SIS Oo New Bearine Doctor Diagnosis of bearing problems. Objective: Smooth & reliable operation.On the occasion of the “New Bearing Doctor” pamphlet being published, we would like to express our sincere thanks for your continuous patronage of NSK products. This pamphlet contains explanations about correct bearing handling, mount- ing, lubrication, and maintenance to pre- vent premature failure together with color photos of bearing failures. Please be ‘sure to consult the NSK Rolling Bearing Catalog (CAT.No.E1101a)for more details regarding handling, maintenance, etc. Bearings become unserviceable when they suffer premature failure which is due to a lack of attention to proper han- dling and/or maintenance. Premature failure is completely different from flaking (life) due to rolling fatigue. This pamphlet is useful in determining causes of and countermeasures against premature failure. It’s our pleasure to offer you this pamphlet.Index of “‘New Bearing Doctor’ Topic 1. Introduction. 2. Bearing Handiing....... 2:1 Protautons for Handing 2.2 Mounting ....... 2.8 Check the Operation 3, Bearing Maintenance. 4, Bearing Performance Factors 4.1 Bearing Noise.... 4.2 Bearing Vibration 4.3 Bearing Temperature 4.4 Effects of Lubrication 4.5 Selection of Lubrication 4.6 Replenishment and Replacement of Lubricant... 5. Bearing Inspection 6. Running Traces and Applied Loads Page oo sea 7. Bearing Damage and Countermeasures. 7.1 Faking i 7.2 Peeling 73 Scoring 7.4 Smearing .. 7.5 Fracture 76 Cracks 7.7 Cage Damage. 78 Denting.... 79 Pitting 7.10 Wear...... 7.11 Fretting « 7:42 False Brineling . 7.13 Creep 7.14 Seizure . 7,45 Electrical Corrosion 7.16 Rust and Corrosion ......... 7.17 Mounting Flaws. 7.18 Discoloration Appendix: Bearing Diagnostic Chart 9 10 12 13 15 17 18 20 22 23 24 25 26 27 28 29 30 31 1. 82 . 331. Introduction When a rolling bearing is damaged during machine operation, the entire machine or equipment may seize or malfunction. Since bearings that fail prematurely or unexpectedly cause trouble, it is important to be able to iden- tify and predict failure beforehand, if possible, so that preventive measures can be adopted. Generally, bearing inspection or housing in- spection can identify the cause of the problem. Often the cause is attributable to poor lubrica- tion, improper handling, selecting the wrong bearing, or not enough study of the shaft and housing. Usually the cause can be determined by considering operation of the bearing before the failure, investigating the lubrication condi- tions and the mounting condition, and carefully observing the damaged bearing itself. Sometimes bearings are damaged and fail both quickly and unexpectedly. Such prema- ture failure is different from fatigue failure which is due to flaking. Bearing life can be separated and categorized into two types: premature failure and normal rolling contact fatigue. 2. Bearing Handling = 2.4 Precautions for Handling ‘Since rolling bearings are high precision machine parts, they must be handled carefully. Even if high quality bearings are used, their expected life and performance cannot be at ‘tained if they are used improperly. The main precautions to be observed are as folows: (1) Keep the Bearings and Surrounding Area Clean: Dust and dit, even if invisible to the naked eye, have harmful ef- fects on bearings. It is necessary to prevent the entry of dust ‘and dir by keeping the bearings and their environment as ‘lean as possible. (@) Careful Handling: Heavy shocks during handling may scratch or cause other damage to the bearing possibly result- ing in bearing failure. Strong impacts may cause brineling, breaking, or cracking. {@) Use Proper Tools: Always use the proper tool when han- dling bearings and avoid general purpose tools. (@) Prevent Corrosion: Since perspiration on the hands and various other contaminants may cause corrosion, keep yout hands clean when handling bearings. Wear gloves it possible. 3 NSK 2.2 Mounting itis advisable to study the bearing mounting thoroughly since the quality ofthe bearing mounting influences the bear ing's running accuracy, life, and performance. It is recom: ‘mended thal the mounting method inctude the folowing steps. (Q) Clean the bearing and surrounding parts. {@)Check the dimensions and finish conditions of related parts {@) Follow mounting procedure. {@) Check i the bearing is mounted correctly {6) Supply with correct kind and quantity of lubricant Since most bearings rotate with the shatt, the bearing mount ing methed is generally an interference (tight fit forthe inner ring and shaft while giving a clearance (oose) it for the outer ring and housing 2.3 Check the Operation ‘After mounting the bearing, itis important to carry out an ‘operating test to confirm that the bearing is mounted properiy. Table 2.1 indicates operating test methods. If irregularities are detected, immeciately suspend the test and consult Table 2.2 Which lists appropriate countermeasures to specific bearing problems.Table 2.1 Methods to check operation ‘Manual operation. Turn the bearing by hand. it no problems are detected, then proceed to operate the ‘machine ‘Stickslip (Debris, cracks, dents). ‘Uneven rotating torque (Faulty mounting) Excessive torque (Error in mounting oF neuficiont ‘ackal internal clearance), Poner operation. intial start at alow speed and without a load. Gradualy increase speed and load to reach rating. ‘Check for irregular noise. Check for bearing temperature rise. Lubricant leakage. Discoloration, fale operation. Tum ON power and allow machine to rotate slowly. Turn OFF the power and allow the Beering to coast toa stop. If no iregularties are detected by the test, then proceed tothe loaded rotation testing Vibration Noise, et. Power operation. Folow the same power operation testing as used for small machine testing. Flow the same checkpoints asthe smi machine test. ‘Table 2.2 Causes and countermeasures for operating iregularities ‘Abnormal load Improve the ft, Internal clearance, preload, position of housing shoulder, et. Incortect mounting Improve the machining accuracy and algnment of