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";s:4:"text";s:22654:"Discoloration of cages, rolling elements and raceway rings occurs due to their reacting with lubricant at high temperature or as a result of corrosion. There are three main points to consider. Info@met-tech.com During the test, vibrations are acquired and traditional metric values such as peak-to-peak value, RMS, Crest factor and kurtosis are calculated. Fatigue damage in a loaded zone of a tapered roller bearing inner ring, Flaking on the edge of a tapered roller inner ring, A spherical roller damaged as a result of flaking and fatigue, Flaking on a ball bearing outer ring raceway, Fatigue at both sides of a crack in a Tapered roller cone, A spherical roller raceway with surface material peeled away, A spherical roller central divider scored as a result of an ineffective lubricant film thickness being present, A prominent scoring mark caused by a lack of radial clearance during service rotation, A smeared end of a tapered rolled as a result of excessive sliding contact against the roller retaining rib, Smearing on the inner races of a duplex tapered roller, Fracture of a spherical roller bearing outer ring as a result of a high thrust impact load causing cracks, Cracking in the outer ring of an angular contact bearing, Outer ring crack caused by a heavy impact through the rolling elements, Inner ring crack caused by excessive hoop stress, Tapered roller cage with worn side pillars caused by the bearing having run in a reduced lubricant condition, Wear in a brass cage pocket due to low lubrication, An angular contact bearing cage deformed due to rubbing contact with other assembly parts, Wear of pocket surface. It’s most important to correct the causes and prevent future failures and the costs that follow. The new grease was a light aqua color and thought to be XXXXXX XXXX electric motor bearing grease as shown in Figure 7. Metallurgical signs of electrical arcing induced overheating were noted in the balls and in the raceways. to change the photo. Flaking due to rolling fatigue occurs when small pieces of bearing material are lifted and broken off the smooth surface of the raceway or the rolling elements. Upload your photo Send us your bearing photo’s for analysis. The large ball exhibited late stages of contact fatigue cracking and surface material spalling. Case Studies. We’ll use our knowledge of bearings and real-life conditions to help resolve your bearing issue as quickly and cost-effectively as possible. The diagnosis highlighted: a lubrication problem, but that was not the main cause of the failure 100X), Figure 18: Increased magnification SEM image of the inner race on a large seized bearing showing the electrical pitting damage. Spalling can occur on the inner … These sections were prepared for metallographic examination per ASTM E3-01. The outer edges exhibit crack progression marks indicative of continued damage by contact fatigue spalling. Premature roller bearing failure can affect business, the environment and personnel — should the bearing cause an explosion. Failure to observe the following warnings could create a risk of death or serious injury. Fatigue failure-usually referred to as spalling-is the fracture of the running surfaces and subsequent removal of small. Failure Analysis and Recovery of a 50mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application Christopher DellaCorte and S. Adam Howard NASA, Glenn Research Center And Lewis (Chip) E. Moore III NASA Marshall Space Flight Center 43nd Aerospace Mechanisms Symposium May 4th, 2016 Santa Clara, California . Failure to observe the following warnings could create a risk of serious injury. The deteriorated grease was inhibiting motion rather than enabling it. There were remnants of contact fatigue cracking noted at the edges of the spall. 2. (Photo XXXX-MB12, Mag. There were no signs of mechanical, electrical or corrosion damage on the outer surfaces of the seized bearings. (Photo XXXX-U18), Figure 8: Photograph of a seized small bearing showing the heavily worn and cracked (arrows) cage. bearing failure analysis. It describes failure by wear, failure by fretting, failure by corrosion, failure by plastic flow, failure by rolling-contact fatigue, and failure by damage. JAD Analysis - Bearing Failure Analysis. How To Diagnose Plain Bearing Failures. Bearing faults diagnosed by vibration analysis are outer race, inner race, ball or roller, cage damage, looseness, bearing misalignment, inadequate lubrication. 50X, nital etch), Figure 26: Photomicrograph of the spalled surface of a ball from a small seized bearing showing the remnant contact fatigue cracks (arrows) at the edge of the spall, as shown in Figure 25. Bearing failure demands immediate attention because it can cost as much as $25,000-$50,000 per hour—in lost productivity, unplanned outages and downtime. Follow Us: Forensic Failure Analysis, Corrosion Investigation, Metallurgical Testing and Engineering • Located in Mooresville, NC, Spectrometry / Scanning Electron Microscopy. (SEM Photo XXXX-SA31, Mag. This ball-bearing inner ring suffered extreme fatigue spalling that led to a fracture. Scoring is surface damage due to accumulated small seizures caused by sliding under improper lubrication or severe operating conditions. (Photo XXXX-MB15, Mag. 10X), Figure 12: Photograph of a typical ball showing a semi-circular patch of contact fatigue surface spalling. They are reliable even under the toughest conditions. … Microstructure composition and imaging. (Photo XXXX-MB23, Mag. 500X, nital etch), Figure 25: Photomicrograph of the cross-section through a ball from a small seized bearing showing the complete loss of material at the spalled surface. The results of the analyses are shown in Table 1 along with the requirements of E52100 bearing steel per SAE J404. (SEM Photo XXXX-SB2, Mag. Lieblein J. and Zelen A. conducted a study of the fatigue life of deep groove ball bearings. Pitting has a dull lustre and appears on the rolling element surface or raceway surface. Call us on +44 (0)1673 843059 to talk to our bearings failure expert. Most of the deteriorated grease was collected and saved, and then the bearings were cleaned for further examination. 