Rolling and Fluid film Bearing

Prepared by: Dr. Ibrahim El Fahham

1. Antifriction Bearing
An antifriction bearing or rolling-element bearing is a bearing which carries load by inserting round
elements between the two pieces. Relative motion of the pieces causes the round elements to roll
with little sliding.

One of the earliest and best-known rolling-

element bearings are sets of logs laid on the
ground with a large stone block on top. As the
stone is pulled, the logs roll along the ground
with little sliding friction. As each log comes
out the back, it is moved to the front where the block then rolls on to it.

A rolling-element bearing uses a shaft in a much larger hole, and ball or cylinders, called "rollers"
tightly fill the space between the shaft and hole. As the shaft turns, each roller acts as the logs in the
above example. However, since the bearing is round, the rollers never fall out from under the load.

Rolling-element bearings have the advantage of a good tradeoff between cost, size, weight, carrying
capacity, durability, accuracy, friction. Other bearing designs are often better on one specific
attribute, but worse in most other attributes. Only plain bearings have as wide use as rolling-element
bearings. Typical rolling-element bearings range in size from 10mm diameter to a few meters
diameter, and have load-carrying capacity from a few tens of grams to many thousands of tones.

A particularly common kind of rolling-element bearing is the ball bearing. The bearing has inner and
outer races and a set of balls. Each race is a ring with a groove where the balls rest. The groove is
usually shaped so the ball is a slightly loose fit in the groove. In principle, the ball contacts each race
at a single point. However, a load on an infinitely small point would cause infinitely high contact
pressure. In practice, the ball deforms (flattens) slightly where it contacts each race, much as a tire
flattens where it touches the road. The race also dents slightly where each ball presses on it. Thus, the
contact between ball and race is of finite size and has finite pressure.

Main Bearing manufacturer: FAG – SKF – TIMKEN – NTN – NSK - INA - KOYO

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1.1 History
FAG Company’s Friedrich Fischer (1849-1899) is the founder and inventor of the
ball grinding process which permitted series production of high-precision,
hardened steel balls of uniform size.
His revolutionary invention was the historical beginning of the rolling bearing
industry worldwide.

1.2 Rolling Bearing Types

1.2.1 Deep groove ball bearings
• Are used in nearly all machines, vehicles and devices
• Offer a very reasonable price-performance ratio.
• Accommodate radial and thrust loads and are suitable for high speeds.

1.2.2 Single row angular contact ball bearings

• Can accommodate radial and thrust loads.
• Single bearings can accommodate thrust loads in one direction
• They are adjusted against a second bearing to accommodate the opposite
thrust load.

1.2.3 Double row angular contact ball bearings

• Are particularly suitable for bearing arrangements requiring rigid axial
guidance. They accommodate radial loads and thrust loads in both
directions.

1.2.4 Self-aligning ball bearings

Due to their self-aligning capability, they can compensate for
misalignments, shaft deflections and housing deformations. They can
accommodate radial and thrust loads in both directions.

1.2.5 Cylindrical roller bearings

are separable. This facilitates mounting and dismounting. As floating
bearings they can compensate for axial length tolerances and thermal
expansions within the bearing. Precision cylindrical roller bearings can
accommodate high radial loads and are suitable for very high speeds.

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1.2.6 Tapered roller bearings
can accommodate very high radial and thrust loads. As they can transmit
thrust loads only in one direction, a second, symmetrically arranged
tapered roller bearing is usually needed for counter guidance.

1.2.7 Barrel roller bearings

Are particularly suitable for applications where a high radial load carrying
capacity and compensation of misalignment are required and shock-type
radial loads have to be accommodated.

1.2.8 Spherical roller bearings

Are made for heavy-duty applications, often involving vibratory stresses.
They have a very high load carrying capacity and can compensate for shaft
deflections and misalignment of bearing seats.

1.2.9 Thrust ball bearings

Are used to accommodate only thrust loads. Single direction (single row)
bearings accommodate thrust loads in one direction where double direction
bearings accommodate thrust loads in all directions.

