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SKF ReliabiJily Syslems - Fundamentals of Machine Condition A-I A-2 SKF Reliability Systems - Fundamentals of Machine Condilion
Why Bearings Fail Why Bearings Fail
have superior sealing capabilities but an even addressing all failure modes is the key to Load Examples: speeds. There is a clear energy
lower tolerance for misalignment. reliability. rolling element bearings over plain
Radial - belt tension, car wheel (straight line)
speed increases.
Axial- driH press, pumps
Selection and Design ,.-rnn;uv Function of a Combined - right angie gearbox., car wheel
(turning)
guide.
elements or the cage
Curl the book into a circle and it becomes the A -Insanity, doing the same thing repeatedly,
one particular area is the inner ring of the bearing. Curl the tabletop expecting a different result.
maintenance approach surface into a Circle and it becomes the outer h/<>li,-.,n,lIt" Maintenance (PRM) goes
of of the bearing. Add a cage to prevent ,hl~'c::hnnlinf1 La:
Fa element contact and we have the
rolling element bearing. Eliminate most failure sources
SKF Reliability Systems - Fundamentals of Machine Condition A3 A-4 SKF Reliability Systems - Fundamentals of Machine Condition
Why Bearings
true causes an analytical Poor Lubrication Contamination Failure mechanisms are created before the
approach shaft makes its first revolution.
Proper operation
~~
:~~--~--------'--l~~~
Parasitic Loads
These loads, above and
reduce the fatigue life of a
Added loads decrease bearing life Poor installation is perhaps the most avoidable
function (approximation. varies with of all bearing failure sources.
type).
and tolerances are
SKF Reliability Systems - Fundamentals of Machine Condiiion AS A-6 SKF Reliabifity Systems - Fundamentals of Machine Condition
Why Bearings Fail Why Bearings
SKF Reliabilily Systems - Fundamentals of Machine Condition A-8 SKF Reliability Systems - Fundamentsls of Machine Condition
versus what is used today? Why was Mark the location of the fixed or ~1:::1tlnlJ::uv
the change ring with to its anchor, such
housing. cut open, the patterns in
What is Ihe condition of the lubricant in
the bearing can be compared to the
machine?
load zone.
Is there any correlation between
use tools that will remove
rates and any lubrication changes?
without loadinQ the raceways
Have there any installation damage
maintenance Have off a shaft
speCifications standards been altered for is evident when performing
or worse? analysis, it may mask
other
made to the
couplings,
iUs
surface
'"'''''''''''''''HV"",."",,,n< - Fundamentals of Machine Condition A-9 A-10 SKF Reliability Systems - Fundamentals of Ma:;hine Condition
FAILURE MATRIX
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Failure modes with .c 0 13 U U 4) 01 Ci
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characteristics I ~
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FaUgue Flaking, spalllng, poe ling ++ ++ ++ + ++ ++ ++ + ++ ++ ++ + ++ ** ++ +_+1
[ - Burnishing, microcracks ++ ++ ++ ++ +t+ ++ + ++ ++ ++ ++ ++ ., +_+ ++ ++, + +.+
Wear Abraslvo Excesslvo wear ++ ++ ++ + ...+ ++ + + ++ ++ ++ ++ + ++ + + ++ -li'+ ++
"- -- Scratchos., scoros ++ ++ ++ ++ ++ ++ "'+ ++
Adhesivo Solzing marks, smearing ++ ++ ... +'+ ++ ++ ++ ++ +... +'+ + ++ .+' ++ ......
Hot runners ++ ++ + + ++ ++ ++ ++ ++ + 11-+ .... ++ ++ ++ ...+ +-+ ... +
Corrosion Moisture corrosion +of ++ + + ++"''1- +
~ T _ ___ Fretting corrosion ++ ++ ++ + ++ + ++ ...+ + ++ ++
'] False brinolllng + ++ + + + ++ +
Electrical eroslon Craters, nuUng ++ +11
Plastic doformatlon Depressions ++ ++ ++ ... + +11- +of +'I- ... t+ ++ + + ++ ++ "'+
- vibrations
- misalignment
- noise
- rigidity
- easy mounting
- availability
- cost -lubricant
- housing - relubricatlon
deformation interval
- seal type
- accessibility
- tooling
- mountlngl
dismounting procedure
are his discovering the cause of failure.
Failure a SvmDtom in Macbine Failure
Bearing Maintenance & Reliability Instructor
the cause
Reliability Maintenance Institute,
me:I.h()dllcallly considering and eliJmillating
the analyst determines the
wbere tbe bearing failed is a much
eqlliplmelnl fails prematurely, the shrewd maintenance life ofllie replacement bearing.
specialist knows that Ibe "more than meets tbe eye." What the
untutored eye sees is a failed bearing - and little more. More often than not, however, a Correctly Ihe condition-monitoring data that makes the analyst's search for
premalure bearing failure is symptomatic of other problems that, left untreated, will cause tbe a cause of bearing easier can also be used to failures before they occur. at
same kind the very least, tbat data can that a bearing be removed from service before a
catastrophic failure occurs, in damage that will probably bide important dues needed
to correctly identify the root cause impending failure.
failure is to send the failed bearing
company could secure training for There "oredictive" technologies with varying levels of sophistication that
ulagrJUsls. Such analyses can maintenance completely. Space permits only a passing
failure and pinpoint action can laken
is the
Vibration analysis can detect and
setup or operating "'''''''',"''''.
are discovered that including rolling-element bearings. By :;m;.,v"IfIV
inner ring. outer elements and cage bearing,
In many cases, a bearing subjected bearing damage caused operation. Any unusual
lubrication failure. However, suspected frequencies immediate concern.
