The premature and unexpected failure of a bearing can be an extremely costly problem, both in terms of financial loss and the disruption caused to production. To identify potential causes of bearing failure and the correct solution requires an accurate diagnosis of the problem. There are many potential causes of bearing failure and it is essential to distinguish between early bearing failure and life-related problems.
Early bearing failure is often caused by contamination or incorrect application. Contamination can be caused by dirt, dust, water, or other foreign materials which become embedded in the lubricant, on the bearing surfaces or between the two. The most common form of contamination is particle contamination, where particles enter the bearing or its lubricant, creating abrasion and wear of surfaces.
Incorrect application includes incorrect installation, excessive or inadequate lubrication or incorrect lubricant type. Bearings should be correctly fitted and lubricated in accordance with the bearing manufacturers recommendations. Slippage caused by incorrect fitting can cause immediate or progressive bearing failure.
Lack of lubrication or incorrect lubrication can cause mating surfaces to wear. Insufficient lubrication can also cause premature bearing seizure due to overheating. Using the wrong type of lubricant can cause poor film formation and accelerate bearing failure.
Improper storage or handling of the bearing can also cause premature bearing failure. Bearings should always be stored in a clean, dry environment. Bearings should be handled with care, avoiding sudden impacts or drops.
Other potential causes of early bearing failure include running the bearing outside of its intended application, operating the bearing at a speed or load that is outside of its rated load limits, or using the wrong type of bearing.
Incorrect assembly can also cause premature bearing failure. Bearings that are misaligned, overstressed, rusted, or damaged can fail prematurely. Assembly should always be performed in accordance with the bearing manufacturers instructions.
In order to maximise bearing life and minimise the risk of premature failure, it is essential to maintain cleanliness, use the correct lubricant and bearing type for the intended application, and store and handle the bearings correctly. Identifying and addressing any potential causes of contamination can help to reduce the risk of premature bearing failure.
By taking the necessary precautions and proactively monitoring the condition of bearings, early and unexpected bearing failure can be avoided.Regular inspection and maintenance of bearings can help to identify potential problems before they become serious, minimising the likelihood of costly damage and disruption to production.
