BEARINGS, FAILURES

CAUSES & REMEDIE

CONCEPT OF ROLLING BEARING
• Things roll better than they slide. Hence the
invention of WHEEL.

• Rolling friction is far lesser (>100 times less)

than sliding friction.

• Microscopic contacts get peeled off and not

sheared off in rolling.
ROLLING BEARING CONSTRUCTION

Outer ring raceway

Cage/
Retainer Shoulder
Inner ring / race

Inner ring raceway

Rolling element
Shoulder

Outer ring / race

Side faces

7
 BEARING DIA

Outside Bore
Diameter

7
BEARING CONSTRUCTION-2

Seal Rolling Elements Inner Ring

Outer Ring Cage Seal
BEARING CONSTRUCTION-3
Outer Ring

Cage

Inner Ring Inner Ring Raceway

Guide Ring

Rolling
Element

Side faces
W33 Lubrication
Groove and
Hole
POINT / LINE CONTACT
 PROPERTIES : BEARING
MATERIALS
• High wear resistance
• High rolling fatigue strength
• Non-metallic inclusions like O, S etc. increase fatigue
cracking
• High dimensional stability
• Heat treatable to high hardness in depth
• High corrosion resistance
• High wettability with oil
• Low coefficient of semi-dry friction
• Good heat conductivity
• Good antiseize properties
 MATERIALS-SKF BEARINGS

BEARING RINGS AND ROLLING ELEMENTS

THROUGH-HARDENING STEELS CASE-HARDENING STEELS

CARBON CHROMIUM STEEL CHROMIUM-NICKEL ALLOYED STEEL

CONTAINING APPROXIMATELY AND MANGANESE-CHROMIUM
1 % CARBON AND ALLOYED STEEL CONTAINING
1,5 % CHROMIUM APPROXIMATELY 0,15 % CARBON
 SKF BEARING MATERIALS -2

• ~SAE 52100

• C-Cr Bearing steel ( ISO 683 -17:1999)

• Ceramics like Si3N4 for ultra high

speed applications

• Stainless steels like X65Cr14

(ISO 683-17:1999)
 BEARING MATERIALS -3
• Highly alloyed steels like 80MoCrV42- 16 for
temperature > 250°C (SKF)
• Case Hardening Steel for shock loads
• DMRL analysis for Russian bearing (6-7000108B,
Central Drive B.B on Ist support assy of TV-2 engine of Mi-8
heptr)
 C~1.0%
 Cr~1.8%
 Si~0.23%
 Mn~0.33%
 steel nearly equivalent to AISI-52100

• Original Russian material is Sh Kh 15

 SPECIAL FEATURES
• Hard Surfaces
 HRC 58-65 for C-Cr bearing steel (SKF)
 DMRL analysis of Russian Bearing
- HV/5Kg : 930 (HRC : 68)
• Perfectly round and incredibly smooth
• Very high surface finish : CLA ~ 0.5 microns
• Addition of Si to improve heat resistance
dimensional stability) at 150-200°C
 Radial loads

 Axial Loads

 Combined loads
AXIAL / THRUST LOADS
Thrust load

Bearings

BAR STOOL BEARINGS

(Man’s wt. causes thrust load)
 RADIAL LOADS
Motor Tension
Radial load

Motors & Pulley Shaft Support Bearings

COMBINED LOADS

Car Wheel Bearing

 CYLINDRICAL ROLLER BRG : Radial load
only (Heavy)
 BALL BRG : Both axial & radial

 TAPERED ROLLER BRG : Radial load &

Axial load in
one direction
also
 Axial load is also called as Thrust load
 RADIAL LOAD

Cylindrical Roller Bearing

Deep groove Angular contact Self-aligning B.B
B.B B.B

Radial load Axial load Speed Accommodates

carrying capacity carrying capacity capability misalignment

Ball Bearings
 Radial Load

Axial Load
(one direction)

Tapered Roller Bearing

 Radial Load

Thrust Thrust

Double Tapered Roller Bearing

 LOAD ZONE

360°

~150°
 BEARING CLEARANCES

Radial
clearance / play

Axial
clearance / play
CLEARANCE DESIGNATIONS

•C1 - less than C2 clearance

•C2 - less than normal clearance
•CN - normal clearance
•C3 - greater than normal clearance
•C4 - greater than C3 clearance
•C5 - greater than C4 clearance
•Russian System ?

