resulting in undue bearing vibration and wear.
Fig-2
P
AGE NO 4
ANALYSIS OF BEARING FAILURE
Fig-3
Frequently seen in electric motors can be eliminated
by ceramic-coating the OD of the bearing.
P
AGE NO 5
ANALYSIS OF BEARING FAILURE
Fig-4
Wear marks are perpendicular to the line of motion,
normally well-defined, and sometimes surrounded by debris occurs
when there is small relative motion between the balls/rollers and
raceways during non rotation times.
Characterized by elliptical wear marks in the axial
direction at each position.
Fig-5
P
AGE NO 6
ANALYSIS OF BEARING FAILURE
P
AGE NO 7
ANALYSIS OF BEARING FAILURE
Fig-6.1
Fig-6.2
The balls will show a band caused by the ball riding over the
edge of the raceway. Failure mode is very similar to that of heavy interface fits. A
thrust load applied to the wrong bearing face results in a wear band
On the balls.
P
AGE NO 8
ANALYSIS OF BEARING FAILURE
→ CREEP OF METALS:
High temperature progressive deformation of a material at
constant stress is called creep. High temperature is a relative term that is
dependent on the materials being evaluated. A typical creep curve is shown
below.
Strain Stage 1
Stage 2 Stage 3
Time
Diagram 1
In a creep test a constant load is applied to a tensile specimen
maintained at a constant temperature. Strain is then measured over a period of
time. The slop of the curve, identified in the above figure, is the strain rate of the
test during stage 2 or the creep rate of the material.
Primary creep, stage1, is a period of decreasing creep rate.
Primary creep is period of primarily transient creep. During this period
deformation takes place and the resistance to creep increases until stage 2.
Secondary creep, stage 2, is a period of roughly constant creep rate. Stage 2 is
referred to as steady state creep.
Tertiary creep, stage 3, occurs when there is a reduction in
cross sectional are due to necking or effective reduction in area due to interval
void formation.
P
AGE NO 9
ANALYSIS OF BEARING FAILURE
T1
T2
Stress
T3 >T2 >T1 T3
Diagram-2
P
AGE NO 10
ANALYSIS OF BEARING FAILURE
Fig-7
Symptoms include red/brown areas on rolling elements,
raceways, or cages. Corrosion usually results in increased vibration followed by
wear, with subsequent increase in radial clearance or loss of preload.
Fig-8.1
Fig-8.2
P
AGE NO 11
ANALYSIS OF BEARING FAILURE
Fig-9
Caused by relative motion between mating parts which, in turn,
causes fretting. Fretting occurs when fine metal particles oxidize, leaving a
distinctive brown color. This normally occurs through outer ring slippage in the
housing due to improper fits outer ring slippage caused by improper housing fits.
Discoloration and scoring will appear on the outside of the outer ring.
P
AGE NO 12
ANALYSIS OF BEARING FAILURE
Fig-10.1
Fig-10.2
Symptoms include discolored blue/brown raceways and
balls/rollers. Restricted lubricant flow or excessive temperatures that degrade the
lubricants properties typically cause failures.
Lubricant failure will lead to excessive wear, overheating and
subsequent bearing failure.
P
AGE NO 13
ANALYSIS OF BEARING FAILURE
(15) OVERHEATING:
Symptoms of overheating are the discoloration of the rings,
balls/rollers and cages from gold or blue. Temperatures in excess of 400 degrees
C.
Fig-11.1
Fig-11.2
Extreme cases result in deformation of balls/rollers and rings.
Primary indications are blue/black and silver/gold discoloration, and balls/rollers
will usually be blue/black.
Fig-12
If clearance is lost in a bearing, it results in rapid temperature
rises accompanied by high torque. Continued operation can lead to rapid wear and
fatigue.
P
AGE NO 15
ANALYSIS OF BEARING FAILURE
S
Stress
N
Cycles to failure
(Diagram-3.1)
→ STRESS RATIO
The most commonly used stress ratio is R, the ratio of the
minimum stress to the maximum stress (Smin/Smax).
P
AGE NO 16
ANALYSIS OF BEARING FAILURE
Maximum stress
Minimum stress
(Diagram-3.2)
Variations in the stress ratios can significantly affect fatigue
life. The presence of a mean stress component has a substantial effect on fatigue
failure. When a tensile mean stress is added to the alternating stresses, a
component will fail at lower alternating stress then it does under a fully reversed
stress.
Fig-13
By using proper method to install the bearing we reduce it.
P
AGE NO 18
ANALYSIS OF BEARING FAILURE
P
AGE NO 19
ANALYSIS OF BEARING FAILURE
P
AGE NO 20
ANALYSIS OF BEARING FAILURE
→ BEARING SELECTION
→ Procure the correct bearing for the application. Often, the
replacement bearing is not compatible with the equipment where it is
to be installed. Depending upon the age of the equipment, advances
in bearing technologies may exist that make the OEM bearing
obsolete. Knowing the limits of the equipment and what bearing best
suit the application will save time and money.
→ determine the maximum load for the bearing. This is important both
vertically and horizontally.
→ Determine the minimum and maximum running speeds for the
bearing. Thus will help determine the correct lubricant and bearing
for the application.
→ Determine all possible environmental conditions to which the bearing
will be exposed. Very hot or cold environments often require require
varied bearing specifications.
P
AGE NO 21
ANALYSIS OF BEARING FAILURE
P
AGE NO 22
ANALYSIS OF BEARING FAILURE
→ Carefully inspect the new bearing for any obvious damage that may
have occurred during shipping, storage, or manufacture. Inspect
bearing to determine if all parts are present. Bearing have been
known to ship from the factory missing roller elements and other
parts. Also, check for factory lubricant. Lack of lubrication from
factory can cause rust.
→ Properly align bearing with shafts. Do not assume the original
bearings were properly aligned even in motors.
→ Never push or pound on bearing surfaces. Use only safe insulation
methods accepted and approved by the manufacturer.
P
AGE NO 23
ANALYSIS OF BEARING FAILURE
P
AGE NO 24
ANALYSIS OF BEARING FAILURE
P
AGE NO 25
ANALYSIS OF BEARING FAILURE
(23) CANCLUSION:
P
AGE NO 26
ANALYSIS OF BEARING FAILURE
(24) REFERANCES
P
AGE NO 27