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The Why
All bearings wear out over time, but here are 10 reasons why they fail at low hours.
1. Overloading
Working long hours in high-load applications can cause bearing lubricants to generate
excess heat and lose viscosity. As the lube film gets thinner, contact between the
bearing’s key components increases, accelerating wear and increasing the odds of an
early failure.
2. Improper lubrication
Several lube-related problems can have a negative impact on bearing life. One problem
is using the wrong lubricant, one that doesn’t comply with OEM recommendations—
putting engine oil in the final drive compartment, for example. Other problems can arise
when lubricant is not maintained at the proper level or the OEM’s guidelines for fluid and
filter changes are not followed. Whether the issue is type, quantity or cleanliness of the
lubricant, the effect on bearings is largely the same: improper lubrication causes
accelerated wear and premature failure.
3. Contamination
Contaminants can be introduced in many different ways—at assembly, during operation
or while a product is being serviced. Contaminants are also generated internally as
components work and wear. Regardless of the source, when contaminants come into
contact with bearings, the risk of premature failure increases significantly. Bearings that
have been subjected to contamination can be scratched, scored, pitted, grooved, bruised,
rusted or exhibit a matte or satin finish.
4. Distortion
Bearing components lose their original shape when they’re forced onto a housing or shaft
that’s out of round or when they’re installed improperly. The resulting distortion
increases the risk of an early fatigue failure.
5. Misalignment
It’s virtually impossible to achieve perfect alignment between a bearing and the housing
or shaft upon which it’s installed. Excess misalignment can be caused by design
deficiencies, installation errors or shock loads and other stresses that occur during
machine operation. Although bearings are designed to accommodate a certain level of
misalignment, exceeding that level causes uneven load distribution, which paves the way
for failure.
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6. Improper fit
Choosing the right-size bearing for a given application is critical. An improper fit—
whether it’s too loose or too tight—impedes bearing performance and reduces life. Signs
of a poor fit include split races, fretting corrosion and creep wear. Additionally, bearings
are designed to align mating parts, like gear sets. When the wrong-sized bearing is used,
mating gears will be misaligned, causing premature gear failure, which results in higher
repair costs and unplanned downtime.
7. Vibration
Excess vibration can compromise bearing life, especially in low-speed, high-load
applications. A high-quality cage, made from brass or a nonmetallic material, helps
minimize the effects of vibration-related problems.
8. Material defects
All bearings are not created equal. Those made from ultra clean steel, using the latest
manufacturing and heat-treating processes, are less likely to contain material defects that
jeopardize performance and life. Material flaws are more prevalent in lower quality
bearings, but in most cases, only a metallurgist can detect the defects.
The How
Knowing why bearings fail at low hours is important, but it’s also critical to understand
how to prevent premature failures. Here are five ways to do that.
4. Control contamination
There are dozens of opportunities to introduce contaminants into your systems while
you’re working, maintaining and servicing your machine. You can reduce the risk of
contamination if you’re willing to work at it. In general:
• Make sure anyone who’s involved with maintenance or service receives
contamination control education.
• Teach people to handle parts properly—with clean dry hands and no dirty rags.
• Clean up the work environment and storage areas.
• Adopt cleaner fluid storage and transfer processes.
• Control operating temperature to reduce internal wear.
• Fix leaks and replace worn seals promptly.
• Talk to your equipment dealer about other ways to control contamination in your
operation.