Example:
A 6210 /C3 ball bearing has 18 - 36 µm
(microns) or 0.0007” - 0.0014” radial internal
clearance
AXIAL INTERNAL CLEARANCE

Example:
A 5210 / C3 ball bearing has
33 - 54 µm or 0.0013” – 0.0021”
axial internal clearance

 25-126114P ball bearing used

in TV-3 aeroengine 2nd Support
should have 140-220 µm axial
internal clearance
 EFFECT OF TEMPERATURE
ON CLEARANCE
COLD (by 5-10°C)
Reduced
radial Compression
clearance

Expansion
WARM
 EFFECT OF FIT ON
CLEARANCE

• INTERFERENCE FIT between shaft and

bearing (inner race) reduces radial
clearance by approx 80% of the fit.
• Because the inner ring expands and the
outer ring contracts.
EFFECT OF LOOSE FIT

N = 3 000
10 hours/day
30 days = 18 000 min

Sliding motion
=0,013 x π x 3 000 x 18 000 = 2,2 x 106 mm
= 2,2 km (1.4 miles) creep
LOAD DISTRIBUTION & CLEARANCE

Less Clearance More Clearance

Pressure between rolling element and races can reach 4 lakhs PSI
 EXCESSIVE CLEARANCE

• Loading area reduces & stress increases

• Bearing rigidity reduces
• Alignment of rolling elements decreases
• Vibration increases at high speeds
• Noise increases
• Running and locating accuracy reduces
 PRELOAD
• Small amount of loading before running of brg
 Causes negative clearance
 Elastic deformation & compressive stress at
contact area
 Bearing rigidity improves
 Vibration at high speeds reduces
 Noise reduces
 Alignment of rolling elements improves
(Thrust brgs)
 Running and locating accuracy improves
EFFECT OF CLEARANCE ON
BEARING LIFE

Life

Preload Clearance

Excessive preload causes high stress and heat generation

 BEARING LIFE

• Repeated compressive stresses (rolling fatigue)

cause flaking of material of raceways and rolling
elements and hence failure.

• Basic Rating Life L10 (90% reliability) of the

bearing is the total number of revolutions in
millions which 90% of the bearings out of the lot
reach before or at which the first signs of flaking
occur under identical operating conditions.
 BEARING LIFE-2

• L10 = (C / P)n
C = Design Load {Basic dynamic rating
load (constant radial or axial load when brg is
rotating) in N that will give bearing life of 106
revs in accordance with ISO 281:1990}

P = Actual equivalent dynamic load in N

n = 3 for ball bearings

3.33 for roller bearings
 BEARING LIFE-3

• If actual load is half of the rated load, life of a ball

bearing will increase by 8 times. (Min. Load*)

• If actual load increases by 25% above the rated

load, the life of a ball bearing gets nearly halved.

• Actual service life may be reduced even further

below the calculated value because of factors
like contamination, misalignment, improper
installation or lubrication etc.

• Effect of overload is more severe on roller brg.

LIFE ADJUSTMENT FACTOR

 Higher the expected reliability, the

lesser is the bearing life.
 L5 (95% reliability) = 0.62 L10
 L3 (97% reliability) = 0.44 L10
 L1 (99% reliability) = 0.21 L10
 WHY BEARINGS FAIL!

• Study in Scandinavian countries

indicates :
 - ~1/3 brgs fail because of Poor
Lubrication
 - ~1/6 brgs fail because of
Contamination
 - ~1/3 brgs fail because of Fatigue
 - ~1/6 brgs fail because of Bad
Installation
 WHY BEARINGS FAIL!-2
In India, there is likely to be greater percentage of
failures because of :-

 Contamination
 Improper installation and lubrication

Lesser percentage of failures because of :-

 Fatigue
FAILURE MODE CLASSIFICATION-1

• As per ISO 15243:2004, there are 15 main

failure modes classified as:
 Fatigue (Repeated compressive stresses)
-Subsurface
-Surface initiated (metal to metal contact)
 Wear
-Abrasive
-Adhesive
FAILURE MODE CLASSIFICATION-2

