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SMBBearings Bearing Failure Guide
SMBBearings Bearing Failure Guide
bearing failures
Welcome to the SMB Bearings guide
to understanding bearing failures
Bearing failures present a paradox: they The diagnosis element is key because
are both relatively rare and relatively the story isn’t over when a bearing fails.
common. They are rare because, Different failures leave different imprints
statistically speaking, only a small or clues that suggest their causes. In
percentage of bearings in use fail. The some cases, only expert analysis with
majority exceed their service life and if expensive equipment can uncover the
you are using high quality bearings and root of the problem, a luxury that not all
maintaining them properly, the risks are manufacturers possess.
further reduced.
Although visual inspection has its
Yet although bearing failures may be rare limitations, in many instances a good
in relative terms, the absolute number basic understanding of bearing failures
of bearing failures is still relatively can equip you with the necessary tools to
high. That’s because there are so many diagnose the problem. Even if you cannot
bearings in use that even a relatively diagnose the exact problem, there will
small percentage of failures is still a high often be clues that can help narrow down
number. the range of possible culprits.
Best regards,
Chris Johnson
Managing director of SMB Bearings
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Understanding failures
Most bearings will outlive their service life. Only one
in approximately 200 bearings will fail. However, as
research by bearing manufacturer SKF has estimated,
there are so many bearings in operation that
approximately 50 million bearings are replaced due to
failure every year.
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Monitoring and inspection
There is usually a gap or window between the onset
of damage and the failure of the bearing. This will
vary depending on the application and the quality
of the bearing. In fast moving bearings, failure could
quickly follow. In equipment that rotates more slowly,
a bearing might remain serviceable for many months
after the onset of damage.
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Heat, noise and vibration
Heat, noise and vibration are the key A more frequent regrease is a good fix for
parameters of any basic monitoring many common problems. For example,
regime. While using your own senses may if the lubricant is contaminated, then
not match up with the latest monitoring relubricating more frequently but with
equipment, it can still give some warning. smaller amounts will help purge the
Just be aware that due to the limitations lubricant of contaminants.
of the human senses, by the time these
symptoms are observable the level of Bearings are not always accessible, but
damage may already be extensive. visual checks should be performed during
routine shutdowns of equipment. The
Listen to your bearings. Bearings in good machinery should be cleaned to reduce the
condition make a soft purring noise. risk of contaminants entering the bearing.
Squeaking or grinding sounds are usually Lubricant samples can be taken. It is often
indicative of poor condition. Pay attention a good idea to keep samples of the original
to vibration. Although all machines lubricant for comparison. You can spread
vibrate, mechanical problems are usually the lubricant over a thin sheet of paper and
accompanied by increases in vibration. examine it under a light to check for signs
of contamination.
Temperature is perhaps the key variable as Having checked the lubricant, you want to
temperature increases are symptomatic of examine and clean any exposed external
so many bearing problems. surfaces. These should be cleaned with a
lint-free cloth. Look for signs of corrosion
You might notice a natural increase in or cracks. If practicable, you can rotate the
temperature after first starting a machine shaft. If there is an uneven level of friction
or when first using it after regreasing. In or resistance, this may also indicate a
most other instances though, temperature problem with the bearings.
increases should prompt further
investigation. The seals are a common culprit in many
bearing problems, so be extra vigilant
Checking the lubrication is a key part of when inspecting these for signs of wear or
this investigation. Check the seals for damage.
lubricant leaks or for signs of damage
that might have permitted the ingress Even if the seals themselves are not the
of contaminants. Relubricate according issue, they are only effective on a smooth
to schedule and ensure reservoir levels counterface. Check to make sure the latter
are correct. If you are using systems to is not damaged, worn or corroded.
automatically relubricate, make sure these
are functioning as intended.
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Fatigue
All of these checks should be performed
systematically, as part of a routine
condition monitoring exercise for all
your equipment. Be warned though that
these symptoms, although indicative of
problems, could be the result of secondary
damage. In other words, they might
Wear
tell you a problem exists, but they will
not necessarily allow you to diagnose it
correctly.