1.2.10 Angular contact thrust ball bearings

Are precision bearings that are mainly used for machine tool applications.
They are characterized by great rigidity, low friction and suitability for
high speeds at fast changes of position

1.2.11 Cylindrical roller thrust bearings

Provide rigid bearing arrangements, which can accommodate high loads
and shock loads without problems. They can accommodate very high
axial loads in one direction.

1.2.12 Spherical roller thrust bearings

Can accommodate heavy axial loads and relatively low radial loads; they
are suitable for relatively high speeds and can compensate for
misalignments.

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1.3 Classification of Roller bearings

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1.4 Bearing Cage
The cage of rolling bearing has a very special and precision design. The cage must:
• keep the rolling elements apart
• keep the rolling elements in position to ensure even load distribution
• guide the rolling elements through the unloaded zone
• prevent the rolling elements from falling out of the bearing

Pressed cage J Pressed cage JN Machined cage M Machined cage MP Machined cage M

Pressed cage JPA Machined cage M1 Moulded cage TV Moulded cage TVP Moulded cage TVP

1.5 Bearing Clearance

The clearance defines the way which one bearing ring can
move in radial or axial direction against the other ring

1.6 Bearing Loading

The load distribution in a radial loaded cylindrical roller bearing is shown
in figure. It is clear that the load is not uniformly distributed on the balls.
This requires a very high precision in manufacturing with high hardness and
stiffness.

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1.7 Bearing Design

There are many issues in rolling-element bearing design. For example, the inner and outer races are
often complex shapes, making them difficult to manufacture. Balls and rollers, though simpler in
shape, are small; since they bend sharply where they run on the races, the bearings are prone to
fatigue. The loads within a bearing assembly are also affected by the speed of operation: rolling-
element bearings may spin over 100,000 RPM, and the principle load in such a bearing may be
centrifugal force rather than the applied load. Smaller rolling elements are lighter and thus have less
centrifugal force, but smaller elements also bend more sharply where they contact the race, causing
them to fail more rapidly from fatigue.

Rolling-element bearings often work well in non-ideal conditions. But sometimes minor problems
cause bearings to fail quickly. For example, with a stationary load, small vibrations can gradually
press out the lubricant between the races and rollers or balls. Without lubricant the bearing fails, even
though it is not rotating and thus is apparently not being used. For these sorts of reasons, much of
bearing design is about failure analysis.

1.8 Bearing Load Calculation

A 3D force analysis of shaft load must be performed in order to calculate the bearing radial load.

The axial load is always supported by only one bearing.

Radial Load at bearing B1: Radial Load at bearing B2:

Fr B1  R B1y 2  R B1z 2 Fr B2  R B 2 y 2  R B2 z 2

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1.9 Bearing Selection
To select the right bearing we must specify 4 main parameters:
- The shaft diameter which is the bearing inside diameter “d”
- The shaft speed “n”
- The bearing Basic Static Load: which is determined from the bearing axial and radial loads
- The Basic Dynamic Load: determined from the bearing axial and radial loads and bearing life

1.9.1 Basic static load rating ( Co )

Basic static load rating is defined as the static load which corresponds to a calculated contact
stress at centre of most heavily loaded rolling element face contact of 4000 : 6400 MPa .this
stress produces a total permanent deformation of rolling element and raceway = 0.0001 of the
rolling element diameter (radial load , or axial for radial Bearing )
Equivalent static load ( Po )
The radial (for radial Bearing) or axial (for thrust Bearing) which if applied would cause the
same total deformation as that which occurs under actual loading condition.
Po = Xo . Fr + Yo .Fa. Fr , Fa = Radial & Axial Load
Xo ,Yo =static Load Factors (from bearing tables).
Ex. For deep groove ball bearing:
if Fa / Fr ≤ 0.8  Xo = 1.0 & Yo= 0.0
if Fa / Fr > 0.8  Xo = 0.6 & Yo= 0.5
Basic static load ( Co )
Co = Fs . Po
Where:
Fs = static stress factor
= 1.2  1.5 for excellent condition of operating smoothness.
= 0.8  1.2 for normal condition of operating smoothness
= 0.5  0.8 for poor condition of operating smoothness

1.9.2 Basic dynamic load rating ( C )

A radial ( for radial Bearing ) or axial ( for thrust Bearing ) constant load in magnitude and
direction under which a group of identical Bearing ,with their outer ring stationary reaches a
Basic rating life ( defined below ) equal to 1000000 revolution .