shaft and housing, accuracy of mounting method. Insufficient or improper lubricant Replenish the lubricant or select another lubricant. ‘Contact of rotating parts Modify the labyrinth sea, ete. Five, cosinor armies on | Replace o cen the aang, row the eased us dean Brineling Replace the bearing and use care when handling bearings. Faking on racoway Roplace the bearing. Excessive clearance Improve the ft, clearance and preload, Penetration of foreign particles Replace or clean the bearing, improve the seals, and use clean | lubvican. Flaws o flaking on balls Replace the bearing. Excessive amount of lubricant Reduce emount of lubricant, select stifer grease. Insufficient or improper lubricant Replenish lubricant or select a beter one. ‘Abnormal load Improve the fit, internal clearance, preload, position of housing shoulder. Incorrect mounting Improve the machining accuracy and alignment of shaft and housing, accuracy of mounting, oF mounting method Creep on fied surface, excessive Correct the seals, replace the beating, correct the fiting or seal fetion mounting. ‘rinsing Replace the bearing and use care when hancling bearings. Fisking Replace the bearing. Incorrect mounting Penetration of foreign panicles Correct the squareness between the shaft and housing shoulder or side of spacer. Replace or clean the bearing, improve the seals. “Too much lubricant, Penetration by foreign matter or abrasion chips. Reduce the amount of iubricant, select stir grease. Replace the bearing or lubricant. Clean the housing and adiacent pars.3. Bearing Maintenance Its necessary to periodically inspect and maintain the bear- ing and its operating conditions in order to maximize the bear ing life. In general, the following method is adopted. (1) Inspection under operating conditions ‘To. determine the bearing replacement periods and replenishment intervals for lubricant, investigate the lubricant properties and consider factors such as operating tempera ture, vibration, and bearing noise. (Refer to Section 4 for more dotails) 4. Bearing Performance Factors Key bearing performance factors during operation are bear- ing noise, vibration, temperature, and lubricant state. Please reler to Table 2.2 if any operation irregularities are detected. 4.1 Bearing Noise During operation, sound detection instruments (stetho- scope, NSK Bearing Monitor, etc) can be used to investigate the volume and characteristics of the bearing rotaion nots. itis possible to distinguish bearing damage such as small lake ing by means of ts unusual yet characteristic noise. 4.2 Bearing Vibration Baring irregularities can be analyzed by measuring the vibrations of an operating machine. A ftequency spectrum analyzer is used io measure the magnitude of vibration and the distribution ofthe frequencies. Test results enable the de- termination ofthe likely cause ofthe Dearing reguiarty. The measured data varies depending on the operating conditions ‘ofthe bearing and the location ofthe vibration pick-up. There- fore, the method requires the determination of evaluation stn dards for each measured machine. itis useful to be able to detect irregularities from the bearing vibration pattern during operation. Please refor to tho NSK pamphlet Pr. No. 410 (Bearing Monitor) for more information about such a device. 4,3 Bearing Temperature ‘Generally, the bearing temperature can be estimated from the temperature ofthe housing outside surface, but a prefera- bile way isto obtain direct measurements trom the bearing out- er ring by a probe going through an oil hol. Usually, the bearing temperature gradually increases after tne stat of operation until reaching a steady state condition about 1 of 2 hours later. The bearing steady state temperature depends on load, rotational speed and heat transfer properties of the machine. insufcient lubrication or improper mounting ‘might cause the bearing temperature to rise rapidly. In such a case, suspend the machine operation and adopt an ap- Propriate countermeasure. 4.4 Effects of Lubrication The two main purposes of lubrication are to minimize tric- tion and reduce wear inside bearings that might otherwise fail prematurely. Lubrication provides the following advantages: (1) Reduction of Friction and Wear ‘Direct metalic contact between the bearing rings, rolling elements and cage, which are the basic components of a bearing, is prevented by an oil film which reduces the fiction 5 NSK @) Inspection of the bearing ‘Bo sure to investigate the bearing thoroughly during times of periodic machine ingpection and part replacement. Check the raceway condition. Determine if damage exists. Confirm if the bearing can be reused or should be repiaced. (Reter to ‘Section 5 for more details.) and wear in the contact areas, (@ Extension of Fatigue Life The roling fatigue life of bearings depends greatly upon the viscosity and film thickness between the rolling contact sur- faces. A heavy flm thickness proiongs the fatigue life, but it is shortened ifthe viscosity of the oli to0 low so that the fm thickness is insufficient, @ Dissipation of Frictional Heat and Cooling Circulation lubrication may be used to carry away either fic- tional heat or heat transferred from the outside to prevent the bearing from overheating and the oil from deteriorating (@) Sealing and Rust Prevention ‘Adequate lubrication also helps to prevent foreign material from entering the bearings and guards against corrosion or rusting 4.5 Selection of Lubrication Bearing lubrication methods are divided into two main catagories: grease lubrication and oll lubrication. A lubrication ‘method is adopted that matches the application conditons and application purpose in order to attain best performance from the bearing. Table 4.1 shows a comparison between grease and oll lubrication. Table 4.1 Comparison between grease and oll lubrication Tem | Grease lubrication | _Oll ubrieation Housing | Simple May be complex, sucture and Careful maintenance seal method required. Speed Limiting spoed is | High limiting speed 6594 ~ 8086 of that with lubriation Cooling effect | Poor Heat transfer ls possible