SKF - Vibration Institute Brg. Failure Presentation 7-8-2010 PDF

Vibration Institute © SKF Group Slide 0
Vibration Institute
Piedmont Chapter
Symposium 2011
Presented by Tom McDermott

SKF Sr. Application Engineer
Friday May 13, 2011
® SKF is a registered trademark of SKF USA Inc.

© 2010 SKF USA Inc.
The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to
ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of use
of the information contained herein.
Discussion topics
• Bearing basics
• Bearing life expectancy
• Bearing failure statistics
• Pre-operational damage
mode causes
• Operational damage
mode causes
• Identifying loading patterns
• ISO Standard 15243
• Bearing damage analysis
• Securing evidence
• Conducting analysis

SKF bearing basics
• Purpose and functions of a bearing

• Bearing components and materials
• Types of bearing loads
• Rolling elements – ball vs. roller
• Contact angle
• Precision class
• Radial and axial clearance

Purpose of a bearing and friction
• To provide low friction rotation of

machine parts.
• To support and locate rotating
equipment.
Resistance to motion which occurs when one

object slides or rubs against another object.
If not controlled, friction will result in:
• Heat generation • Increased wear
• Increased noise • Loss of power

Roles of a bearing
• Reduce friction
• Transmit loads
• Support the shaft
• Locate the shaft

Bearing components
Outer ring
Outer ring raceway
Cage / retainer Bore surface
Inner ring
Inner ring raceway
Rolling elements OD surface

(balls)

Functions of the cage
• Minimize friction and heat

generation.
• Prevent contact between adjacent
rolling elements.
• Guide the rolling elements.
• Provide a surface for the lubricant
to adhere to.
• Retain the rolling elements when
bearings of a separable design are
mounted or dismounted.

Types of bearing loads
Radial load
Axial load
Combined
load

Point and line contact

Types of rolling elements
Spherical roller Spherical roller

Ball (symmetrical) (asymmetrical)
Cylindrical roller Taper roller
Needle roller

Types of ball bearings
Deep groove Angular contact Self-aligning

Types of roller bearings
Cylindrical Taper Spherical CARB

Load carrying capacity relative to bearing type
Load carrying capacity

is expressed as the
“basic dynamic load rating”
or “C” in catalogs

Contact angle
• The lower the contact angle, the higher the radial load capacity
• The higher the contact angle, the higher the thrust load capacity

Bearings and contact angles
As contact angle
increases, radial load
capacity decreases; and
axial load (i.e. thrust)
capacity increases.

Precision classes

Bearing internal clearances
Radial clearance
C1 < C2 < CN < C3 < C4 < C5
Axial
Note: Radial clearances are not
clearance
the same as precision classes

How does temperature affect internal clearance?
Reduced
radial Compression
clearance
Expansion

Bearing life expectancy
Based upon five assumptions :

1. The bearing is defect free.
2. The correct bearing type and size is selected for the
application.
3. Dimensions of the bearing mating parts are correct.
4. The bearing will be mounted without damage.
5. Good lubrication in the correct quantity will always be
available to the bearing.

Circle of bearing life

Why bearings fail
Four predominant 16% Poor Installation

causes of premature
bearing failure
• 90% of bearings outlive
their machinery 36% Poor Lubrication
• 9.5% of bearings will be
removed for preventative
reasons
14% Contamination
• 0.5% of bearings fail in
their application (and this
is generally preventable)
34% Fatigue

Pre-operational damage mode causes
• Damage during transportation, handling and storage.

• Incorrect shaft and housing fits.
• Defective bearing seats on shafts and in housings.
• Faulty mounting practices.
• Static misalignment.
• Passage of electric current through the bearing.

