CHAPTER two

TYPICAL DAMAGES OF MACHINE PARTS

December, 2020/21 /

By : Yinager.T
 BEARINGS

1. SLIDING BEARINGS
 Common types of damages in sliding bearings
 Wear due to static loading
 Wear plus Fatigue by dynamic loading
 Corrosion due to aged lubricants and environment

Sliding bearing
shaft
 bearing-damage1_oil-starvation bearing-damage2_overload+heat bearing-damage3_dirt embedded

bearing-damage4_corrosion from acid bearing-damage5_bent conrod bearing-damage6_tapered journal

FACTORS AFFECTING DAMAGES OF SLIDE BEARING
 Bearing forces,
 Design of bearing, material and lubrication,
 Manufacturing accuracy,
 Assembling conditions:- misalignment causes reduced contact area
which produces fatigue,
 Service and operation conditions

Lubrication
 Mineral oil and grease are most suitable lubricants for slide bearings
2. BALL AND ROLLER BEARINGS
Most common failure is due to fatigue
Overloading and assembly problem may also damage inner and outer races
If not properly lubricated wear can also cause vibration
DEFECTS OF ROLLER BEARING
DEFECT
Bearing inner race lose on shaft
Bearing running dry
Housing bore loose on shaft
Misalignment
Damage of one or more balls/rollers
Damage of running race
Deformed separation
Radial play
CHARACTERISTICS CORRECTION
• Installing sleeve,
• metal deposition by welding
Bearing heat up • Knurling the shaft (temporary)
• Proper lubrication
• Knurling housing bore (temporary)
• Installing sleeve
Vibration and continuous • Proper assembly
knocking
Replace
TYPICAL DAMAGES OF ROLLING BEARINGS
Fatigue
Atmospheric corrosion
wear
Overheating
Inner race spinning
Inner /outer/ race fretting
Roller peeling
 ROLLING BEARING LUBRICATION

Type of lubricant Grease Oils

Temperature Low up to 120C up to 200C
Speed Low speed factor up to 300,000 mm rev/min High speed factor up to 500,000 mm rev/min
Load Low to moderate All type
Type of bearing Radial and roller All type
Housing design Relatively simple Complex
GEAR DAMAGES

When one or more teeth have broken away preventing operation or

When tooth are so badly damaged or worn out creating unacceptable
vibration and noise during operation
 TYPICAL GEAR FAILURES

Failure Characteristics Cause Remedies

Scuffing Disruption of the lubricant film Rise of Use high grade oils with
temperature for high critical temperature
contacting surfaces
Abrasive wear Dull working surfaces Contaminants in protection of oils from
the lubricant contamination
Plastic deformation Overload or over Avoid overload
stress
Tooth breakage
Fatigue
GEAR LUBRICATION AND THEIR FUCTIONS
Commonly used lubricants
Mineral oils
Grease for low speed

FUCTIONS
Lubrication
Cooling
Protection from corrosion
Maintain cleanliness
DAMAGES OF FRICTION SURFACES
Brake and friction lining
Hot spotting – uncomfortable mating
Crazing – overheating
Scoring – abrasive material embedded in the
lining material
Clutch
Dishing, buckling, material transfer,
grooving, bond failure and distortion
 SEALS

seals
Dynamic
- Placed between moving parts or narrow gaps

Static
- Placed between parts that do not move

Pseudo-static
- Placed between parts having limited relative motion

Exclusion
- Used in conjunction with dynamic seals to restrict access
of dirt
SEAL DAMAGES AND REMEDY

DAMAGES REMEDY
Aging Replace
Incompatibility with the lubricant Change lubricant or change seal material

Excessive speed Improve lubrication

hot environment Reduce environmental temperature

Wear Replace
Very high friction Use heavy duty seal
SHAFT FAILURE AND REMEDY

Failure Remedy
Wear Use proper fitting
Fatigue Avoid sharp corners, stress concentration
areas/ proper design
Misalignment Proper assembly
Accidental overload
Corrosion Avoid corrosive environment
Creep stress rapture
Metallurgical and manufacturing defects
hydrogen embrittlement Heat treatment
Measuring shaft run-out with a dial indicator Rotary shaft run-out due to wobble within bearing clearance