using forced ol keulation Fhidiy Poor Good Lubricant | Sometimes aiticut | Easy replacement Romoval of | Removal of parties | Easy foreign from grease is ‘material impossible External | Surroundings seldom) Otten leaks if proper ‘contamination | contaminated by | countermeasures are due to leakage] leakage rot taken. Not sulable if external contamination must be avoided,(1) Grease lubrication ‘Grease is a lubricant that is made from base oll, thickener, ‘and additves. When selecting a grease, it is necessary 10 ‘selact a grease that is suitable to the bearing application con- ditions. There are large differences in performance even be tween different brands of the same type of grease. Therefore ‘special attention must be given to grease selection. Table 4.2 ‘glvas examples of applications and grease consistency. {@) Oil lubrication “There are several diferent of lubrication methods: Oi bath, Drip feed, Splash, Circulating, Jet, Oil mist, and Oil air. Oi lubrication methods are more suitable for higher speed and higher temperature applications than are grease lubrication ‘methods. Oil lubrication is especially effective in the case winre it is necessary to cissipate heat to the exterior. Be sure to select a lubricating ol that has suitable viscosity at the bearing operating temperature. Generally, an ol wth & low viscosity is used for high speed application while an oll with high viscosity is used for applications wih heavy loads For normal application conditions, Table 43 lists the suitable viseosiy range for the operating temperature. For reference when making a selection, Fig. 41 shows the ‘elationship between temperature and. viscosity for the lubricating ol. Table 4.4 gives examples of how to select the lubrication ol for different bearing application conditions. ‘Table 4.2 Examples of applications and grease consistency Table 4.3 Required viscosity by bearing type ] Viscosty at operating Beating tye ea waceia tal bearings, a Cylindrical roller bearings Oe Pe ‘Tapered roller bearings, Spherical rollor boarings ‘Spherical thrust roller bearings 20 mmils or more 32 mmils or more Remarks: 1 me 1 eSt (Cont Stokes) ; i ees segeei Fig. 4.1 Relation between cil viscosity and temperature Consistency number 0 A 2 eB i Consistency (W710 mm) | __355~385 310-340 265=295 220250 175~205 ‘Application ‘Cenival grease | Central grease | General grease | General grease, | High temperature ‘supply suppy, High temperature Low temperature ‘Where freting | Where freting | Sealed ball bearings| Sealed ball bearings| Where grease cours easily occurs easly sed 2s a seal Table 4.4 Selection of lubricating oils for diferent bearing applications Operating 5 crema Speed Light oF normal load Heavy or shock load =30=0°6 _| Below liming speed 180 VG 15, 22, 52 (Retigerator ol) = ‘Bolow 5036 of limiting speed 1SO VG 82, 46, 68 (Bearing al, | 1SO VG 46, 68, 100 (Bearing oil, Turbine oil Turbine ol 050° | Between 503% and 100%6 of limiting | 150 VG 15, 22, $2 (Bearing ol, | ISO VG 22, 32, 46 (Bearing al, speed Turbine ol Turbine oi ‘Above limiting speed 150 VG 10, 15, 22 (Bearing ol) = iow 5036 of limiting speed TSO VG 100, 160, 220 (Boaring ai_| 1SO VG 150, 200, 300 (Bearing ol) Between 50% and 100% of imting | 1SO VG 46, 68, 100 150 VG 68, 100, 150 s0-80°C | speed (Beecing oi, Tubine oil (Bearing oil, Tubine oi) ‘Above limiing speed TSO VG &2, 46, 68 = (Beacing oi, Turbine oi) Boiow 5036 of limiting speed 150 VG $20, 460 (Bearing ol 180 VG 480, 680 (Goaring oi, Gear oi) 0-t102¢ | Between 603% and 100% of imiting | 180 VG 150, 220 (Bearing ol) 180 VG 220, 320 (Bearing oi) speed ‘Above limiting speed 180 VG 68, 100 (Gearing ol, Tubine oi = Notes: 1. As forthe Emitngepeed, use the vale led uncer ubieation inthe Bearing Dimension Tales of “NK Roling Beatings” (No. E140). 2. Retort rolrgarator al (18 K2211), Bearing of IS K2230),Turbna oh IS H2219), Temperature rangos a@ shown nthe let clum Inthe tbl above. For opaaing temperature tala onthe high temperature side ‘scot Lrcaton lf rocormmended, is 2209),4.6 Replenishment and Replacement of Lubricant (1) Replenishing Interval Even if high-quality grease is used, there is deterioration of its properties with time; therefore, periodic replenishment is required. Figs.4.2 (1) and (2) show the replenishment time intervals for various bearing types running at citferent speeds. Figs.4.2 (1) and (2) apply for the condition of high-quality lithium soap-mineral oil grease, bearing temperature of 70°C, and normal load (P/C=0.1). + Temperature It the bearing temperature exceeds 70°C, the replenish- iment time interval must be reduced by half for every 15°C temperature rise of the bearings. + Grease In case of ball bearings especially, the replenishing time interval can be extended depending on used grease type (For example, high-quality lithium soap-synthetc oll grease may extend about two times of replenishing time interval shown in Fig.4.2 (1). If the temperature of the bearings is adil ba baring rfactor Searng 4: Boating bore darter Bearing ftaonal peed, (1) Radial ball beeing and evades cole bearing less than 70°C, the usage of lithium soap-mineral oil {grease or lithium’ soap-syntheticoll grease is appropriate.) Itis advisable to consult NSK. * Load The replenishing time interval depends on the magnitude of the bearing load. Please refer to Fig.4.2 (3), and multiply the replenishing time interval by the load factor. I PIC exceeds 0.16, itis advisable to consult NSK. (2) Lubrication oil replacement interval The oil replacement intervals depend on the operating conditions and the oil quantity. In general, for an operating temperature under 50°C, and in clean envitonments, the replacement interval is 1 year. I the ol temperature Is above 100°C, then the oil should be changed at least once every three months. Remarks P: Equivalentload C: Basie load rating 4: Bearing bore ameter Bearng rtaiona seed, (2) Tapered rotor bearing and sphrical roller bearing Pic | _=006 oa ore [ore | oad factor] 18 1 oes | 04s | @ Load acon Fig. 4.2 Grease replenishment intervals 5. Bearing Inspection When inspecting a