Operational damage mode causes
• Static vibration
• Operational misalignment
• Ineffective sealing
• Ineffective or inadequate lubrication
• Passage of electric current through the bearing
• Excessive loading

Identifying loading patterns: inner ring rotation
Load
Load
Zone
Load
Zone
Identifying loading patterns: outer ring rotation
Load
Load
Zone
Load
Zone

Load zone when thrust loads are excessive

Thrust load + radial load = combined loads

Internal preload & out of round housing

Out of round housing visible in outer ring

Affects of misalignment in a bearing

Misalignment in a ball and roller bearing

Bearing damage
analysis
Classifications: ISO system
• The ISO classification system is divided in six main areas

and then further divided into sub-areas.
• Going through the table, 15 categories in total can be
observed in which the damage can be classified.
• These categories will be covered, one by one, indicating
the features. A number of typical examples are shown.
• There are some other reasons for bearing damage, such
as design problems, etc. These are not classified in the
ISO standard.

Bearing damage classifications: ISO 15243

Fatigue: subsurface fatigue
1.1. Subsurface fatigue

1. Fatigue
1.2. Surface initiated fatigue
• Repeated stress changes

• Material structural
changes
• Micro-cracks under the
surface
• Crack propagation
• Flaking, spalling and
peeling

Fatigue: subsurface fatigue

1. Fatigue

Fatigue: surface initiated fatigue

1. Fatigue
• Surface distress
• Reduced lubrication
regime
• Sliding motion
• Burnishing, glazing
• Asperity micro-cracks
• Asperity micro-spalls

oil film =
0.2 micron
Hair strand
(cross section)
1 micron
50 microns
Dirt particle
10 microns


1. Fatigue



Hydrogen Embrittlement

Wear: abrasive wear
2.1. Abrasive wear

2. Wear
2.2. Adhesive wear
• Progressive removal of
material
• Ingress of dirt particles
• Accelerating process
• Dull surfaces

Wear: abrasive wear
2.1. Abrasive wear

2. Wear
2.2. Adhesive wear

Wear: abrasive wear

Wear: adhesive wear
2.1. Abrasive wear

2. Wear
2.2. Adhesive wear
• Low loads
• Accelerations
• Smearing / skidding / galling
• Material transfer / friction heat
• Tempering / re-hardening
• With stress concentrations and
cracking or flaking

Wear: adhesive wear
2.1. Abrasive wear

2. Wear
2.2. Adhesive wear

Wear: adhesive wear

Corrosion: moisture corrosion
3.1. Moisture corrosion 3.2.1. Fretting

3. Corrosion corrosion
3.2. Frictional corrosion
3.2.2. False brinelling
• Oxidation / rust
• Chemical reaction
• Corrosion pits / flaking
• Etching
(water/oil mixture)






Corrosion: frictional corrosion: fretting

• Micro-movement
between mating
surfaces
• Oxidation of asperities
• Powdery rust / loss of
material
• Occurs in fit interfaces
transmitting loads



Vibration Institute
5/13/2011 © SKF Group Slide 55 © SKF Group Slide 55
SKF Field Training Series
Corrosion: frictional corrosion: false brinelling

• Rolling element / raceway

• Micro movements / elastic
deformations
• Vibrations
• Corrosion / wear / shiny /
red depressions
• Stationary: rolling element pitch
• Rotating: parallel flutes




Electrical erosion: excessive voltage
4. Electrical 4.1. Excessive voltage

erosion 4.2. Current leakage
• High current / sparking

• Localized heating in very short Interval / melting / welding
• Craters up to 100 µm




Electrical erosion: current leakage
4.1. Excessive voltage

4. Electrical
• Low current intensity

• Shallow craters closely positioned
• Development of flutes on raceways & rollers, parallel to
rolling axis
• Dark gray discoloration


erosion
4.2. Current leakage


Plastic deformation: overload
5.1. Overload
5. Plastic 5.2. Indentation from debris
deformation
5.3. Indentation by handling
• Static or shock loads

• Plastic deformations
• Depressions in rolling
element distance
• Handling damages

5.1. Overload
deformation


Plastic deformation: indentation from debris
5.1. Overload
deformation
• Localized overloading
• Over-rolling of particles ð dents
• Soft / hardened steel / hard mineral

5.1. Overload
deformation


Plastic deformation: indentation from handling
5.1. Overload
deformation

Indentation from handling: localized overloading

Fracture: forced fracture
6.1. Forced fracture
6. Fracture 6.2. Fatigue fracture
6.3. Thermal cracking
• Stress concentration >

tensile strength
• Impact / overstressing



Fracture: fatigue fracture
• Rings and cages - Crack initiation / propagation

• Exceeding fatigue strength under bending
• Finally forced fracture

Fracture: fatigue fracture

Fracture: thermal cracking
• High sliding and / or

insufficient lubrication
• High friction heat
• Cracks at right angle
to sliding direction

