Introduction
The failure of rolling element bearings is a common problem faced by many industrial applications. Rolling elements bearings, which are of vital importance to the industrial sector, may fail due to various factors such as improper installation, inadequate lubrication, incorrect clearance, excessive bearing load, component defects and fatigue damage. Although bearing failures are often caused by randomness, general trends and patterns are visible throughout the various failure modes. Understanding the various modes of bearing failure, their causes and effects, is essential for ensuring the longevity of a bearing and the entire system.
Classification of Bearing Failures
Rolling element bearings can fail in the form of fatigue, impact and corrosion. Depending on the failure mode, the causes of the bearing failure and the mode of prevention can vary significantly.
1. Fatigue failures:
Fatigue failures occur when the bearing components are subjected to repeated cyclic loading which exceeds the components fatigue strength. The fatigue strength is the maximum load a component can withstand before failing. The main causes of fatigue failure are excessive loads and speeds, improper lubrication and inadequate support conditions.
2. Impact failures:
Impact failures occur when the bearing components are subjected to sudden loads. Factors such as high centrifugal forces, large impact or sudden spikes in load can cause significant damage to the bearing components.
3. Corrosion failures:
Corrosion failures occur when the bearing components are exposed to destructive corrosive forces. Corrosive media such as water, acids, chemicals and humid environments can cause corrosion of the bearing components.
Causes of Bearing Failures
1. Improper bearing selection:
Choosing the wrong bearing for the application can cause significant damage to the bearing components. Factors such as unsuitable speed, radial or axial forces, and surface texture can lead to premature bearing failure.
2. Misalignment:
Misalignment between the bearing and the shaft can cause uneven load distribution, leading to premature fatigue failures. Misalignment can be caused by factors such as improper installation or deformation of the mounted component.
3. Contamination:
Contamination of the bearing components can cause bearing failure due to corrosion and surface damage. Contamination can be caused by contact with chemical agents, dust, dirt and other abrasive particles.
4. Inadequate lubrication:
Insufficient lubrication can cause a variety of problems including surface damage, fatigue failure and increased friction.
Effects of Bearing Failures
The effects of bearing failure can be catastrophic if not dealt with promptly. Bearing failure can cause disruption of production cycles, increased downtime, and increase maintenance costs. Frequent bearing failure can also lead to decreased operational efficiency, higher energy consumption and decreased component life expectancy.
Conclusion
Bearing failure is a common problem faced by various industrial applications. Understanding the various modes of bearing failure, their causes and effects, is essential for ensuring the longevity of a bearing and the entire system. Bearing failure can cause disruption of production cycles, increased downtime, and increase maintenance costs. Proper maintenance and selection of appropriate bearing components for a given application is the only way to prevent bearing failure and ensure maximum operational efficiency.