bearing during periodic inspection of ‘equipment, operating inspections, or replacement of adjacent parts, determine the condition of the bearing and if its con- tinued service is advisable. ‘A record should be kept of the inspection and external ap- pearance of dismounted bearings. After taking a grease sam- pile and measuring the quantity of residual grease, the bearing should be cleaned, Also, determine whether abnormalities ‘and damage exist in the cage, fiting surfaces, rolling element surfaces, and raceway surfaces. Refer to Section 6 regarding the observation of running traces on the raceway surface. ‘When evaluating whether a bearing can be reused or not, the following points need to be considered: degree of bearing ‘damage, machine performance, critical nature of the applica tion, operating conditions, inspection interval. If the inspection reveals bearing damage or abnormalities, then try to confirm the cause and determine a countermeasure by referring to Section 7 and then carry out the countermeasure. If your inspection discovers any of the following kinds of damage, which would prevent the bearing from being reused, then the bearing must be replaced with a new one. 7 NSK (1) Cracks or chipping in the cage, rolling elements, or race- way ring, (@) Flaking in the roling elements or raceway ring, {@) Notable scoring on the roling elements, rib face (collar), or raceway surface. (4) Notable wear on the cage or loose rivets (6) Flaws or rust on the rolling elements or raceway surface. (6) Notable dents on the roling elements or raceway surace. (7) Notable creep of the outer ring outside surface or inner ring bore. (@) Discoloration due to heating (@)Serious damage on shield or seal of grease packed bearings.6. Running Traces and Applied Loads AAs the bearing rotates, the raceways of the inner ring and ‘outer ring make contact with the rolling elements. This results in a wear path on both the rolling elements and raceways, Funning traces are useful, since they indicate the loading con- ditions, and should be carefully observed when the bearing is disassembled, If the running traces are clearty defined, its possible to de- termine whether the bearing is carrying a radial load, axial load or moment load. Also, the roundness condition of the bearing can be determined. Check whether unexpected beer- Ing loads or large mounting errors occurred. Also, determine the probable cause of the bearing damage. Fig. 6.1 shows the running traces generated in deep groove bearings under various load conditions. Fig. 6. 1 (a) shows the most common running trace generated when the inner rng ro- tates under a radial load only. Figs. 6.1 (e) through (h) show ‘several different running traces that result in a shortened life due to their adverse effect on the bearings. @ © Similarly, Fig. 62 shows different roller bearing running ‘races: Fig. 62 () shows the outer ring running trace when @ radial load is properly applied to a cylindrical roller bearing which has a load on a rotating inner ring. Fig. 6.2 ) shows the running trace in the case of shaft bending or relative inciina- tion between the inner and outer rings. This misalignment leads to the generation of sightly shaded (dull) bands in the \iath direction. Traces are diagonal at the beginning and end of the loacing zone. For doubleow tapered roller bearings where a single load is applied to the rotating inner ring, Fig 6.2 (k) shows the running trace on the outer ring under radial load while Fig. 6.2 () shows the running trace on the outer ring Under axial load. When misalignment exists between the inner and the outer rings, then the application of a radial load Causes running traces to appear on the outer ring as shown in Fig. 6.2 (m). © v Inner ring rotation Fadil load Cuter ring rotation Radia load Inner ting oF liner ring rotation ‘outer ring rotation Radial and axial loads ‘Axial load in one direction ® ) | @ 0 ! \ ’ 7 Inner ring rotation ial load and ‘icalignment Inner ring rotation Moment load (Wisalgnment) Fig. 6.1 Typical running traces of deep groove ball bearings, Inner ring rotation No radial internal clearance (Negative operating clearance) Inner ring rotation Housing bore is oval0 o w 0 (=) liner ting rotation Facial load Innor ring rotation Moment load (izaligrment) Fig. 6.2 Typical running traces on roller bearings 7. Bearing Damage and Countermeasures In general, if roling bearings are used correctly, they will survive to their predicted fatigue life. Bearings, however, often fail prematurely due to avoidable mistakes. In contrast to fa- tigue lf, this premature failure is caused by improper mount. ing, mishandling, poor lubrication, entry of foreign matter or abnormal heat generation. For example, one cause of premature falure is rib scoring Which is due to insufficient lubrication, use of improper lubri- cant, faulty lubrication system, entry of foreign matter, bearing mounting error, excessive defiection of the shaft or some com bination of thase. If all conditions are known for the times both, 9\NSK Inner ring rotation Radial load Inner ring rotation ‘eal load (eager) before and after the failure, including the application, the oper- ating conditions, and environment, then a countermeasure can be determined by studying the nature of the failure and its probable causes. A successful countermeasure will reduce similar failures or prevent them from happening again. Sections 7.1 through 7.18 give examples of bearing damage and countermeasures. Please consult these sections when trying to determine the cause of bearing damage. By the \way, the bearing diagnostic chart in the Appendix may be use- ful as a quick reference guide.7.4 Flaking Damage Condition Possible Cause Countermeasure Flaking occurs when small paces of | Excessive load ‘© Reconfirm the bearing application and check ‘bearing material are spit of from the | Poor mounting (misalignment) the load conaitions ‘smooth surface of the raceway or | Moment load ‘Improve the mounting method ‘oling elements due to roling fatigue, | Entry of foreign debris, water penetration ‘Improve the sealing