500X, nital etch). Worn and fractured cages were found in the disassembled bearings. In this paper, an effort has been put to analyze the rolling ball bearing using finite element analysis the contact pressure level, stress or displacement behavior of rolling ball bearing. This window will act as a slideshow; click left or right arrows Chemical composition analysis of a large seized bearing inner race, outer race, and ball was performed according to ASTM E419-99a. The three smaller bearings were (double) sealed XXX XXX XXX. Scanning electron microscopic (SEM) examination of a large and small inner race clearly showed the flattened edges of the (electrical) pitting. Early failure is mostly attributable to inadequate handling or maintenance. 16X), Figure 13: Photograph of a typical ball showing a circular patch of contact fatigue surface spalling. This paper determines the method to find out the shoulder height in an angular contact ball bearing using a 3D contact analysis. The first thing to look for is an illustration that depicts similar damage to the failed bearing. Illustrations from SKF Bearing Catalogue. Each bearing … Our team works hand-in-hand with customer engineering & quality departments, providing a direct line of access to support. (SEM Photo XXXX-SA13, Mag. (SEM Photo XXXX-SA3, Mag. Engineers should not wait until the bearing failure becomes catastrophic, as this makes root cause analysis difficult. The seals on the four seized bearings were intact and undamaged. When a bearing does fail prematurely, it is usually due to causes that could have been avoided. The microstructure of both balls was predominantly tempered martensite with some undissolved carbides, typical of E52100 bearing steel. When sudden overheating occurs during rotation, the bearing becomes discoloured. The first step is therefore to perform a careful inspection of the failed roller bearing race, cage and housing. This can be seen in Figures 25 and 26. It is the heating which deteriorates the grease to the point where it inhibits motion rather than enables it. (SEM Photo XXXX-SB7, Mag. This means that similar failures could occur again, resulting in further damage and costly unscheduled downtime. It was immediately noted that the grease in the four bearings had turned to a thick (viscous) black sludge, full of particulate. Roller bearings, which operate with rolling elements such as balls or rollers in … The effect of hoop stresses on the rolling-element fatigue life of angular-contact and deep-groove ball bearings was determined for common inner-ring interference fits at the ABEC-5 tolerance level [1]. Among the different types of fretting, false brinelling is the occurrence of hollow spots that resemble brinell dents and are due to wear caused by vibration and swaying at the contact points between the rolling elements and raceway. JAD Analysis - Bearing Failure Analysis. (Photo XXXX-MB4, Mag. Smearing is surface damage which occurs from a collection of small seizures between bearing components caused by oil film rupture and/or sliding. Failure FAQ. How To Diagnose Plain Bearing Failures. The robustness and reliability of ball bearing are essential for the machine health. Fracture refers to small or large metallic pieces which were broken off due to excessive load or shock load acting locally on a rolling element, rib or section of a raceway ring. Root Cause Analysis Cost Information Wear is surface deterioration due to sliding friction at the surface of the raceway, rolling elements, roller end faces, rib face, cage pockets, etc. This report states that the Weibull slope of this group is 2.23, meaning that this distribution is mono sloped. How To Diagnose Rolling Bearing Failures. NTN-SNR offered to undertake a comprehensive appraisal of several bearings to try and solve this recurring problem. Call our bearings failure expert on +44 (0)1673 843059. However, the figures are applicable, with some modifications, to other types of bearing as well. Bearings may fail earlier than the expected rolling fatigue life. While performing failure analysis is commonly left to outside vendors, the actual collecting of information can make a great difference in correctly diagnosing bearing failure. 5X), Figure 9: Photograph of a large bearing outer race ID ball path showing wear on one side, indicative of axial (thrust) loading. Light etching areas of untempered martensite, indicative of severe overheating were also observed at some locations around the perimeter of the ball. Failure analysis researches were done by applying of stereographic, optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spec-troscopy analysis and hardness test. (Photo XXXX-MB10, Mag. There was no heat tint or signs of corrosion observed on any of the bearing outer surfaces. Tensile stresses can be very high in tightly fitted bearing components. The points of contact are melted locally to form "fluting" or groove-like corrugations which can be seen by the naked eye. The core microstructure was tempered martensite with fine carbides. Note the cracks propagating parallel to the surface. 