T H E B C B C O M M U N I C A T O R 35

Effects of Bearing Misalignment

on Bearing Performance
Provided by Bob Ramsden, District Sales Manager, Rexnord Canada Limited
Background
Theoretical bearing ratings are based on the assumptions
that the bearing shall be:
1. absolutely clean
2. perfectly aligned
3. properly lubricated.
Unfortunately these conditions cannot be fully attained
even under laboratory conditions. This is the discussion of
one aspect, alignment, and is aimed at an awareness of
types of misalignment, capabilities of different bearing
designs to accept misalignment, and the performance effects
of misalignment on various bearing designs.
Misalignment
The inability to perfectly align the bearing with the shaft
and the mounting is present, to one degree or another, in
every application. Accurately machined housings and shafts
with press ts, in rigid structures minimize misalignment.
However, inaccuracies of fabricated equipment, or designs in
which structure deection is involved, etc., accentuate the
need for a bearing that will accommodate this situation.
Installation Misalignment
Initial misalignment, or installation misalignment, is that
condition created when the bearing or mounted unit is
initially installed on the application in a position such that
is not properly aligned with the shaft and/or structure. With
mounted units this can be due to uneven bases, non-parallel
bases, non-perpendicular mounting holes, etc. With
installation misalignment, the bearing or unit must
compensate one time, for the initial condition, and then
operate in that position.
Operating Misalignment
Operating misalignment stems frequently from a bent shaft
or similar situation that causes a misalignment cycle, in con-
junction with operation frequently each revolution. Some
dynamic or shock load situations cause a momentary deec-
tion of machinery and thus a momentary deection of
machinery and thus a momentary operating misalignment.
In operating misalignment, there is a change in the degree
of misalignment during rotation, and the bearing or unit
must accept this motion in both planes as it rotates.
Self-Alignment Capabilities
Self-alignment, or the capability to accept misalignment,
is found in a variety of designs, both inside the bearing
itself as well as in the housing. To be self-aligning a
segment of sphere must be present in the design. If the
segment of a sphere is a raceway internal to the bearing, it
is known as internal or inherently self-aligning design
(figures 1 and 2).
If on the other hand the segments on the sphere are
outside to the bearing itself, such as in the housing, it is an
external self-aligning bearing (gure 3).
If no spherical segment is present, the bearing is not self-
aligning (gure 4).
Figure 1
Figure 2
Figure 3
Effects of Misalignment on Operation
Internal Self-Aligning Bearings
Internal self-aligning bearing can normally accept 1-2
degrees of misalignment in either direction, without forcing
the roller off the spherical race surface. As long as the roller
maintains full contact, the bearing is capable of providing
full capacity with essentially no change in operating
characteristics. However, if operational misalignment is
involved, there is a slight increase in the scrubbing action,
and a potential for minor temperature increase. Internal
self-aligning mounted units accept both operational and
installation misalignment.
External Self-aligning Bearings
External self-aligning units accept installation misalignment,
but are normally not capable of accepting operating
misalignment effectively. If the spherical segment of the
housing is left loose enough to allow sliding motion, fretting
or vibration can occur, which causes other problems. Also, to
induce the misalignment motion at the housing spherical
surface, there must be enough force exerted on the end of the
roller, through the race rib, to force metal on metal between
sliding and housing under load. To achieve this takes a
tremendous amount of force, and a more common result is
severe wear on the ends of tapered or straight roller bearings.
Non-self-aligning Bearings (gure 4)
Straight or tapered roller bearings accommodate
misalignment only due to internal operating clearances. The
effect on capacity of non-self-aligning bearings (straight
roller or tapered roller), when misalignment is introduced, is
dramatic. As shown in Figure 4a below, the impact of being
even a few thousandths off alignment on a tapered or
cylindrical bearing can reduce the life of this style of
bearing by as mush as 80%.
Seals and Housings
Typical split housing units are equipped with self-aligning
bearings that accept +1
1
2 degrees of misalignment; however,
triple ring seals limit the unit to +
1
4 degrees to +
1
2! In fact
seal gap is used as an alignment check. Also, some mounted
unit designs involve bearings that misalign, but when in a
misaligned condition, seal performance is adversely affected
due to gapping, etc. Certain seal designs, including all Rex
seals, are designed to be fully self-aligning and should be
used in conjunction with self-aligning roller bearings for full
utilization of bearing capabilities.
Summary
It is important to remember that there are two basic types
of misalignment, installation and operating. Internal
self-aligning bearing units can accept either type; however,
a mounted bearing unit designed with external self-
alignment capability is capable of handling ONLY installation
misalignment. Thus, if fabricated equipment, structural
variations and/or deection are involved it is wise to utilize
an internal bearing unit.
Within design limits, internal self-aligning bearing
performance is not affected by installation or operating
misalignment. Conversely, the effect on life performance for
straight and tapered roller bearings can be devastating, even
when only a fraction of a degree of misalignment is involved.
To assure a successful mounted unit installation, both housing
and seals must be able to accommodate misalignment.

36 T H E B C B C O M M U N I C A T O R
Tech Tips
Figure 4
Figure 4a
M I S A L I G N M E N T I N D E G R E E S
R
E
L
A
T
I
V
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L
I
F
E
Internal Self-aligning Bearing
Non-
Self-aligning
Bearings