Understanding the Progression of Roller Bearing Failures

Figure 1 – The four stages of bearing failure

When analyzing vibrations using FFT (Fast Fourier Transform), five distinct stages
of bearing failure can be observed. Here is a description of these stages in relation to the
observed characteristics in the FFT :
Stage 1 :
At this stage, only subsurface damages are present, usually caused by friction and
slight impacts. Very high-frequency vibrations are generated around 20 kHz, with the
appearance of stress waves from 5 kHz. Slight noises may also be observed, but the
temperature remains normal. The impacts are short in duration.

Figure 2 – Bearing failure spectrum (Stage 1)

Stage 2 :
At this stage, vibrations have reached a significant amplitude, which can be detected
by bearing sensors. Envelope analysis (demodulation) can be effectively used to detect
signs of defects in the spectrum. However, the vibration velocity spectrum does not yet
clearly reveal the specific frequency of the defect. Harmonic variations and sidebands may
start to appear, indicating progressive deterioration of the bearing.

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 Figure 3 – Bearing failure spectrum (Stage 2)

Figure 4 – Subsurface damage of bearings

Stage 3 :
Damages to the bearings become more significant and can be caused by multiple
reasons. Very high-frequency vibrations increase in amplitude. Envelope demodulation is
highly effective in detecting defects, but it is important to correctly set the filters during
configuration. Harmonics and sidebands may appear in the spectrum, indicating signs of
more pronounced damage. This can result from increased wear, structural failures, or any
other factors that can lead to significant bearing deterioration.

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 Figure 5 – Bearing failure spectrum (Stage 3) with highlighted BPFI frequency

Figure 6 – Bearing failure spectrum (Stage 3) with highlighted BPFO frequency

Figure 7 – Bearing failure spectrum (Stage 3) with highlighted BS frequency

Stage 4 :
Damages to the bearings become even more significant, and there is a high risk of
imminent bearing failure. At this stage, defect frequencies, harmonics, and sidebands

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become more apparent, but mainly in the low-frequency range. Vibration amplitudes
are high and manifest as pronounced peaks in the higher frequencies. It is crucial to
take action promptly at this stage to prevent catastrophic bearing failure, as continued
damage can lead to serious consequences for equipment and operational safety.

Figure 8 – Bearing failure spectrum (Stage 4)

Stage 5 :
At this stage, damages to the bearings are so significant that the fundamental ro-
tational frequency (1x) and its harmonics become highly visible in the low-frequency
spectrum. Vibration amplitudes are high and manifest as wide and pronounced peaks,
often referred to as ”humps,” in the lower frequencies. In the higher frequencies, only
high-amplitude humps appear. These signals indicate severe bearing deterioration and
the imminent possibility of complete failure. It is imperative at this stage to replace the
damaged bearing as soon as possible to avoid severe consequences such as equipment
breakdown or costly production downtime.