16X), Figure 15: SEM image of the inner race on a small seized bearing showing a localized patch of electrical pitting made of numerous individual pits. The rollers may be forcefully expelled. However, the bearing is often the “victim” and not the root cause. Most bearing failures such as flaking and pitting, spalling unusual wear patterns, … Bearing Time-to-Failure Estimation using Spectral Analysis Features Reuben Lim Chi Keong1, 2, ... the ball bearings inside the outboard shaft were found to have extensive pitting on ball elements and spalling in the bearing races as shown in Figure 2a. 1,000X), Figure 17: SEM image of the inner race on a large seized bearing showing a localized patch of electrical pitting made up of numerous individual pits. When electric current passes through a bearing, arcing and burning occur through the thin oil film at points of contact between the raceway and rolling elements. Read the text associated with the picture, so as to get a better understanding of why the bearing failed. Test bearings are normal state bearing with outer raceway defect, bearing with inner raceway defect, bearing with ball defect, and combination of bearing elements defect when no load attached to the disks. which the bearing … A systematic … The results of the analyses show that the inner and outer races and the ball met the chemical composition requirements of E52100 per SAE J404. Figure 1: Photograph of the six submitted bearings showing the new bearings in the left column, two small seized bearings in the center column, and two large seized bearings in the right column. Bearing failure analysis November 4, 2015 By Mike Santora Leave a Comment When bearings fail to meet their expected life or performance levels, the consequences are … Call our bearings failure expert on +44 (0)1673 843059. and caption in a pop up window. Brass cage pillar wear caused by lack of lubrication, Dented cross roller thrust bearing raceway caused by dirt ingress following a strip down and re assembly, Raceway damaged by contaminant in the lubricant, Pear skinning caused by metal debris from a fatigue failure being pressed onto the remainder of the contact surface, Fatigue occurring on a ball bearing inner ring due to stresses induced around an impact dent, Light pitting as seen on the two sides of a spherical roller inner ring, Pitting around the circumference of a cylindrical roller inner ring, Rotation and surface wear in the bore of a tapered roller bearing inner ring, Close up of a Tapered Roller nose with heavy burrs and rotational scuffing, Top surface of a thrust bearing showing sliding wear marks to one side of the ring, Fitting marks and fretting corrosion caused by the bearing vibrating on the shaft, Fretting Corrosion and Fitting marks on the outside diameter of a spherical roller outside diameter, False brinelling caused during transportation of the stationary component, False brinelling and scratches likely to have been caused during transportation of inappropriately packed bearings, Inner ring bore creep due to a worn shaft, Tapered Roller Inner Rings distorted as a result of overloading and lack of lubrication, The remnants of rollers removed from a seized Taper Roller Bearing, Outer raceway from a seized tapered roller bearing, An angular contact bearing inner ring with material deposition from the balls following seizure, Tapered roller assembly with skewed and friction welded roller on one cone caused by assembly with an excess of end float, Electric arc pitting in a cylindrical roller outer ring, Electrical pitting in a spherical roller bearing, Electrical Pitting in a Spherical Roller bearing, Inner ring side face rusting caused by a build-up of moisture in the bearing housing close to this deep groove ball bearing, Rust corrosion on a raceway caused by a bearing standing in moisture, Rusting of a ball bearing inner ring caused by moisture in the lubricant, Axial lines on the surface of a bearing roller caused by sliding during disassembly, Outer surface scratches caused during fitting, Damaged outer surface of a double row Tapered Roller Bearing, Line on a spherical roller outside diameter caused by a split housing design, A wheel hub with a damaged abutment shoulder, a worn and tapered housing bore and excessive corrosion, A vehicle stub shaft with wear caused by inner ring rotation and pick up, JAD Associates (Improvement Solutions) Limited, Stratford House, 4 Plough Drive, Market Rasen. Wear, corrosion and burrs caused by repeated replacement of new bearings, a contaminated or moist environment or heavy handling during bearing removal. This has a negative impact on your reputation, and your bottom line. 100X, nital etch), Figure 29: Photomicrograph of the damaged surface in a ball from the large seized bearing showing contact fatigue cracks. We list the most common bearing failures to help you decide what has happened This was especially evident in one of the large bearing outer races shown in Figure 9. Six ball bearings were sent for metallurgical analysis – three smaller and