mechanism, prevent thereby creating regions having Poor lubrication, improper lubricant rusting during non-running rough and coarse texture. Unsuitable bearing clearance «© Use a lubricant with a proper viscosity, Improper precision for shaft or housing, Improve the lubrication method Lunevenness In housing rigidly, large stan | © Check the precision of shaft and housing bending "© Check tne bearing internal clearance Progression from rust, corrsion pis, smearing, cents (rineling) Photo 71-1 Photo 7-1-2 Part: Inner ring of an angular contact ball bearing Part: Inner ring of an angular contact ball bearing ‘Symptom: Flaking occurs around half of the ccumforence Symptom: Flaking occurs diagonally along racoway ofthe raceway surfaco Cause: Poor alignment betwoon shaft and housing ‘Cause: Poor lubrication du to entry of cuting coolant ‘during mounting into bearing Photo 7-1 Photo 7-1-4 Part: Inner ring of deep groove ball bearing Part: Inner ring of an angular contact ball bearing ‘Symptom: Flaking of raceway at ball pitch ‘Symptom: Flaking of raceway at ball pitch Cause: Dents due to shock load during mounting Cause: Dents due to shock load while stationary NSK 10Photo 7-1-5 Part: Outer ring of Photo 7-1-4 ‘Symptom: Flaking of raceway surlaco at ball pitch Cause: Denis dus to shock load while stationary Photo 7-1 Part: loner ring of @ spherical rcler bearing ‘Symptom: Flaking ct enly one raceway over its entire cexeumleronce Cause: Excessive aval load Photo 7-6 Part: Balls of Photo 71-4 ‘Symptom: Flaking of bal suriace Cause: Dents due to shock load while stationary Photo 7-1-8 Part: Outer ring of Photo 74-7 ‘Symptom: Flaking of only one raceway over is entire ckrcumerence Cause: Excessive axial load Photo 7-1-9 Part: nner ring of a spherical roler bearing ‘Symptom: Flaking of only ane row of raceway Cause: Poor lubrication 11 NSK Photo 7-1-10 Part: Rollers of a cyfindtical roller bearing ‘Symptom: Premature laking occurs axialy cn the coling surfaces Cause: Scralches caused during improper mounting7.2 Peeling Damage Condition Possible Cause ‘Countermeasure ‘Dull or cloudy spots appear on ‘Unsuitable lubricant ‘¢ Select a proper iuorcant ‘surface along with ight wear. From | Entry of debris into lubricant ' Improve the sealing mechanism ‘such dull spots, tiny cracks are | Rough surface due to poar lubrication © improve the surtace finish of the roling (generated downward to @ depth of | Surface roughness of mating cling part mating parts| '5~10 ym. Small particles fall off and minor faking occurs widely. Photo 7-2-1 Part: nner ring of a spherical roler ‘Symptom: Round shaped peeling pattern occurs fon the center of the raceway ‘Cause: Poor lubrication Photo 7-2-2 bearing Part: Enlargement of pattem in Photo 7-21 ‘surface Photo 7.2.3, Photo 7-2-4 Part: Convex rollers of Photo 7.2.4 Part: Outer ring of a spherical roller bearing ‘Symptom: Found shaped peeling pattern occurs ‘Symptom: Pesling occurs near the shoulder of the raceway over ‘on the center of the roling surfaces the enie crcumforence Cause: Poor lubrication cause: Poor lubrication NSK 127.3 Scoring ‘Damage Condition Possible Cause Countermeasure ‘Scoring is surface damage due to accumulated ‘small seizures causod by siding under improper lubrication or uncer severe operating conditions. Linear damage appears circumferential on the raceway surface and roling surface. ‘Gycloidal shaped damage on the roler ond ‘Scoring on rib suriace contacting roller end Excessive oad) Poor lubrication Particles are caught in the surface Inclination of inner and outer rings Shatt bending Poor precision of the shaft and housing cessive preload (Check the size of the load Adjust the pretoad 1 Improve the luvicant and the |uorieation metnos ‘© Check the precision of the shaft and housing Photo 7-2-1 Part: Ianor ring of a ephorical roller bearing ‘Symptom: Scoring on large rib face of inner ring Cause: and deceleration Photo 7.3.3 Part: FRoler sipping due to suddon acceleration Photo 7:3-2 Part ‘Convex rollers of Photo 7-2-1 ‘Symptom: Scoring on roler enc face Roller sipping due to sudden acceleration and deceleration Cause: Photo 7-3-4 ‘Symptom: Scoring ant Inner ring ofa tapered role thrust bearing fave of inner ring rd ‘Wor particles become mixed with lubricant, and breakdown of cl fim occurs due to excessive load I: Rolle of a doublesow cylindrical roller bearing symptom: Scoring on the roller end face Cause: Poo" lubrication and excessive axial loadPhoto 7-3-5 Photo 7-3-6 Parts Inner ring of @ ephericaltheuet roller bearing Part: Convex rllors of Photo 735 ‘Symptom: Scoring on tho rib face of inne ting ‘Symptom: Scoring on tho rallor end face ‘Cause: Debris, whichis caught in surface, and excessive ‘Cause: Debris, whichis caught in suace, and excessive axial loading axial loading Photo 7-2-7 Part: Cage of a deep groove ball bearing ‘Symptom: Scoring on the pressed-siee! cage pockets Cause: Entry of debris7.4 Smearing Possible Cause Countermeasure callecton of small seizures betwoon boaring ‘Components caused by oll fim rupture andior sling, ‘Surlace roughening occurs along with meting. High speed and light ioaa ‘Suddon accelorationeceleration Ienproper lubvicant Entry of water Improve the preload Improve the bearing clearance: © Use a Wbricant with good ol fn formation abilty «Improve the hudrication method Improve the sealing mechanism Photo 7-4-1 Part: Inner ring of a eylingtcal roller bearing ‘Symptom: Smearing oocurs ccumferenially on raceway surface Photo 7-4-2 Part: Outor ring of Photo 7-4-1 ‘Symptom: Smearing accure cicumferentially on raceway surface Cause: Roller slipping due to excessive grease filing Cause: Role sipping due to excossive groace filing Photo 7-4-3 Part: Inner ring of @ ophorical roller bearing ‘Symptom: Smearing occurs ccumforentialy on raceway surface Cause: Poor lubrication. 