 Corrosion
- Moisture,
- Fretting
- False Brinelling

 Electrical Erosion
-Excess voltage
- Current leakage
 FAILURE MODE CLASSIFICATION-3

• Plastic Deformation
- Overload
- Indentation from debris
- Indentation by handling
• Fracture
- Forced
- Fatigue
- Thermal Cracking
SYMPTOMS OF BEARING FAILURE

- Overheating
- Noise
- Vibration
- Obstruction of movement (RDT reduces)
- Shaft jammed
- Others ?
 FAILURES,
CAUSES & REMEDIES
– FEW EXAMPLES
CORROSION
 CORROSION
Appearance Cause Action

Grey black streaks Presence of water, Improve sealing. Use

across the raceways, corrosive substances lubricant with better
mostly coinciding with in the bearing over a rust-inhibiting
the rolling element long period of time. properties.
spacing. At a later
stage, pitting of
raceways and other
surfaces of the
bearing.
WEAR-ABRASIVE PARTICLES

Fig 19 Outer ring of a

spherical roller bearing
with raceways that have
been worn by abrasive
particles. It is easy to
feel where the dividing
lines goes between
worn and unworn
sections.
 WEAR-ABRASIVE
PARTICLES
Appearance Cause Action

Small indentations Lack of cleaning Do not unpack bearing

around the raceways before and during until just before it is to
and rolling elements. mounting operation. be mounted. Keep
Dull, worn surfaces. workshop clean and
Ineffective seals. use clean tools.
Check and possibly
improve sealing.
Lubricant
contaminated by worn Always use fresh
particles from brass clean lubricant. Wipe
cage. the grease nipples.
Filter the oil.
 WEAR-INADEQUATE LUBRICATION

Fig 20 Cylindrical roller with mirror- Fig 21 Outer ring of a spherical roller
like surface on account of lubrication bearing that has not been adequately
starvation lubricated. The raceways have a
mirror finish
 WEAR-INADEQUATE
LUBRICATION
Appearance Cause Action

Worn, frequently Lubricant has Check that the

mirror-like surfaces. gradually been used lubricant reaches the
At a later stage blue up or has lost its bearing. More
to brown lubricating frequent lubrication.
discoloration properties.
WEAR DUE TO VIBRATION
 WEAR DUE TO VIBRATION
Appearance Cause Action

Depressions in the The bearing has been Secure the bearing

raceways. These exposed to vibration during transport.
depressions are while it was Provide a vibration
rectangular in roller stationary. damping base.
bearing and circular in Where possible use
ball bearing. The ball bearing instead of
bottom of these roller bearing. Employ
depressions may be oil bath lubrication,
bright or dull and where possible.
oxidized.
 INDENTATIONS -
FOREIGN PARTICLES

Fig 31 Indentations
caused by dust in one
of the raceways of a
roller bearing-50 x
Magnification
 INDENTATIONS -
FOREIGN PARTICLES
Appearance Cause Action

Small indentations Ingress of foreign Cleanliness to be

distributed around the particles into the observed during the
raceways of both rings bearing. mounting operation.
and the rolling Uncontaminated
elements. lubricant.
Improved seals.
FRETTING CORROSION
 FRETTING CORROSION
Appearance Cause Action

Areas of rust on the Fit too loose. Proper fit and housing.
outside surface of the Shaft or housing seating
outer ring or in the bore with error of form.
of the inner ring.
Raceway path pattern
heavily marked at
corresponding positions.
SMEARING
 SMEARING
Appearance Cause Action

Scored and discolored Sliding under heavy More suitable

roller ends and flange axial loading and with lubricants.
faces inadequate lubrication.
ELECTRIC CURRENT EROSION
 ELECTRIC CURRENT EROSION

Appearance Cause Action

Dark brown or greyish Passage of electric Re-route the current to

black fluting (corrugation) current. bypass the bearing.
or crater in raceways and Use insulated bearings.
rollers. Balls have dark When welding, arrange
discoloration only. earthing to prevent
Sometime zigzag burns in current passing through
ball bearing raceways. the bearing.
Localised burns in
raceways and on rolling
elements.
• Working surfaces become dull after operation.