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 Equivalent dynamic load ( P )
An hypothetical load constant in magnitude and direction, radial (for radial Bearing) or axial (
for thrust Bearing) which if applied the Bearing would have the same life as the actual load to
which the Bearing is subjected
P =X.V . Fr + Y .Fa.
X ,Y = dynamic load factors (from bearing tables) , V = rotation factor
= 1.0 for inner ring rotation
= 1.2 for outer ring rotation
= 1.0 for self aligning bearing
Basic dynamic load ( C )

C  K s P L10  ε
1
K s  service factor (From tables)  = 3 for ball bearings
L10 = basing rating life in million of revolution = 10/3 for roller bearings
Ks Ball roller
uniform load 1 1
light shock 1.5 1
moderate shock 2 1.3
heavy shock 2.5 1.7
extreme shock 3 2
K P
For high reliability (>90%) C  s L10  ε
1
where aD is load adjustment reliability factor
aD

1.9.3 Bearing life

The number of revolution, which the Bearing runs before the first evidence of fatigue develops in the
material of either ring, cage or rolling element.
There are two limits to lifetime or load capacity of a bearing: fatigue & pressure-induced welding.
 Fatigue is when a material breaks after it is repeatedly bent and released. Where the ball or roller
touches the race there is always some bending, and hence a risk of fatigue. Smaller balls or rollers
bend more sharply, and so tend to fatigue faster.
 Pressure-induced welding is when two metal pieces are pressed together at very high pressure and
they become one. Although balls, rollers and races may look smooth, they are microscopically
rough. Thus, there are high-pressure spots which push away the bearing lubricant. Sometimes, the
resulting metal-to-metal contact welds a tiny part of the ball or roller to the race. As the bearing
rotates, the weld is torn apart, but it may leave race welded to bearing or bearing welded to race.
ε
 C 
Basic rating life ( L10 ) L10   
 Ks P 
The number of revolution that 90% of the group will complete or exceed before the first evidence of
fatigue developed in millions of revolution.

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For fluctuating bearing loads
60 n
C   K s P  L10 h  6

n= speed in rev./min
10
if Pi is applied at ni (r.p.m) during si of the cycles
60 i m
C   K S L10 6  s i n i Pi
10 i 1

For high reliability (>90%) C  K s P  L10 / a L 

1
ε where aL is life adjustment reliability factor

1.9.4 Bearing Selection Tables

Each bearing manufacturer provides detailed catalogue for all types of bearings and tables
Ex: a deep groove ball bearing catalogue page for shaft diameters of 100 mm and 110 mm
Principal Dimensions Basic Load Ratings Limiting Speeds Weight
Bearing
d D B Cr Cor Grease Oil
Number
mm kN rev/min kg
150 50 240 398 2400 3200 3.3 24020CA

180 46 318 425 2200 3000 5.35 22220

180 46 318 425 2200 3000 5.34 22220K

100
215 73 580 735 1700 2200 13 22320

215 73 580 740 1700 2200 13.2 22320CA

215 73 580 740 1700 2200 13 22320CAK

170 45 280 453 2200 3000 4.1 23022

180 56 373 581 1900 2600 6.1 23122CA

180 56 373 58l 1900 2600 5.9 23122CAK

180 69 418 694 1700 2400 7.2 24122CA

200 53 397 546 2000 2800 7.3 22222CA

110
200 69.8 457 658 1600 2000 9.6 23222CA

200 69.8 457 658 1600 2000 9.57 23222CAK

240 80 721 901 1600 2000 17.9 22322

240 80 721 901 1600 2000 17.5 22322K

240 80 725 963 1600 2000 17.4 22322CA

d = inner diameter D = outer diameter B = bearing width

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Deep groove ball bearings 61900-2RSR (main dimensions to DIN 625-1, lip seals on both sides)