15 NSK Photo 7-4 Part: Outer ring of Photo 7.4.3, ‘Symptom: Smearing occurs elteumerentialy on raceway surtace Cause: Poor lubricationPhoto 7-4-5 Photo 7-4-6 Par Inner ring of @ spherical roller bearing Part: Outer ring of Photo 74-5 ‘Symptom: Partial smearing ccours clrcumferentially on raceway ‘Symptom: Patil smearing cocurs crcurnferentally on raceway surface surface Cause: Poor lubrication Cause: Poor lubrication Photo 7-4-7 Parts Convex rolls of Photo 7.45 ‘Symptom: Smearing occurs at the center ofthe roling surface Cause: Poor lubrication7.5 Fracture ‘Damage Condition Possible Cause (Countermeasure Fracture refers to small pieces which were broken | Impact during mounting Excessive load oor handling such as cropping . ‘off due to excessive load or shock load acting locally on a part ofthe roller corner or rib of 2 raceway rng "© Improve the mounting method (Shrink fit, use of proper tools) ieconsider the loading conditions Provide enough back-up and support for the bearing rid Photo 7-5-1 Part: Inner ring of a doublo-row cylindrical roller bearing ‘Symptom: Chipping occurs atthe center rib Cause: Excessive load during mounting Photo 7-5-9 Part: Inner ring of a spherical thust roller bearing Symptom: Fracture occurs atthe large fib Cause: Repeated load 17|NSK. Photo 7-5-2 Part: Inner ring of a tapered roller bearing ‘Symptom: Fracture occurs atthe cone back face rib Cause: Large shock during mounting Photo 7-5-4 Part: Outer ring ofa solid type needle roller bearing ‘Symptom: Fracture occurs atthe outer ring rid ‘Cause: Roller incination due to excessive leading (Needle rollers are long compared to the lameter. Under excessive or uneven loading, rolless become inclined and push against the ribs.)7.8 Cracks Damage Condition Possible Cause ‘Countermeasure (Cracks in the raceway ring and roling elements. | Excessive intererence ‘© Correct the interference Continued use under this condition leads to larger | Excessive load, shock load ‘© Check the load conaione cracks or fractures. Progression of aking «Improve the mounting method Heat generation and fretting caused by | @ Use an appropriate shatt shape contact between mounting paris and raceway ring Heat generation due to creep Poor taper angie of tapered shaft Poor ojindicaity of shat Interference with bearing charter due to large shat comer radius Photo 7-6-1 Photo 7-6-2 Part: Outer ring of a double-ow cylindrical roller bearing Part: Rollor of a tapered roller thrust bearing Symptom: Thermal cracks occur on the outer ring side face Symptom: Thermal cracks occur at large end face of roller Cause: Abnormal heat generation due to contact siding Cause: Heat generation due to sliding withthe inner cing io bbotween mating part and face of outer ring under poor lubrication Photo 7-6-3. Part: Outer ring of a dauble-+ow cylincrcal roler bearing ‘Symptom: Cracks propagated outward in te axial and Circumferential directions from the flaking origin on the raceway surface Cause: Flaking from a flaw due to shock NSK 18Photo 7-6-4 Part (Outer ring of a double-row cylindrical roller bearing ‘used for autar ring raling (Outer ring roition) Symptom: Cracks occur on outside surtace Flat wear and neat generation due to non-ottion of the outer ring ie Photo 7-6-5 Part: Raceway surface of outer ring in Photo 7-64 ‘Symptom: Ouiside Surface crack developing on the raceway Photo 7-6-6 Part: Inner ring of a spherical eller bearing ‘Symptom: Arial cracks occur on raceway surface Cause: Lage fing stress cue to temperature diterence between shaft and inner ring. Photo 7-6-8 Pant: ‘Symptor 19 NSK ler of a spherical roller bearing Axial racks occur on roling surface Photo 7-6-7 ‘Cross section of a fractured inner ring in Photo 7-66 ‘Symptom: Origin s drectly beneath the raceway sutace7.7 Cage Damage Damage Condition Possible Cause (Countermeasure “Gage damage incudes cage Poor mounting (Bearing misalignment) "© Check the mounting method deformation, fracture, and wear | Poor handling ‘© Ghack the temperature, rotation, and load Fracture of cago pillar Large moment load conditions Deformation of side face ‘Shock ang largo vibration ‘# Reduce the vibration ‘Wear of pocket surface Excessive rotation speed, sudden acceleration | © Select a cage type Wear of guide surface and decoration 1 Solet a lubrication method and lubricant Poor lubrication Temperature rise Photo 7-7-1 Photo 7-7-2 Parts Cage of a deep groove ball bearing Par: Cage of an angular contact ball beering ‘Symptom: Fracture of pressed.stee! cage-pocket ‘Symptom: Pocket pilar fractures from a cast iron machined cage Cause: Abnormal load action on cage due to misaligned ‘mounting between inner and outer rings Photo 7-7-3, Photo 7-7-4 Part: Cage of an angular contact ball bearing Part: Cage of a tapered roller bearing ‘Symptom: Fracture of machined high-tension brass cage Symptom: Pilar fractures of pressed:steel cagea Photo 7-7-5 Photo 7-7-6 Part: Cage of an angular contact ball bearing Part: Cage of a cynical roller bearing ‘Symptom: Pressad-steol cage deformation ‘Symptom: Deformation ofthe sie face of a machined high- Cause: Shock load ave to poor handling tension brass cage ‘Cause: Laige shock during mounting Photo 7-7-7 Photo 7-7-8 Par ‘Cage ofa cylindrical roller bearing Par (Cage of an angular contact ball bearing ‘Symptom: Delormation and wear of a machined high-ension ‘Symptom: Stepped wear on the ouside surface and pocket brass cage surface of @ machined high-tension brass cage 21 NSK7.8 Denting Damage Condition Possible Cause (Countermeasure When debris such as small metalic particles are | Debris such as metalic parices are ‘caught in the roling contact zone, denting occurs | caught in the surtace ‘on the raceway surface or roling element surface. | Excessive load ‘Shock during transport or mounting Denting can interval if there Grinell dents). a the rong element pitch isa shock during the mounting ‘© Wash the housing Improve the sealing mechanism Fler the lbecation ait © Improve the mounting and handing methods Photo 7-0-1 Part: Inner ring of a double-row tapered roller bearing Symptom: Frosted raceway surface. Cause: Debris caught inthe surface Photo 7-0-2 Part: Outer ring of a double-row tapered roller bearing ‘Symptom: Indentalons on raceway eurlace Gause: Debris caught in the surface Photo 7-8-3 Part: Inner ring of a tapered roller bearing ‘Symptom: Small and large indentations