three larger. Bearing Fracture For failure analysis, it is important to accurately determine the time a fracture occurs, because the possible causes of failure can be limited in according to the time of … Bearing shapes: a) deep groove ball bearing, b) angular contact ball bearing, c) self-aligning ball bearing, d) cylindrical roller bearing, e) tapered roller bearing, f) spherical roller bearing, g) needle roller bearing, h) thrust ball bearing. Always follow installation instructions and maintain proper lubrication. When bearing failure is found, even if it is insignificant, it is important to investigate the phenomenon to determine the causes. Therefore, It is important to investigate and perform a bearing failure analysis to find the root cause of the failure and prevent it from recurring. Note the fractured cage. Then, the raceway rings, rolling elements, and cage will soften, melt and deform as damage accumulates. Microstructural degradation of bearing steels, Fig. / Ball Bearings / Bearing failure analysis. (Photo XXXX-MB26, Mag. Cracks in the raceway ring and rolling elements. Creep is the phenomenon in bearings where relative slippage occurs between fitting surfaces and thereby creates a clearance between the surfaces. The three larger bearings were (double) sealed XXX XXXX XXX. Note the caked black grease chunks on the sides. Send us your photos of failed or damaged bearings through this website for analysis. which the bearing has operated. The bearing needs to be properly mounted to an accurately sized shaft. Worn and fractured cages were discovered. Failure FAQ. The third large bearing was new. (SEM Photo XXXX-SA2, Mag. Fluting occurs in a drive motor bearing and dri-ven machine’s bearings … The hardness of the inner and outer races from the same seized large bearing was measured to be 61 HRC, respectively. happening again. 50X), Figure 20: SEM image of the edge of one of the small seized bearing ball spalls showing crack progression marks indicative of contact fatigue. The first step is therefore to perform a careful inspection of the failed roller bearing … BEARING FAILURE ANALYSIS TYPE OF DAMGE/FAILURE Dark brown or greyish black fluting (Corrugation) or creaters in raceways & rollers. RELATION OF BEARING FAILURE AND LIFE WITH L10 AND MEDIAN LIFE 20 RELATIVE LIFE 0 BEARING FAILURES (PERCENT) 15 10 5 0 5 YRL 1 YRL 50 10 10 20 40 50 60 80 L50 is the LIFE where 1/2 the bearings have failed. Small particles of material then peel from the surface with areas of minor flaking starting to occur. This was typical of through-hardened E52100 bearing steel. We can provide independent third-party inspection to provide meaningful and unbiased testing of bearing quality, performance and failure analysis upon request. (704) 663-5108 | Fax: (704) 662-0898 @JAD_Analysis. For this reason, the possibility of reaching conclusions about the cause of a defect by means of studying its appearance is very useful. 500X, nital etch), Figure 28: Photomicrograph of the cross-section through the damaged surface in a ball from the large seized bearing showing overheat and later stages of contact fatigue and surface spalling. Click any image to see an enlargement This was confirmation of the electrical pitting as these layers represented re-cast and untempered martensite from tiny arc strikes. Contact us. Bearing failure is one of the prime causes of breakdown in rotating machinery, resulting in expensive systems downtime. 400X), Figure 19: SEM image of a large arc strike on the surface of a ball from a small seized bearing. The ball bearings were replaced when before the expected lifetime of the bearing the measured vibration exceeded the tolerated level. Ball bearings are the most commonly used in a wide range of industrial rotating machinery. Passage of electric current through rotating bearing. Send us your bearing photo’s for analysis. Click X to close the window. We'll be in The small ball exhibited a complete loss of material at its surface spall. Reveals grain structure, thermo mechanical processing & flaw and defect characteristics. Many bearings that fail are removed and replaced too quickly without sufficient levels of analysis into what caused their failure. Bearing Failure Analysis An ISO / TS 16949 Certifi ed Company 28397_GBC-Hyatt broch_R1.indd 1 12/23/11 11:36 AM. The ball bearing was replaced with the old style bearing. Providing inspections & investigations into failed or damaged ball & roller bearings; 3 levels of reporting from Remote Photo Reviews to Expert Witness. Early failure is mostly attributable to inadequate handling or maintenance. Determine cause of failure & recommend ways to prevent future recurrence. FatIgue SpaLLIng geometriC StreSS Spalling from misalignment, deflection or heavy loading. The main target is to find the most influencing parameters for radial stiffness of the bearing under an axial load. (Photo XXXX-U4, Mag. Diagnosing plain bearing failures is all about recognising the tell-tale signs of different wear out and other failure modes. Bearings are main part of rotary machines that work for years if they work in a proper situation. Fine localized regions of arc-shaped white areas were also noted along the fine pitted regions. Bearing Failure Analysis The accurate diagnosis of a bearing failure is imperative to prevent repeated failures and their additional expenses. Image courtesy of Solano-Alvarez, Wilberth. 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