BearingMaintenance v02

BEARING MAINTENANCE
High-speed bearings for wire rod mills
Protection notice / Copyright notice
Contents
Morgan design philosophy Frequency of bearing replacement Reconditioning Condition monitoring Failure analysis
Page 2
May 2010
MillMeasurements_v01.ppt
I IS MSR Long Rolling

Copyright Siemens AG 2010. All rights reserved
Bearings Design Philosophy
Design Parameters
Max Load / Min Speed
Bearing Life Oil Film Thickness
Max Speed / Min Load

Skidding Limiting Speed Oil Film Thickness
Page 3
May 2010

Bearings Design Philosophy Design Parameters Housings, Shafts, & Cartridges
Page 4
May 2010

Design Parameters
Housings, Shafts, Cartridges & Retainers
Page 5
May 2010 MillMeasurements_v01.ppt

Design Parameters
Page 6

Design Parameters
Page 7

Design Parameters
Lubrication
Circulating System Jetted Properties and Additives
Page 8
May 2010

Bearing Life
Conventional Bearing Life
L10(hours) = ((C/P)*10/3) x 1,000,000/60 x rpm L10(hours) = ((C/P)*3) x 1,000,000/60 x rpm
New Life Theories

Lube Condition Mounting Practice Load Condition Housing Condition
Morgan Practice
Design Load Bearing Theory and Morgan Experience
Page 9

Commercial vs. Special Bearing Features in Special Bearings

Inner Race Fit No. and Size of elements Roller & Race Profiles
Even Pressure Distribution Misalignment Capability
Internal Clearance Precision Class Cage Design
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May 2010

Design Life 4 To 5 Years With Good Maintenance Practices
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May 2010

Equipment Rebuild Frequency
Morgan Recommend a 4 5 Year Rebuild Frequency Rebuild Based on Fixed Duration in Service Rebuild Based on Condition Monitoring Best Practice
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May 2010

Reconditioning
Restoration
Chrome Plating Nickel Plating Weld Spray Metal Sleeve or Cartridge
Reconditioning
Shaft Run-out & Shoulder Condition Cartridge Concentricity & Shoulder Condition Retainer Flatness & Parallel Condition Housing Bore Size, Shape & Alignment
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May 2010

Vibration Monitoring
Vibration Threshold Bearing Defect Frequencies

Element Spin Frequency Train Passage Frequency Inner Ring Defect Outer Ring Defect
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May 2010

Bearing Failures Bearing Failures occur for a variety of reasons but bearings are selected and specifications are made to suit the application and expected life. Manufacturing/Handling/Packaging Design Life Lubrication Machine Components Assembly
Why Failures Occur Failure Modes Opportunities Of Failure Analysis
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May 2010

Bearing Failure Analysis
Failure Modes
Cage Failure Inner Race Spinning Skidding Lube Deficiencies Spalling Due to Load
In House Capability Outside Services
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May 2010

Why Bearings Fail?
54% Of Failures Are Related To Lubrication Conditions 17% Of Failures Are Related To Handling & Installation 15% Of Failures Are Related To Manufacturing 14% Of Failures Occur Other/Electrical Fluting, Thermal Runaway, Combined Failure Influences, End Of Useful Life, Etc.
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May 2010

Failure Modes Cage Failure
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May 2010

Failure Modes Inner Race Spinning
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May 2010

Failure Modes Skidding
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May 2010

Failure Modes Lube Deficiencies
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May 2010

Failure Modes Fatigue Spalling
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May 2010

Assembly Inspection Of Components Spacers & Retainers Heating Bearings For Mounting Handling
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May 2010

Failure Modes Spalling Surface Initiated Mechanical
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May 2010

Failure Modes Spalling Surface Initiated Chemical
Page 25
May 2010

Failure Modes Spalling Surface Initiated Electrical
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May 2010

Failure Modes Spalling Subsurface Initiated Material Defect
Inclusion
Typical Sample
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May 2010

Failure Modes Spalling Subsurface Initiated Fatigue
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May 2010

Failure Modes Spalling Fatigue Life
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May 2010

Failure Modes Continued Lubrication Particulate Contamination Spalling
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May 2010

Failure Modes Continued Lubrication Particulate Contamination Wear
Page 31
May 2010

Failure Modes Continued Lubrication Fluid Contamination Corrosion
Page 32
May 2010

Failure Modes Continued Lubrication Fluid Contamination Loss Of/Low Viscosity
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May 2010

Failure Modes Continued Lubrication Poor Film Strength Thermal Fluid Contamination
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May 2010

Failure Modes Continued
Misalignment Raceway Damage
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May 2010

Misalignment Cage Damage
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May 2010

Misalignment Cage Damage
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May 2010

Failure Modes Continued Over Speed Conditions
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May 2010

Failure Modes Continued Thermal Runaway
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May 2010

Failure Modes Continued Other
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May 2010

Failure Modes Continued Other
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May 2010

Opportunities Of Failure Analysis
Improve Mill Utilization Improve Lubrication Improve Mechanical Equipment Improve Equipment Life Predictions Improve Bearing Design Identify Common Problem Areas
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May 2010

Bearing Summary
Actual Bearing Life
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May 2010

Thank you for your attention!
Page 44
May 2010

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BEARING MAINTENANCE

High-speed bearings for wire rod mills

Protection notice / Copyright notice

I IS MSR Long Rolling

Bearings Design Philosophy

Max Speed / Min Load

I IS MSR Long Rolling

Bearings Design Philosophy Design Parameters Housings, Shafts, & Cartridges

I IS MSR Long Rolling

Bearings Design Philosophy

I IS MSR Long Rolling

Bearings Design Philosophy

I IS MSR Long Rolling

Bearings Design Philosophy

I IS MSR Long Rolling

Bearings Design Philosophy

I IS MSR Long Rolling

Bearings Design Philosophy

New Life Theories

I IS MSR Long Rolling

Bearings Design Philosophy

Commercial vs. Special Bearing Features in Special Bearings

Internal Clearance Precision Class Cage Design

I IS MSR Long Rolling

Design Life 4 To 5 Years With Good Maintenance Practices

I IS MSR Long Rolling

Equipment Rebuild Frequency

I IS MSR Long Rolling

I IS MSR Long Rolling

Vibration Threshold Bearing Defect Frequencies

I IS MSR Long Rolling

I IS MSR Long Rolling

Bearing Failure Analysis

In House Capability Outside Services

I IS MSR Long Rolling

Why Bearings Fail?

I IS MSR Long Rolling

Bearing Failure Analysis

Failure Modes Cage Failure

I IS MSR Long Rolling

Bearing Failure Analysis

Failure Modes Inner Race Spinning

I IS MSR Long Rolling

Bearing Failure Analysis

Failure Modes Skidding

I IS MSR Long Rolling

Bearing Failure Analysis

Failure Modes Lube Deficiencies

I IS MSR Long Rolling

Bearing Failure Analysis

Failure Modes Fatigue Spalling

I IS MSR Long Rolling

I IS MSR Long Rolling

Failure Modes Spalling Surface Initiated Mechanical

I IS MSR Long Rolling

Failure Modes Spalling Surface Initiated Chemical

I IS MSR Long Rolling

Failure Modes Spalling Surface Initiated Electrical

I IS MSR Long Rolling

Failure Modes Spalling Subsurface Initiated Material Defect

I IS MSR Long Rolling

Failure Modes Spalling Subsurface Initiated Fatigue