occur over entire raconay surtace Cause: Debris Caught in the surace Photo 7-8-4 Part: "Tapered rolls of Photo 7.8.9 ‘Symptom: Small and large indentations occur over the rolling surtace (Cause: Debris caught in the surtace NSK 2279 Pitting Damage Condition Possible Cause (Countermeasure “The pited surface has a dull uster which appears| Debris becomes caught in the lubricant | © Improve the sealing mechanism (on the rolling element surface or raceway surface. | Exposure to moisture in the atmosphere | Filler the lubrication oil thoroughly Por lubrication (Use a proper lubricant Photo 7-0-2 Part: Outer ring ofa slewing bearing Part: Ball of Photo 7.94 Symptom: Piting occurs on the raceway surface ‘Symptom: Piting occurs on tho roling element surface Cause: Rust at bottoms of indentations 23 NSK7.10 Wear ‘Damage Condition Possible Cause ‘Countermeasure Wear is surface deterioration due to shang tretion atthe surface of the raceway, roling elements, Toller end faces, rib face, cage pockels, ete nity of debris Progression from rust and electrical Poor lubrication Sling due to regular motion of roling elemenis ' lmprove the sealing mechanism Glean the housing Filter the lubviction oil thoroughiy © Check the lubricant and lubrecation method ‘© Prevent misalignment Photo 7-10-1 Part: Inner ring ofa cylindrical roller bearing ‘Symptom: Many pits occur cue to electrical corrosion and wave ‘Shaped wear on raceway surface Cause: Electrical corrosion Photo 710-3 Patt: Cause: stationary Inner ring of @ doubleox tapered raller bearing ‘Symptom: Freting wear of raceway and stepped wear on the rib Freting progression due fo excessive load wile Photo 7.10.2 Pant Outer ting of @ spherical roler bearing ‘Symptom: Wear having a wavy or concave-and-conwex texture ‘on loaded side of raceway surface cause: stationary Photo 7-10-4 Par: mpto Cause: stationary Entry of debris under repeated vibration while “Tapered rollers of Photo 7-103 : Stepped wear on the roller head end face Felting progression due to excessive load while NSK 247.41 Fretting Damage Condition Possible Cause (Countermeasure ‘Wear occurs due to repeated sliding between the | Poor lubrication Use @ proper lubricant ‘wo surfaces. Vibration with a small amplitude © Apply a preload Freting occurs at fiting surface and also at Insufficient interference * Check the interference fi contact area between raceway ting and rolling © Apply a flim of lubricant to the fiting jements surface Freting corosion Is another term used to descibe| the reddish brown or black worn particles. Photo 7-11-1 Photo 7-11-2 Part: inner ting of a deep groove ball bearing Part: Inner ring of an angular contact ball bearing Symptom: Freting occurs on the bore surface ‘Symptom: Notable fretng occurs over entice circumference of Cause: Vibration bore suriace Cause: Insufficient interference fit Photo 7-11-3 Part: Outer ring of a double-ow cylincrical roller bearing Symptom: Fretting occurs on the raceway surface at roler pitch intorvale 25 NSK7.12 False Brinelling Damage Concition Possible Cause (Countermeasure ‘Among the diferent types of eting, false brineling is the occurrence of holow spots that resemble brine denis, and are due to wear Caused by vibration and swaying atthe contact Points between the rong elements and raceway. ‘Oscilaton and vibration of a stationary beating during such times as transporting Oscillating motion with a small ampitude| Poor lubrication "© Secure the shat and housing during tansporting ‘© Transport with the inner and outer rings packed separataly ‘¢ Reduce the vibration by preloading 1 Use a proper lubricant Photo 7-12-1 Part: Inner ring of a deep groove ball boating ‘Symptom: False brineling occurs on the raceway ‘Cause: Vibration from an external source wile stationary Photo 7.123 Part: Outer ring ofa thrust ball bearing ‘Symptom: False brineling of raceway surface at ball pitch Cause: Repeated vibration with a'small oscillating angle Photo 7.12.2 Part: Outer ring of Photo 7-121 ‘Symptom: False brineling oocurs on the raceway (Cause: Vibration from an external source while stationary Photo 7-12-4 Part: Rollers of a cylindrical roller bearing ‘Symptom: False brineling occurs on roling surface Cause: Vibration from an extemal source whlo stationary NSK 267.13 Creep Damage Conaition Possible Cause (Countermeasure (Creep isthe phenomenon in bearings] Insufficient interference or loose ft “© Check the intererenoe, and prevent rotation where relative sipping occurs atthe. | Insufficient sleeve tightening 1 Corres the sleeve tightening fiting surfaces and thereby creates a ‘© Siugy the shaft and housing precision clearance atthe fiting surtace, * Preload in the axial direction (Creep causes a shiny appearance, 1 Tighten the raceway ring side face ‘occasionally with scoring or wear © Apply adhesive 10 the fiting surface ‘© Apply afm of lubricant tothe fting surface Photo 7-131 Photo 7.13.2 Part: Inner ring of a spherical roller bearing Part: Outer ring ofa spherical roller bearing ‘Symptom: Creep accompanied by scoring of bare surface Symptom: Creep occurs over entire circumference of outside Cause: Insufficient interference surface Cause: Loose it between outer ring and housing 27|NSK7.14 Seizure ‘Damage Condition Possible Cause (Countermeasure When sudden overheating occurs during retation, the bearing becomes ‘scolored. Next, raceway rings, foling elaments, and cage wil Stten, ‘melt and deform as damage ‘sccurmulates, Poor lubrication Excessive load (Excessive preload) Exoassve retalonal speed Excessively small internal clearance Enty of water and debris Poor precision of shaft and housing, excessive shat bending ‘Study the lubricant and lubrication method 1 Reinvestigate the suabilty ofthe Dearing type selected ‘© Stugy the prelosa, bearing clearance, and ‘ting ‘Improve the sealing mechanism ‘© Check the precision of the shaft and housing Improve the mounting method Photo 7-141 Part raconay Insufficient lubrication Cause: Photo 7-142 Part: Cause: insufficient lubrication Inner ring ofa spherical roller bearing Symptom: Raceway is ciscolored and melted. Worn particles