1.9.5 Bearing Numbering System

The international bearing numbering system is summarized in the following figure:

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Bearing Numbering System (Type)
Ball Bearings
 600  6400
 6000  6700
 6200  6800
 6300  6900
Angular Contact Bearing Series
 7000
 7200
 7300
Double Row Angular Contact Bearing Series
 3200  5200
 3300  5300
Double Row Self Aligning Bearing Series
 1200  2200
 1300  2300
Thrust Ball Bearing Series
 51100  51300
 51200  51400

Bearing Numbering System (Size)

The last two digits of the base bearing number indicate the diameter (size) of the bearing’s bore in
millimeters.
The first four (4) must be memorized.
 00 = 10mm  01 = 12mm  02 = 15mm  03 = 17mm
When the last two digits of the base bearing number are 04 or larger, simply multiply the double digit
number by five (5) and you have the bore size in millimeters.
i.e., 04 = 20mm, 10 = 50mm, and 24 = 120mm.

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Example 1
What is the rating life in hours of operation (L10h) for deep groove ball bearing 6208 operating at a
rotational speed of n = 650 rpm, with a radial load F of 3.2 kN?
Solution:
From formula P ＝ X.V. Fr ＋Y Fa
The dynamic equivalent radial load:
P＝F＝3.2kN
FAG 6208 has an inner diameter of 40 mm and outside diameter of 80 mm width 18 mm
Basic dynamic load rating Cr for bearing 6208 given on catalogue is 22.4 kN,
ε 3
 C   22.4 
L10   
 for a uniform loading L10    L10 = 343 million rev.
 Ks P   1  3.2 
L10h = 343 ×106 / (650 × 60) = 8795 hr

Example 2
In a particular application, the radial load acting on a bearing fixed on a 50 mm shaft is 5 kN. The
shaft is running at a speed of 1450 rpm under moderate shock loading. Select a suitable cylindrical
roller bearing when the expected life for 95% of the bearings is 8000 hr.
Solution:
The equivalent static load: Po＝F ＝5kN
Co= Fs . Po assume Fs = 2 Co = 10 kN
The equivalent dynamic load: P＝Fr＝5kN
L10 = 8000 × 1450 × 60 / 106 = 696 million rev. Ks = 1.3 aL = 0.6
C  K s P  L10 / a L  ε C  1.3  5  696/0.6  10  53.98 kN
1 3

Considering an inner diameter of 50 mm and a dynamic load capacity of 53.98 kN the selected
cylindrical roller bearing would be FAG NU2210 which has a dynamic load capacity of 58.5 kN and
Static load capacity of 42.5 kN.

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1.10 Fits and Tolerances
In the ISO system there are 27 positions provided for 18 grades of tolerances on both shaft and
holes. The most precise fits and tolerances are those specified for bearings and bearing
housing.
The fits and tolerances depend on the type of bearing, whether the inner or outer ring is
stationary or rotating and on the type of loading.

Type of Load Bearing Type Shaft Diameter Axial Displaceability / Load Fit

Point Load on Ball, Roller, and All Sizes Floating Bearings with Sliding g6 (g5)
Inner Ring
Inner Ring Needle Roller Anngular Contact Ball Bearings h6 (j6)
and Tapered
Bearings Roller Bearings with Adjusted
Inner Ring
Circumferential Ball Bearings up to 40 mm Normal Load j6 (j5)
Load on Inner up to 100 mm Low Load j6 (j5)
Ring or Indeter- Normal and High Load k6 (k5)
minate Load up to 200 mm Low Load k6 (k5
Normal and High Load m6 (m5)
over 200 mm Normal Load m6 (m5)
High Load, Shocks n6 (n5)
Roller and up to 60 mm Low Load j6 (j5)
Needle Roller Normal and High Load k6 (k5)
Bearings up to 200 mm Low Load k6 (k5)
Normal Load m6 (m5)
High Load n6 (n5)
up to 500 mm Normal Load m6 (m5)
High Load, Shocks p6
over 500 mm Normal Load n6 (p6)
High Load p6

