Paper A

Miettinen, J., Andersson, P. Methods to Monitor the Running Situation of Grease

Lubricated Rolling Bearings. In: COST 516 Tribology Symposium. Espoo,
Finland, the Technical Research Centre of Finland. VTT Symposium 180. 1989.
ISBN 951-38-4573-7. pp. 92-101.

METHODS TO MONITOR THE RUNNING

SITUATION OF GREASE LUBRICATED
ROLLING BEARINGS
Juha Miettinen1 and Peter Andersson2
1
Tampere University of Technology, Machine Design, Tampere,
Finland
2
VTT Manufacturing Technology, Espoo, Finland
ABSTRACT
The present paper describes the vibration analysis methods for
monitoring the running situation of a rolling bearing. The introduction
briefly describes the principles and the equipment adopted in different
methods, including the measurement procedure. The methods
included in this study are the vibration overall method, the envelope
based spectrum measurement method, the first and second derivative
of vibration acceleration signal method, the PeakVue method, the
shock pulse method, the spectral emitted energy (SEE) method and
the acoustic emission (AE) method.
The results comprise descriptions of the influence of lubrication on
the measurement signal. The lubrication situations in the bearing tests
comprised two types of clean grease and greases mixed with two
types of solid contaminants. As reference measurements, tests with
dry and oil lubricated bearings and a bearing with a defect on its outer
race are used.
1 INTRODUCTION
Provided that a bearing is correctly chosen and mounted, the main
reason for premature damage of it is usually inadequate lubrication.
The lubrication can be insufficient due to an incorrect lubricant type
or amount, or due to contaminants that have found their way into the
lubricant through the seals. Vibrations induced by phenomena like
those mentioned above are not cyclic, and therefore difficult to
monitor for example with the enveloping technique, which is useful

for detecting cyclic phenomena, such as traditional bearing defect

frequencies. One possibility to overcome the problem related to the
monitoring of lubricated applications is to use high frequency
measurement methods.
In the condition monitoring of rotating machines, it is common
practice to measure the vibration velocity or acceleration. The
velocity amplitude is almost independent from the vibration
frequency in the range 10 Hz - 2 kHz. At higher frequencies the
vibration displacement amplitude becomes very low but the vibration
acceleration rises to a high level. The vibration displacement, velocity
and acceleration amplitude changes as a function of the frequency are
shown in Fig. 1 [1]. For machines rotating at high speed with a rolling
bearing failure at a very early stage, acceleration measurements are
usually a more reliable indicator [1].

Fig. 1. Principle for vibration displacement, velocity and acceleration

amplitude of sinusoidal vibration as a function of frequency [1].
2 MEASUREMENT METHODS
In the vibration overall method, the vibration rms-value in a chosen
bandwidth is measured. Some standards, for example the SFS-ISO
2372 [2], determines the bandwidth from 10 Hz to 1 kHz, and the
value measured is the vibration velocity. With the vibration overall
method it is, however, not possible to identify the frequency
components. In the present study, the bandwidth in the vibration
overall measurements was 0.5-100 Hz. The parameter measured was
the vibration acceleration.
The envelope-based spectrum measurement method is a very efficient
method for rolling bearing condition measurements. The method is
used for detecting cyclic vibration components, such as the bearing

component fault frequencies. The method is based on an amplitude

modulation phenomenon. The cyclic fault in the bearing excites the
eigenfrequencies of the bearing components and its support structure.
The high eigenfrequency, typically 500 Hz - 2 kHz [3], acts as a
carrier wave, and the modulating wave is the fault frequency. In the
envelope spectrum method, a bandpass filter is used for measuring the
vibration in the high frequency area. Using demodulation techniques
and rectifying the signal, a spectrum containing fault frequencies is
obtained.
The speed of change in the acceleration is expressed by the first
derivative of the vibration acceleration time signal, and the parameter
is called jerk (unit m/s3) [4]. The derivation amplifies the high
frequency vibration components. From the derived signal we can
calculate the amplitude spectrum or some characteristic values like
the crest factor value, the courtosis value or the peak value.
The analysis of the signal peak values in a band-limited signal is
called the PeakVue analysis. In the PeakVue analysis, samples are
collected from the time signal with a sampling time increment t =
(2.56fmax)-1, where fmax is the sampling rate [5]. An example of the
time signal and the corresponding PeakVue signal is presented in Fig.
2. From the PeakVue signal it is possible to calculate, for example,
the amplitude spectrum or the peak value.