from the cage were rolled and attached to the Convex rollers of Photo 7-144 ‘Symptom: Discoloration and melting of roller roling surface, adhesion of worn paricles from cage Photo 7-143 Part: cause: Photo 7-14-4 Pant cause: Photo 7-145 Part: Cause: inner ring of an angular contact ball bearing ‘Symptom: Raceway ciscoloration, meiting occurs at ball pitch Intervals Excessive preload Outer ring in Photo 7-14-3 ‘Symptom: Raceway discoloration, melting occurs at ball pitch Intervals Excessive preload Balls and cage of Photo 7-149 Symptom: Cage is damaged by melting, balls become discolored and melted Excessive preload NSK 287.16 Electrical Corrosion Damage Condition Possible Cause ‘Countermeasure \Whon electric current passes through a bearing, | Elocrical potential diference between | Design eleciric circuits which prevent arcing and burning occur through the thin ol fim | inner and outer rings ‘current flow through the bearings, at points of contact between the race and roling | Electical poteniaitference of a high | Insulation of the bearing ‘loments. The points of contact are matted locally | frequency thal is generated by to form “futing” or groove corugations which | instruments or substrates when used are Seen by the naked eye. The magnification of | near a bearing, these grooves wil reveal crate-ike depressions Uihich indicate melting by acing. Photo 7-15-1 Photo 7-15-2 Part: nner ring of a tapered roller bearing Part: Tapered rollers in Photo 17-16-1 ‘Symptom: Striped pattern of corrosion occurs on the raceway ‘Symptom: Striped pattern of corrosion occurs on the roling surtace surface Photo 7-153 Photo 7-154 Part: "Innor ring of a cylindrical roller bearing Part: Balls of a groove ball bearing ‘Symptom: Bot pattesn of electical corrosion accompanied by ‘Symptom: Electrical corrosion has a dark color that covers the pits on the raceway surtaco centie ball surface Photo 7-155 Photo 7-15-6. Part: Imerring ofa deep groove bal bearing Part: Outer ring of a deep groove ball bearing ‘Symptom: Fluting occurs on the raceway ‘Symptom: Fluting occurs on the raceway surlace surtace (High frequency) Enlargement (High trequeney) 29 NSK7.16 Rust and Corrosion Damage Condition Possible Cause Countermeasure Iinprove the sealing mechanism Study the lubrication method [Antivustlreatment for periods of non ‘Bearing rust and corrosion are pits on the surface | Entry of corosive gas or water Of rings and roling elements and may occur at the| Improper lubricant Foling element pitch on the rings or over the enti) Formation of water droplets due to Dearing surfaces, ‘condensation of moisture running High tomperature and high humidity | @ Improve the storage methods while stationary © Improve the handling method Poor rust preventive treatment during transporing Improper storage condtions Improper handling Photo 7-16-1 Photo 7-16-2 Part: Outer ring of a cynical roller bearing Part: Outer sing ofa slewing ring Symptom: Rust on the rip face and raceway surface ‘Symptom: Ruston raceway surface at bell pitch (Cause: Poor lubrication dus to water enty Cause: Moisture condensation during stztonary periods Photo 7:16-3 Photo 7-16-4 Pert: Inner ring of a spherical roller bearing Part: Rollers of a spherical roller bearing ‘Symptom: ust on raceway surfece at roller pitch Symptom: Pit-shaped rust on roling contact surface. Cortoded Cause: Entry of water into lubricant portions Cause: Moisture condensation during storage NSK 307.17 Mounting Flaws ‘Damage Condition Possible Cause Countermeasure ‘Sraight ne soratches on surface of raceways oF roling elements caused during mounting or dismounting of bearing ‘ismountng Tnalinaton of Inner and outer rings ‘during mounting or dismounting, Shook load during mounting oF * Use appropriate ig and tool © Avold @ shock load by use of a press machine © Center the relative mating parts during mounting Photo 7-17 Part: inn ‘Symptom: Aval scratches on racoway surface ring of a oylingtical roller bearing Cause: Inclination of inner and cuter rings uring mounting Photo 7-17.3 Part: Rollers of a cylindrical roller beating ‘Symptom: Axial scratehas on roling curiace Cause: Inclination of nor and auter rings during mounting 31 NSK Photo 7-17-2 Part. Outer ring of a double-row cylindrical roller bearing Symptom; Axial scratches at rollr pitch intervals on raceway surface ‘cause: Inclination of ianer and outer rings during mounting7.18 Discoloration Damage Condition Possible Cause: Countermeasure Discoloration of cage, roling elements, and oor Libreation * Improve the lubrication method raceway ring occurs due to a reaction with (Ol stain due to @ reaction with lubricant lubricant anc high temperature. High temperature Photo 7-181 Photo 7-18-2 Part: Inner ring of an angular contact ball bearing Part: Inner ring of a ¢-point contact ball bearing ‘Symptom: Bluish oF purplish dlscoleration on raceway surface ‘Symptom: Blush or purpish discoloration on raceway surace Cause: Heat goneration cue to poor lubrication, Cause: Heat ganeration due to poor lubrication NSK 32Appendix Bearing Diagnostic Chart a eae oe lHenaing] Bearing | Lub: | Load | Speed §] : 3 : ile 5 Bl .| esl lelesl_ le ised ole gee lel sila|i have al s\iugs|s|a\ade 8 Sig) Damage name Location (Phenomenon) 2 (52/65| 2) 5] 5 |e 5 |£3\6a| & Remarks. SaaS AGIs 2. Peeling Bearing outside surface ae “Mating rolling (Rolling contact) ee mye Part Sas ; Fee ws elalalalelalalag a/eotd Cag ide surte Pocke Z| pea eae como APIS FEREEM oe ee as alaiolcl=lslal os ae aa alo Cracks | ib surtace, Roler ond face, Cage Aloe reannien 5 : ena 5 alg 5 (Weer) oO o o}ololo oO ae SUREMIE rsceiray (Doiie on the roing ‘element pit 28. a 2 FER Soon, tors aa aisles aa nan Sceas Sure, aller ee face 2) ee aes ay ome [1am olloltf ea T Pe access = ‘surface (Contact with housing and o|o ° shaft) Sa ala 5 ee osc slalelofol ronal alee fae SSaSaae 5 : Fea aS aaa cae =e ‘corrosion * wea Seg sow to Reve ; conroson | Cage ° o}o}olo FREES ose a ars ail Ra aa ear aaee 5 ns 3 eee = al Remark: This charts nt comprehensive. I sony the mare commonly ccowring damages, eaves, end locations 33 NSK