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1.11 Bearing Mounting and Dismounting
1.11.1 Work Planning
•Study shop drawing and plan individual operations

1.11.2 The right bearing

•Compare inscription on package with data on drawing

1.11.3 Checking of Surrounding parts

All surrounding parts should be carefully checked for dimensional and form accuracy prior to
assembly. Non-observance of the tolerances for shaft and housing seat diameters, out-of-roundness
of these parts, out-of-square of abutment shoulders etc. impair bearing performance and may lead to
premature failure.

1.11.4 Inspection of Bearing Seats

Normally, the diameter is measured in
two different cross sections and several
planes.Many tools are used in measuring
inside and outside diameters.

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1.11.5 Mounting and dismounting tools
For mounting and dismounting of small and medium sized bearings with cylindrical and tapered
bore.

Double Hook Wrench Nut and Hook Wrench

Hammer and Mounting

Device Hammer and Metal Drift

Extractor Nut and Thrust Screws

Mechanical and Hydraulic Press Hydraulic Nut

1.11.6 Hammer and Mounting Device

Mounting
Small size (< 80 mm) bearings with a cylindrical bore
 Mounting done by gentle taps with a hammer, when fit is not too tight
 A soft steel mounting sleeve with a flat face is recommended
 Mounting Sleeve is to be applied at the ring which has the tighter fit

1.11.7 Extractor
Dismounting
 Small and medium sized cylindrical bored bearings
 The extractor always has to be applied to the tight - fitting ring
 Extractor with three adjustable arms
 Extractor with puller arms for split ring

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1.11.8 Mechanical and Hydraulic Press
Mounting
 All sizes of bearings with cylindrical bore
 Useful for mounting and dismounting for series
without heating
 Available in a great variety of types

Dismounting
• Space to be provided “under” bearing

1.11.9 Nut and Hook Wrench

Mounting
 For tapered bore bearings of size < 100 mm
 Mounting with adapter or withdrawal sleeve
 Mating surfaces covered with a very thin oil film
 After mounting, the radial clearance has to be measured Nut is tightened

with a hook wrench

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1.11.10 Thermal method
 For mounting of cylindrical bore bearings with tight fits
 Used when mechanical pressing is not applicable

Oil Bath Induction Coils

Heating Plate Hot Air Cabinet

Induction Heating Heating Ring

1.11.11 Induction Heating

Mounting
 For small and medium sizes
 Suitable for all bearing types
 Fast and clean
 Suitable for series mounting
 The heated parts get magnetized, but after heating, the
parts are automatically demagnetized

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1.12 Bearing Fixation:
1.12.1 Shoulder & Spacer

1.12.2 Sleeve & Cover

1.12.3 Shoulder, Sleeve & Cover

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1.12.4 Snap Ring

1.12.5 Special washer & Nut

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1.13 Lubrication
Some modern bearing assemblies require routine addition of lubricants, while others are factory
sealed, requiring no further maintenance for the life of the mechanical assembly. The lubricant is
intended to reduce friction. However, if the lubricant becomes contaminated by hard particles, such
as steel chips from the race or bearing, sand, or grit, the lubricant quickly begins to act as a grinding
compound. This greatly reduces the operating life of the bearing assembly.

The primary purpose of the lubricant is to Material and

Consequential Production
build a load-carrying film separating the Mounting Damage Faults
Faults 5% less than 1% Unsuitable Choice of
bearing components in rolling and sliding Liquid
5% Bearing
( design, size, load
Contamination carrying capacity)
contact in order to minimize friction and 5% 10%

Aged
wear. The lubricant should also protect the Solid
Lubricant
Contamination
bearing against corrosion. If required, it 20%

should also act as a sealant, and in case of Insufficient Unsuitable

Lubricant
Lubricant
20%
circulating oil lubrication, as a coolant. 15%

Why does a bearing fail?