Fig. 2. An example of a time signal and the corresponding PeakVue

signal [5].
The shock pulse method is a high-frequency measurement method.
The sensor is of the resonant type, with a resonance frequency of 32
kHz. The measurement device measures the maximum shock pulse
energy value and the shock pulse energy carpet value [6].
The vibration measurement bandwidth in the acoustic emission
method is typically in the range 100 kHz to 1 MHz. Vibrations in that
range occurs in a material by fracture of crystallites, crack nucleation

and growth, several mechanisms involving dislocations, phase

transformations in materials, boiling and electrical discharges. Each
of these mechanisms is characterised by a rapid collective motion of a
group of atoms. Situations of this kind can occur in a rolling bearing
when the lubrication is insufficient or the lubricant contains wear
particles or other solid contaminants. The phenomena must occur at a
velocity near the acoustic velocity of the material[7]. For the
measurements in the area of acoustic emission vibration, the methods
used in the present study were the Spectral Emitted Energy (SEE)
method and the AE method.
The AE method used was based on resonant-type sensors, which have
a strong amplification in a narrow bandwidth. The resonance
frequency of the sensor used in the present study was around 150
kHz. Some principles that can be used in measuring the acoustic
emission time signal are shown in Fig. 3. [8]. In the present AE
measurements, the pulse count method, (pulses/second), and the
continuous emission method were used. The continuous emission is
the rms (root mean square) value of the emission time signal.

Fig. 3. Principles for the AE time signal measurement [8].

In the spectral emitted energy method, vibration in the area of
acoustic emission is measured. The principle is to measure highfrequency metal-to-metal contacts. When the bearing fault becomes
larger, the edges of the fault become more rounded, and for that
reason the impact becomes less sharp. Therefore, the SEE value and
all similar high-frequency measurement methods can lead to lover
measurement values although the fault is large. In the SEE
measurement system used, the measurement frequency bandwidth was
from 250 kHz to 350 kHz. The device calculates the SEE spectrum
using envelope techniques, and the SEE value [9]. The bandwidth in
the present SEE value measurements was 0.5-100 Hz.

3 MEASUREMENTS
The aim of the measurements was to find out how two different types
of clean grease and wear particles affect the vibration measurement
signals. The possible factors affecting the signal are, for example, the
base oil viscosity, the type of thickener of the grease, the hardness and
the shape of the wear particles and the damping characteristics of the
grease regarding the vibration signal. The main interest in the
measurements was in the AE and the SEE methods, because these
methods should be sensitive to inadequate lubrication and to early
stage bearing faults.
3.1 Measurement arrangements
The tests were carried out using the rig for grease lubricated bearings
shown in Fig. 4. A rotational speed of 800 rpm was kept constant in
all the measurements. The bearings used in the measurements were
deep groove ball bearings with an outside diameter of 62 mm, an
inside diameter of 30 mm and a width of 16 mm. The bearing load
corresponded to a C/P value of 10, and it was static and purely radial.

Fig. 4. The grease lubrication bearing test rig at TUT.

The temperature was measured from the surface of the bearing in the
load zone.
3.2 The measurement procedure
A total of seven (7) sets of measurements (Meas) were carried out
within the present study, as presented in the following:
Meas 1: Grease 1, NLGI Grade 2 lithium soap with mineral base oil.

