Chris Napoleon

President and Chief Engineer of Napoleon Engineering Services

 •Global Bearing Industry
50.5 Billion Dollars
Annually

•Global Bearing
Demand to increase
8.5% through 2014
Top Bearing Manufacturers:
-Europe
-Asia Pacific
-United States
 Quality/Counterfeit
issues Establish New Sources
of Credible Supply
Reduction in
performance from
current supplier Reduce Bearing
Risk Reward Costs
Inadequate
engineering support
Reduce Lead
Times/Improved
Variations in performance Production Supply
between plants from same
company
 Poll Question
Please Indicate Your Job Title:
• Supply Planning
• Research/Development
• Design/Application Engineer
• Quality Engineer
• Test Engineer
• Other
• Large bearing manufacturers are buying plants around
the world and establishing global sources.
• Available sources of US made bearings has dwindled.
• Smaller bearing manufacturers from remote regions of
the world now have access to you, creating apparent
opportunities for additional sources.
• Divergence of bearing quality
• Bearing engineering support has changed with influx of
off-shore suppliers.
• Low Risk Switch & Go is no longer true
• OEM responsibility for bearing design has increased
significantly
• Accept and acknowledge:
– Bearings are not a commodity
– Resources are required to achieve a positive outcome
• time, staff development, financial resources, management support.
• Determine possible sources who appear to meet commercial needs:
– Bearing type
– Manufacturing Capacity
– Quality Systems
– Cost
• Determine Supplier Type
– Defines contractual agreements, expectations, communication chain, test requirements
that are required.
– Distributor, Broker, Off-Shore Manufacturer, US Sales unit of foreign manufacturer,
Manufacturers Rep
• Determine Bearing Types and Sizes
• Establish plant and manufacturing line
– Qualification is ONLY for specific product and manufacturing line
• Determine available application engineering support, failure analysis and
testing capability
– It is relative to the criticality of the bearing in the application
• Understand Application Conditions – Criticality of the Application
• Quality Systems Audit – Plant or Distribution Facility
– Audit by Quality Department
• Evaluate Bearing Failure Modes and Warranty Data for existing supplier
• Perform Bearing Manufacturing Plant Audit
– Design, Material, Turning, Heat Treatment, Grinding, NDT,
Inspection, Assembly, Mark/Wash/Preserve/Package

• Develop Product Qualification Plan and Capability:

– Inspection
– Modeling
– Testing
• Lab
• Application/Field
 Poll Question
What current method of bearing sourcing do
you use? (can indicate more than one):
• Bearing Lab Testing
• Bearing Field Testing
• Bearing Inspection
• Bearing Modeling
• No Sourcing Strategy
• Testing via Lab and/or Field Test

• Results provide no explanation for why bearing

passed or failed the test
• Offers no long term benefit to future bearing
qualifications
• Provides no assignable cause for failures
• Can Increases cost and qualification time
 First Step in Product Qualification Program
o Goals:
o Design Intentions
o Manufacturing Capability
o Quality of Workmanship
o Consists of:
o Detailed Dimensional Analysis
of Internal Geometries
o Visual Inspection
o Noise Testing
o Seal Dimensional Evaluation
o Material Chemistry,
Microstructure, Grain Size,
Cleanliness, and Hardness
• RC/EP/Contact Angle
• Face offset – Preload or Endplay
• Raceway Curvature
• Deviation of True Form
• Hertzian Stress
• Surface Finish
• Roundness, Waviness, Harmonic Analysis
• Capacity
• Cage clearances and quality of workmanship
• Noise
• Seal torque and contact interference
• Grain size, retained austenite, carbide banding, cleanliness
• Roller Bearings:
– RC/Contact Angle/EP
– Raceway and Roller Contour Geometry
– Roll to Ring End Clearance
– Raceway flange angles
– Surface Finishes
– Raceways, flanges, roller OD/flanges
– Roller end/raceway flange contour
– Roundness, waviness, harmonic analysis
– Cage design-diametral clearance, axial/circumferential pocket
clearance
– Capacity calculation – Effective Length
– Grain size, retained austenite, carbide banding, cleanliness
o Understand why the baseline is effective
o Determine why suppliers perform differently
o Openly communicate design issues with bearing
manufacturer
o Control the bearing design to ensure success in the global
supply chain
o Reduce both time and cost in any future qualification
undertakings
o Enhance the technical aspect of requirement drawings
o Accurately model bearing performance characteristics
through software programs such as Romax, Shaberth, Cobra, etc.
 Raceway-Roller Stress Profile
300000