to do a better job is 10 rush
have failed, but poor delivery or maintenance methods vibration analysis tools include "smart" handheld dala lo~~gers/lmaJY2:ers
type may not cause of the failure. to the detection, analysis and
frequency analysis feature that overlays
To understand why additional analysis is often necessary, one must realize that an the detection and identification of machine problems.
abnormal operating condition often excessive heal within a bearing, The heat handheld "pocket" computers that support operator-based malinte:na!lce,
buildup lowers the of the the thickness of the fluid film that constanlly monitor bearings and other components
separates the component The result is metal-to-melal contact The surface for managing, maaipulaling and analyzing machine-condition dala.
damage and increased rTiction that results from the metal-to-metal conlact further increase the
bearing's operating while reducing the lubricant's and fluid-film Lubricant can reveal the condition of bearings lubricated by either a stalic
thickness more. such conditions, continued seriously jeopardize the or circulating for the amount of contamination present in the system. In addition
bearing and will result .in bearing failure. In such 10 incorrectly an indication of the bearing components' condition, the analysis also gives an
diagnose as lubrication problem. whether the oil in the lubrication system is exhibiting lower
oxidatjon, loss of additives, etc.). Again. can be used in
sucb as whether to change the oil
mainl<enance or replace the bearing.
2
new classes of bearings that last as much as three times longer than traditional bearings. Other high
tech bearings currently available include new electrically insulated bearings that can withstand 1,000
Correcting the causes of bearing failure volts and serve as "drop-in" replacements for stock bearings in electric motors and generators and high
The most common causes of premature bearing failures fall into four general temperature bearings that perfonn at temperatures up to 350C (662F). There are even no-wear
categories: poor installation, contamination, poor lubrication, and fatigue. bearings with a thin diamond-like carbon coating on their rolling elements and, if required, lheir
raceways, resulting in a loog-life bearing for the most demanding environments.
Poor installations account for about 16 percent of all premature bearing failures .
A systems approach pays off
Service personnel need to be aware ofwbich tools to use and bave training in using tbem. For
example, a bearing installation may require mechanical, hydraulic or beat application methods A need exists on the part of maintenance departments to look at their plants' equipment as
for correct and efficient mounting or dismounting. Bearing users have the options of securing systems operatillg in specific envirollments and sllpported by specific operational practices. They need
training for their personnel or contracting to have installations done by outside professionals. to look beyond the bearings and employ condition monitoring and predictive maintenance practices as
In either case, quality bearing installations employing specialized tools and techniques, is a well as corrective maintenance programs - machine alignment, precision balancing, lubrication
management and bearing analysis, to name a few - designed to eliminate the root causes ofbeariog
positive step toward achieving ma-.;imum machine uptime. Improper installation techniques
failures. In companies where resource or training limitations exist, outsourcing such services to
can lead to failures from load imbalance, misalignment or improper load distributions within complement internal competencies can help move a reliability program into high gear.
the bearing.
The payoff will be an increase in machine reliability or uptime, which translates into increased
Contamination contributes to about 14 percent ofprernature bearing failures. A capacity or production capability. Some maintenance professionals who place importance on machine
bearing is a precision component that will not operate efficiently unless both the bearing and reliability measure uptime in tenns of mean time between repairs (MTBR), a measure that should be
its lubricants are isolated from contamination. Since already-greased, sealed-far-life bearings replacing mean time between failures (MTBF) in environments where reliability programs virtually
eliminate failures of critical machines.
account for only a small percentage of bearings in use, care must be taken to eliminate
contamination from bearings. Today, bearing users have available sealing solutions that can Finally, a reliability program that looks beyond Ule bearing when a bearing fails and takes
be tailored to the most arduous operating environments. Typical failures can be the result of steps to eliminate future failures will, in many cases, maintain or even improve the efficiency,
excessive wear, abnormal surface stresses caused by debris denting or corrosion in the case of capacity, and capability ofmachines to produce products to specifications. Such a result amounts to an
liquid contamination, such as water. increase in productivity, since out-of-spec products either cannot be sold or must be sold at a reduced
price, negatively atTecting both productivity measures and a company's bottom line.
Poor lubrication practices coupled witb errors in specifying bearings result in 36
percent ofpremarure bearing failures. While sealed-for-Iife bearings can be fitted and
forgofLen, any bearing deprived of proper lubrication will fail long before its Donna1 service
life. Because bearings are often the least accessible components ofmacbil1ery, neglected
lubrication frequently compounds the problem. Wherever manual maintenance is not feasible,
a fully automatic lubrication system can be installed to lubricate a bearing with the right
amount of lubricant at the correct lubrication intervals. Failures can be the result of using tbe
wrong lubricant type, mixing lubricants, improper re-lubrication amounts and improper
additives.
Fatigue accounts for the remaining 34 percent of early bearing failures. Whenever
machines are overloaded, unbalanced, or misaligned, bearings sutTer the consequences. These
abnormal conditions cause unintended "'parasitic" loads on the bearings that can quickly add
up to a dramatic reduction in service life. Premature failures from fatigue may appear at first
glance to be the result of lubrication problems. Don't be fooled. Most of these problem
conditions can be detected using predictive or condition-monitoring techniques long before
failure occurs. A thorough analysis and corrective action can often be applied before
catastrophic failure, machine damage and costly production loss occur.
Another strategy open to bearing users with chronic bearing-failure probJems is a bearing
upgrade to high-tech bearings lhat reduce the impact of machine problems. For example, a new
bearing with a toroidal roller design serves as a non-locating bearing that acconunodates shaft
deflection and fmds the best posilion to carry a load no matter how the shaft moves. Also available are