Analysis and Findings:

Review of Bearing Costs And Frequency of Replacement

Rotor dynamic analysis to calculate bearing reaction forces and

shaft flexure from fiber band load.

Review of the bearings specified

19
 Bearing Failures Per Year

60

50

40

30

20

10

0
1994 1995 1996 1997 1998 1999 2000 2001
Y ear

20
The shaft-roll was modeled to calculate:
The rotor natural frequencies
Deflections from the fiber band loading
Bearing reaction loads (for bearing calculations).
!

21
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% ' # %
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*

22
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- &
+ + ) *

23
Corrosion between rollers and the bearing outer race. The flaw initiator
was identified as high water content in the oil.

24
Severe fretting corrosion of the bearing bore had occurred due to a
loose shaft to bearing bore fit.

25
Typical bearing failure.
Bearing housing bore was worn oversize 0.026 inch.
Severe damage to the bearing races
There was fretting corrosion of the shaft fit and scoring of the shaft
fit due to the race turning on the fit.

The race was cracked during

disassembly.

26
Sludge buildup in bearing oil feed
groove.
Two oil holes blocked.
One open oil inlet hole.
Three holes are equally
spaced around the
bearing.

27
Shaft Roll Reliability Problem Areas
1. Bolts & Joint Integrity
2. Bearings
3. Shaft Repair Process

28
Typical Bearing Fit Damage Caused By Bearing-Shaft Fretting

29
In this bearing fit failure, the fit was under size 0.075 Inch. The
metalizing material had completely failed.

Turned out to be common to find metalizing material with poor

bonding to shafts. (Which launched a search for a better repair
process)

30
Shaft Roll Reliability Problem Areas
1. Bolts & Joint Integrity
2. Bearings
3. Shaft Repair Process
4. Roll Repair Process

31
Working with the repair shop resulted in much improved finish and
machining accuracy of the roll mating surfaces and roll OD.

32
Mating Face of roll shows improved machined surface
finish.

33
Shaft Roll Reliability Problem Areas
1. Bolts & Joint Integrity
2. Bearings
3. Shaft Repair Process
4. Roll Repair Process
5. Condition Monitoring and testing to identify existing and
developing problems

34