Meas 2: Grease 2, NLGI Grade 1.5 lithium complex with synthetic

base oil.
Meas 3: Grease 1 mixed with Fe particles (500 g grease + 1 g Fe).
Meas 4: Grease 1 mixed with quartz particles (500g grease + 1g
quartz).
Meas 5: Grease 1 and a fault on the outer race of the bearing.
Meas 6: Grease 2 and a fault on the outer race of the bearing.
Meas 7: Reference measurement (unlubricated and oil lubricated).
The size range of the Fe particles was 1 - 60 m and the size range of
the quartz particles was 1 - 40 m. The wear particles were mixed
into the grease by using a mixing apparatus at VTT [9].
4 RESULTS
4.1 Results of the tests with clean grease
The bearing studied in the Meas 1 was the same as in the Meas 2, and
during the change of the grease the bearing was not removed. It was
washed with petroleum benzine as mounted in the test rig. When regreasing the bearing, about 200 g of new grease was pumped trough
the bearing under slow rotation of the shaft.
The results of Meas 1 and 2 are shown in Figs. 5 and 6. The results
show that the AE pulse count value with grease 2 is about 25 times
higher than with grease 1. Furthermore, the continuous emission with
grease 2 is about 3 times higher than with grease 1.
Continuous
emission:
40mV-60mV

Temperature
39 oC

Fig. 5. Results of Meas 1, pulse count and continuous emission.

Continuous
emission:
140mV-160mV

Temperature
41 oC -45 oC.

Fig. 6. Results of Meas 2, pulse count and continuous emission.

4.2 Results of the tests with grease containing solid particles

The measurements using the contaminated grease were carried out
with different bearings, and the mounting of the bearings has an effect
on the results. The results are shown in Figs. 7 and 8, for Meas 3 and
4. For example, the AE pulse count level in Fig. 7 (area Clean grease
1) is much lower than the corresponding value of the same grease in
Fig. 5. The results show that the AE pulse count and the continuous
emission reaches its maximum values with grease containing quartz
particles, Fig. 8. With Fe particles the corresponding values were
about 3.5 times lower, see Fig. 7.

Continuous
emission:
Clean grease 1
40mV-50mV
Grease 1+Fe
particles
90mV-110mV

SEE:
Clean grease 1
0.97 See
Grease 1+Fe
particles
1.54 See

Fig. 7. Results of Meas 3, pulse count and continuous emission,

temperature 38 oC.

Continuous
emission:
Clean grease 1
45mV - 70mV
Grease 1+ Quartz
particles
200mV-530mV
SEE:
Clean grease 1
1.43 See
Grease 1+Quartz
particles 3.79 See

Fig. 8. Results of Meas 4, pulse count and continuous emission,

temperature 38 oC.
The SEE values in Figs. 7 and 8 were higher with grease containing
quartz particles (3.79 See) than with Fe particles (1.54 See). In the
figures 7 and 8 is shown that the addition of clean grease into the
bearing increases the AE pulse count value for a short time.
4.3 Results of the tests with a bearing with an outer race fault, an
unlubricated and a lubricated bearing
The fault on the test bearing was made by scratching the outer race
surface with a diamond bit. The length of the scratched area in the
rolling direction was about 4 mm, so the fault was very clear. The
results of the measurements Meas 5 and 6, are presented in Table 1.
Table 1. Results of Meas 5 and 6, bearing with an outer race fault.
Env SEE
SPM
x(3) x(4) PV Ovr AE
Meas 5
1
1
1
1
1
1
1
1
Meas 6
2.5
1.3
0.6
0.8 0.8 1.8 1.6
2
Meas 5 is grease 1 and Meas 6 is grease 2
Env: envelope spectrum amplitude value at
fault frequency
SEE: See value
SPM: shock pulse peak value
PV: PeakVue spectrum amplitude value at
fault frequency

Ovr: vibration overall value

x(3) : first derivative of
acceleration, maximum peak value
x(4) : second derivative of
acceleration, maximum peak value
AE: average amount pulse/sec