• ‘Path Pattern’ (dull surface) varies in

appearance according to the rotational and
loading conditions.

• By experience, we can learn to distinguish

abnormal paths from normal paths and hence
get clues to brg failure reasons.
PATH PATTERN INTPT-2

Uni-directional Radial Load

PATH PATTERN INTPT-3

Uni-directional Radial Load

PATH PATTERN INTPT-4

Uni-directional Axial Load

PATH PATTERN INTPT-5

Uni-directional Radial Load + Creeping* Outer Ring

PATH PATTERN INTPT-6

Uni-directional Radial Load + Tight Fit / Preloading

PATH PATTERN INTPT-7

Oval Compression of Outer Ring

PATH PATTERN INTPT-8

Outer Ring Misaligned

PATH PATTERN INTPT-9

Inner Ring Misaligned

PATH PATTERN INTPT-10

Combined Uni-directional Radial & Axial Loads

 LUBRICATION MODES

2018-05-30 ©SKF Slide 77 [Code]

GREASE RUN-IN
AXIAL LOCATION

"Non-located" bearings
that can move axially
 STORAGE AND REPACKING
BEARING STORAGE ROOM

BEARINGS SHOULD BE STOCKED IN A SEPARATE

STOCKING PLACE

CONDITIONS :
* CLEAN (no dust)
* DRY (Max 60 % humidity)
* DRAUGHTS TO BE AVOIDED (no windows opened)
• AWAY FROM VIBRATION
• TEMPERATURE AROUND 20 DEGREES C.
* NO TEMPERATURE FLUCTUATIONS (avoid condensation)

“AIR CONDITIONED” IN HOT & HUMID CLIMATES

“Never touch aviation bearing with hand.”
 STORAGE AND REPACKING
STORAGE IN RACKS
1. FIRST IN, FIRST OUT
* OLDEST BEARINGS ALWAYS IN FRONT AND ON THE TOP OF THE PILE

2. DO NOT PILE UP TOO HIGH

* IT DOES DAMAGE THE PACKING

3A. STOCK LARGE BEARINGS FLAT (O.D. > 420 mm)

* AT THE BOTTOM OF THE RACKS
* STOCK FLAT (not vertical)
* STOCK UNOPENED (individually packed in box)
* NUMBER READABLE (up front)

3B. MEDIUM SIZE BEARINGS

* NUMBER (designation) UP FRONT)

3C. SMALL BEARINGS

* IN DRAWERS OR BOXES (keep away from dust)
* DESIGNATION ON DRAWER (box)
 STORAGE AND REPACKING
STOCKING RECOMMENDATIONS

3 GOOD REASONS TO KEEP BEARINGS IN THE ORIGINAL PACKING :

* BEARINGS ARE CLEAN AND ARE PROTECTED WITH A RUST

INHIBITIVE OIL.

* BEARINGS ARE WRAPPED IN A SPECIAL PAPER OR PLASTIC

SHEETING FOR PROTECTION.

* BEARINGS ARE PACKED IN CARDBOARD BOXES FOR PROTECTION

REMARK :
* LARGE SIZE BEARINGS ARE INDIVIDUALLY PACKED IN WOODEN
BOXES FOR PROTECTION.
 STORAGE AND REPACKING
RENEWING ANTI-RUST (AND PACKING)
1. WASH
* WHITE SPIRIT
* CLEAN AREA
* LET DRY

2. INHIBITING OIL PROTECTION

* 40 % QUAKER 5815 BASE AND 60 % WHITE SPIRIT
* DIP AND ROTATE
* DRY 7 HOURS
* CLEAN AREA

3. PACK
* WRAP IN POLYETHYLENE COATED "VPI" PAPER
* PACK IN (CARTON) BOXES

4. IDENTITY
* INDICATE FULL BEARING NUMBER
* INDICATE BRAND !!
 VARIOUS ROLLING ELEMENTS

Spherical roller Spherical roller

Ball
(symmetrical) (asymmetrical)

Cylindrical roller
Taper roller

Needle roller