Fracture: thermal cracking

Classifications: securing evidence
• Collect operating data, monitoring data

• Collect lubricant samples
• Check bearing environment
• Assess bearing in mounted condition
• Mark mounting position
• Remove, mark and bag bearing and parts
• Check bearing seats
• Lubricant condition (color, presence of water, viscosity,
consistency, distribution in the bearing, etc.)

Classifications: conducting the analysis
• Examine bearing and parts

• Record visual observations
• Record pictures of bearing and pertinent parts
• Use the failure modes to eliminate improbable causes and
determine the original cause of the failure
• Use external resources such as SKF Bearing Inspector at
@ptitudeXchange.com or SKF Bearing Installation and
Maintenance Guide #140-710
• Contact external resources for assistance, if needed
• Initiate corrective action, if desired.
• Consider SKF analysis services ($)

Available training courses
• WE201: Bearing Maintenance and Technology

• WE202: Bearing in Rotating Machinery Applications
• WE203: Lubrication in Rolling
Element Bearings
• WE204: Root Cause Bearing
Damage Analysis

Thank you!


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Vibration Institute © SKF Group Slide 0

Presented by Tom McDermott

® SKF is a registered trademark of SKF USA Inc.

Vibration Institute © SKF Group Slide 2

• Purpose and functions of a bearing

Vibration Institute © SKF Group Slide 3

• To provide low friction rotation of

Resistance to motion which occurs when one

Vibration Institute © SKF Group Slide 4

Vibration Institute © SKF Group Slide 5

Cage / retainer Bore surface

Rolling elements OD surface

Vibration Institute © SKF Group Slide 6

• Minimize friction and heat

Vibration Institute © SKF Group Slide 7

Vibration Institute © SKF Group Slide 8

Vibration Institute © SKF Group Slide 9

Spherical roller Spherical roller

Cylindrical roller Taper roller

Vibration Institute © SKF Group Slide 10

Deep groove Angular contact Self-aligning

Vibration Institute © SKF Group Slide 11

Cylindrical Taper Spherical CARB

Vibration Institute © SKF Group Slide 12

Load carrying capacity

Vibration Institute © SKF Group Slide 13

Vibration Institute © SKF Group Slide 14

Vibration Institute © SKF Group Slide 15

Vibration Institute © SKF Group Slide 16

C1 < C2 < CN < C3 < C4 < C5

Vibration Institute © SKF Group Slide 17

Vibration Institute © SKF Group Slide 18

Based upon five assumptions :

Vibration Institute © SKF Group Slide 19

Vibration Institute © SKF Group Slide 20

Four predominant 16% Poor Installation

Vibration Institute © SKF Group Slide 21

• Damage during transportation, handling and storage.

Vibration Institute © SKF Group Slide 22

Vibration Institute © SKF Group Slide 23

Vibration Institute © SKF Group Slide 25

Vibration Institute © SKF Group Slide 26

Vibration Institute © SKF Group Slide 27

Vibration Institute © SKF Group Slide 28

Vibration Institute © SKF Group Slide 29

Vibration Institute © SKF Group Slide 30

Vibration Institute © SKF Group Slide 31

• The ISO classification system is divided in six main areas

Vibration Institute © SKF Group Slide 33

Vibration Institute © SKF Group Slide 34

1.1. Subsurface fatigue

• Repeated stress changes

Vibration Institute © SKF Group Slide 35

1.1. Subsurface fatigue

Vibration Institute © SKF Group Slide 36

1.1. Subsurface fatigue

Vibration Institute © SKF Group Slide 37

Vibration Institute © SKF Group Slide 38

1.1. Subsurface fatigue

Vibration Institute © SKF Group Slide 39

Vibration Institute © SKF Group Slide 40

Vibration Institute © SKF Group Slide 41

Vibration Institute © SKF Group Slide 42