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Fatigue Wear
Stress changes can produce damage Abrasive wear refers to the progressive
at both the surface level and the sub- removal of material. Abrasive particles
surface level of the rolling elements. wear down the rotating elements over time.
Fatigue can be initiated at the Often, the metal cage is the first
subsurface level, meaning the cracks component to begin suffering the impact
begin below surface level and are not of this.
immediately visible. This will often lead
to increases in noise and vibration. Bearings will experience some light
The crack will usually work its way to wear during the initial running in-stage.
the surface over time. The bearing More severe wear is usually the result of
may remain serviceable after spalling inadequate lubrication or the presence of
has begun, but the deterioration will solid contaminants. The visible signs of this
gradually increase. form of damage are usually dull surfaces.
Fatigue can also be initiated at the The second type of wear is adhesive
surface level. This is most often a wear. Also known as smearing, this is
consequence of damage to a rolling where material is transferred from one
contact surface resulting from surface to another. The process is usually
inadequate lubrication. accompanied by friction and heat and
is uncommon under normal operating
Although the damage is at the surface conditions. It is a vicious cycle because it
level, it is often not visible to the hardens the material and thins the oil film.
naked eye but will be visible under
a microscope. Microspalls are only a
few microns in size, so the surface will
simply look dull and grey.
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Corrosion Electrical
erosion
Moisture corrosion can be caused by When electrical current passes from one
ineffective sealing arrangements. ring to another via the rolling elements,
Marine applications face environmental damage can occur. The heat damages the
conditions where the risks of this are material and the signs of this are often
high. It is also a common form of bearing visible in the form of discolouration or
failure in paper machines and in the food shallow craters where material has broken
and beverage sector. away. Sometimes, you might spot zig-zag
shaped burn marks on the raceways.
Frictional corrosion can be further broken
down into either fretting corrosion or Current leakage erosion is a similar
false brinelling. Small particles can break problem. In this instance, the craters will be
away from a bearing’s surface and when shallower during the initial stages, because
exposed to air they will oxidise quickly. the current is smaller. Over time, this
form of damage often leaves a trademark
Fretting corrosion is visible in the form of washboard pattern.
rust on the outside surface of the outer
ring or the bore part of the inner ring.
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Plastic Fracture and
deformation cracking
Shock loads, improper handling or static If concentrations of stress exceed the
overloading can all cause overload tensile strength of the material, the result
deformation. Whichever of these three is can be a forced fracture. Rough treatment
the cause, the resulting damage will look is a common cause of forced fracture. For
the same. example, someone might wrongly attempt
to mount their bearings using a hammer
If a new bearing is making noise, in addition and chisel.
to the possibility of incorrect mounting,
it might be that it was damaged in transit Fatigue fractures, in contrast, occur when
or storage. The importance of storage is the fatigue strength of the material
often underestimated, but it is critical at is exceeded under cyclic bending. The
every stage. repeated bending causes a hairline crack to
emerge.
During manufacturing, in storage and
in transit – the bearings must be stored Another process to be aware of in this
and cared for correctly to keep them category is known as thermal cracking.
protected. This is another reason for When two surfaces slide against one
working with a trusted supplier. another the frictional heat produced
can sometimes lead to cracks. These will
Deformation can also take the form of usually be at right angles to the sliding.
indentations from debris. Contaminants
can enter the bearing via the seals or
the lubricant. Even soft particles can be
problematic if they are large enough.
This reinforces the importance of clean
lubricants and careful handling.
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Frequently asked questions
What makes a
quiet bearing?
Noise in a bearing is caused by several
What are corrosion-
factors that increase vibration. Rough
or damaged balls or raceways, poor ball
resistant bearings?
or raceway roundness, contamination
As the name suggests, corrosion-resistant
inside the bearing, inadequate lubrication,
bearings can be used in applications where
incorrect shaft or housing tolerances and
corrodible materials would be unsuitable,
incorrect radial play can all contribute to
such as food processing, chemical
noise.
manufacturing, pharmaceutical production
and marine applications. Stainless steel is
the most obvious material choice for this
Will relubrication type of bearing, but ceramic bearings can
make rough bearings also be used.
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Got any more questions?
sales@smbbearings.com