250000

200000
Stress, PSI

150000 Outer-Roller
Inner-Roller
100000

50000

0
1 2 3 4 5 6 7 8 9 10 11 12

0 AZIMUTH NORMAL FORCES (POUNDS) HZ STRESS (LB/IN**2)

0 ANGLE (DEG.) CAGE OUTER INNER OUTER INNER
.00 .000 2469.225 2465.123 210192.600 267162.100
15.00 .000 2146.634 2143.006 198798.700 253211.700
o Test Types:
o Environmental
o Dynamic
o Impact or Static Load
o Mud Slurry
o Dust Box
o Salt Spray
o Humidity

o Evaluates Seal
Effectiveness, wear
resistance and corrosion
resistance of coatings,
platings or materials
o Performed to confirm
effectiveness of
o Materials
o Product Design
o Manufacturing process
o Performed at
accelerated conditions
to reduce test time
o Adds to knowledge
database for risk
reduction
o Life Adjustment Factors (LAF)
o Load Rating Validation
o Fast Track Qualification - Temp/Torque Testing
o Weakest Link Failure Mode
o Material/Process Validation Endurance Testing
o Establish Life Adjustment Factors (LAF)
Re lia So f t W e ibull+ + 7 - w w w . Re lia So f t . co m
Probability - Weibull
99.000
Pro ba bilit y-W e ibull

F o lio 1 \Supplie r A
W e ibull-2 P
90.000 RRX SRM MED F M
F = 1 2 /S= 0
Da t a Po int s
Pro ba bilit y Line

F o lio 1 \Supplie r B
W e ibull-2 P
RRX SRM MED F M
F = 1 2 /S= 0
50.000 Da t a Po int s
Pro ba bilit y Line
U n r e lia b ilit y , F ( t )

10.000

5.000

Chris Truma n
Na po le o n Engine e ring Se rvice s
9 /1 5 /2 0 1 1
1.000 1 0 :0 5 :4 7 AM
10.000 100.000 1000.000 1 0 0 0 0. 0 0 0
T ime, (t)
F o lio 1 \Supplie r A:
F o lio 1 \Supplie r B:
o Life adjustment Factors
o Knowing the normalized life, the OEM can now
establish bearing life enhancement or reduction
value relative to the application for the new supplier
Normalized Life
4
3
2
1
0
Theoretical Supp A Supp B
• Load Rating Validation - Bayesian Testing
• Roller Bearing Fast Track Qualification
– Temperature/Torque Testing
• 28 hour test for determining product acceptability based on
break-in and stabilized operating temperature and bearing
torque.
o Weakest Link Failure Mode
o Dynamic testing can highlight design or
manufacturing deficiencies that can result in
surface or subsurface initiated failures. It also
provides validation of knowledge gained through
inspection process.
o High Operating Temps
o Cage Issues
o Surface Finish Issues
o Poor Contact Load Profile
• Material or Process Validation Testing
– Foundation Testing of Manufacturing Lots
• Ball testing
– Material Design Change
• Cage
 Static/Impact Rig

o TRB Static axial load test

o Evaluates cone rib
strengths and undercut
design
o Impact testing
o Material choice vs. true
brinelling
o Reduce risk and qualification time
o Inspection provides a link between the baseline and the
application.
o Comparing inspection and test results link alternate supplier
performance capability to the application
o Inspection and testing performed within 4-6 month window
o Make informed decisions
o Plan provides technical information about:
o Design
o Manufacturing capability
o Workmanship quality
o OEM’s can gain more knowledge about how the product will perform
in their applications
• Acknowledge Risks & Responsibilities
• Determine Supplier Sources & Structure
• Define Bearing Types & Sizes
• Establish Production Plants Sites & Manufacturing Lines
• Evaluate Engineering Support Capability
• Define Application Conditions & Criticality of Bearing In Application
• Conduct Quality Systems Audit
• Conduct Manufacturing Audit
• Develop Capability/Resources for:
– Inspection
– Modeling
– Testing - Lab and Application
• Develop Mitigation Plan Meeting Risk, Time & Budget Constraints
The Largest Independent Bearing Testing and Inspection Facility in the United States

-Unbiased Bearing Qualification Programs Customized to Your Needs

-Over 35 Bearing Test Rigs Encompassing 100 Bearing Test Positions
-Serving Industries from Agriculture to Aerospace

-Contact: Eric Schenfield – eschenfield@nesbearings.com

-www.nesbearings.com
877-870-3200