Lubricating film
thickness 3µm

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1.14 Common Forms of Bearing Damages
• False brinelling • Lip fractures • Seizure
• Overheating • Contamination • Lubricant failure
• Outer ring fracture • Axial cracks • Corrosion
• Misalignment • Normal fatigue • Fluting
• Slippage tracks • True brinelling
• Excessive loads • Fretting

1.14.1 Lubrication Failure

Symptoms include discolored (blue/brown) raceways and
balls/rollers.
Causes
• Restricted lubricant flow
• Excessive temperatures
• Notes:
• Pure oil has a useful life of 30 years at 30°C
• The life is cut in half for each 10°C rise
• i.e. at 100°C oil has a useful life of 90 days.

1.14.2 Poort Lubricant

Causes
• insufficient lubricant supply
• operating temperature to high water penetrates

1.14.3 Overheating
Symptoms of overheating are the discoloration of the rings,
balls/rollers and cages
from gold to blue. Temperatures in excess of 400 oC.
Causes
• Heavy electrical heat loads
• Inadequate heat paths
• Insufficient cooling or lubrication
•

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1.14.4 Outer Ring Fracture
Causes
• Poor support of the ring in the
bearing housing
• Pre-load due incorrect
bearing clearance

1.14.5 Excessive Load

Symptoms are the same as normal fatigue, although
showing heavier ball wear paths,
Greater evidence of overheating, and a more widespread
and deeper spalling
Causes
• Excessive loading of the bearing

1.14.6 Normal Fatigue

Is characterized by "spalling", or a fracture of the running
surface(balls, rollers or raceways) and subsequent
removal of small, discrete particles of material.
Causes
• Bearing has remained in operation beyond ist
calculated fatigue life.

1.14.7 Normal Wear

• Under circumferential load, the track spreads over
the entire raceway circumference
• In case of point load, the track on the stationary ring
is shorter than half the raceway circumference.

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1.14.8 Misalignment
Misalignment failure can be detected on the raceway of the non-
rotating ring
by a rolling element wear path that is not parallel to the raceway
edges.
Causes
• Shaft deflection
• Misaligned housing halves or plummer block housing
• Out-of-square abutment surfaces
• Too much bearing clearance in combination with moment
load

1.14.9 Corrosion
Results from the chemical attack on bearing materials by hostile
fluids or atmospheres.
Symptoms
• Red/Brown areas on rolling elements, raceways, or cages
Causes
• Exposing bearings to corrosive
fluids or atmospheres

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1.15 Bearing and Vibration
Antifriction bearings are considered as one of the major elements in vibration analysis
of a system because:
• Bearings represent a fundamental and basic element that controls the stability and rigidity of
a dynamic system
• They may be an important source of vibrations
• This is why they are considered as a fundamental and crucial feature in a Predictive
Maintenance Program of a system.
For example Self aligned ball bearing
• - Decrease the effect of misalignment on the stability of the transmission.
• It is considered as a pivot and hence decrease the rigidity of the system.
Cylindrical roller bearing
• can not withstand the effect of misalignment of the shaft
• It is considered as a rigid fixation and hence increase the rigidity of the system
Example
The figures below give examples of envelope spectra of a ball bearing in 4 conditions

Good rolling element bearing

Bearing with misalignment of the outer race

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 Bearing with misalignment of the outer race

Wear of a rolling surface

Crack on a rolling surface

Condition Monitoring / offline

 Various analyzing methods of vibration signal
 Early detection of bearing damage and gear damage
 User is assisted by automatic diagnosis method (expert system)

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 Local data analysis: information instead of data flow
 Automatic alarm functions
 Tele service functions via Internet or wireless links
 Affordable entry level with easy expansion
 Suitable for complex machines with multiple vibration sources
 Detects bearing damage in earliest stages of development

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