The results are presented relatively so that values in measurement

Meas 5 are set to 1. With all the methods the fault was found, which
was an expected result. All the other methods, except the higher

derivative method and the SPM method, showed higher levels with
grease 2. The measurement with the unlubricated and the lubricated
bearing, Meas 7, was made only using the AE pulse count method,
which showed a very high rise in the AE activity in the dry contact in
comparison with the oil lubricated contact.
5 DISCUSSION
The tested greases were very different in behaviour, one to another.
The AE method proved to be very sensitive for monitoring the
lubrication situation in the grease lubricated rolling bearings. The AE
activity showed clear differences between the clear greases, as shown
in Figs. 5 and 6. Furthermore, the contaminants caused a radical
increase in the level of the AE signals, and was clearly seen by the
SEE method, Figs. 7 and 8. During the measurements it was noticed
that the running conditions have a great effect on the acoustic
emission signal level, for instance that an increase in the rotational
speed causes a significant increase in the AE activity. The changes in
temperature, within the range that was used in the measurements, did
not particularly affect the AE activity, which can be seen for example
in Fig. 6. At the higher temperatures, the change in the temperature
was found to have a great influence on the AE activity.
In the outer race fault tests the fault represented a large fault in the
bearing, and was found with all methods. The signal level in all other
methods except in the higher derivative method and the SPM method
was higher with the grease type 2, as can be seen in Table 1. Using
the AE method, the difference between the greases was smaller in the
test with the faulty bearing than in the clean grease test. One reason
for this might be that the signal level caused by the fault was so high
that the AE activity of the clean grease remained lower than in the
clean grease test.
6 CONCLUSIONS
The aim of the present study was to compare the influence of two
different types of grease and the influence of contaminants in the
grease on the results of certain vibration measurement methods. In
this study, the AE method proved to be the most sensitive method in
monitoring the behaviour of the tested clean grease types and in
monitoring the grease containing solid particles.

10

ACKNOWLEDGEMENTS
The authors are grateful for the financial and technical support from
the following companies and institutions: The Technology
Development Centre of Finland (Tekes), SKF Engineering &
Research Centre B.V., Mobil Oil oy ab, Rautaruukki Oy, VR Ltd.,
Acutest Oy and the Finnish Maintenance Association.
REFERENCES
1. Berry, James E. How to track rolling element bearing health with
vibration signature analysis. Sound and Vibration, November
1991. pp. 24 -35.
2. SFS-ISO 2372 Standard. 1992. Mechanical vibration of machines
with operating speeds from 10 to 200 rev/s. Basis for specifying
evaluation standards.
3. Berry, James E. 1997. Tracking of rolling element bearing failure
stages using both vibration signature analysis as well as high
frequency enveloping and demodulation special techniques (3rd
edition). Technical Associates Of Charlotte, P.C., Charlotte,
North Carolina. U.S.A. 64 p.
4. Lahdelma, Sulo. 1992. About the new criterion of the vibration
levels in condition monitoring (Koneiden kunnonvalvonnan
uusista vrhtelyjen voimakkuuden arvosteluperusteista, in
Finnish ). Rapport nr. 85. University of Oulu. 18 p. ISBN 951-423347-6.
5. Robunson, J. C., Canada, R. G., Piety, K. R. PeakVue analysis new methodology for bearing fault detection. Sound and
Vibration, November 1996. pp. 22 -25.
6. SPM Instruments. SPM Shock Pulse Manual. 1991/8.
7. Battie, A.G. Acoustic emission, principles and instrumentation.
Journal of acoustic emission, vol.2, nr.1/2 January/Aplil 1983. pp.
95-128.
8. Hanchi, J., Klamecki, B.E. 1991. Acoustic emission monitoring of
the wear process. Wear, 145, pp. 1-27.
9. SKF.1991. SKF SEE Pen instruction manual CM143E/9105.
10. Andersson, P., Sainio, H., Miettinen, J. Procedure for ferrographic
analysis of grease samples from bearing tests. Paper presented at
the COST 516 Tribology Symposium in Espoo, Finland, 1415.5.1998.