Bearing Failure Analysis

2013-09-13 ©SKF Slide 1 [Code]

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Bearing failure analysis

Overview:
•Load path patterns
•Failure mode classification
•How to secure evidence
•Hands-on exercises

2013-09-13 ©SKF Slide 2 [Code]

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Bearing failure analysis

The best way to become expert is to examine damaged bearings. Evidence will emerge
to allow root cause analysis and hence corrective action. Many of ball and roller bearings
never attain their calculated life expectancy. .

The calculated life expectancy of any bearing is based on four assumptions:

1.Good lubrication in proper quantity will always be available to the bearing.

2.The bearing will be mounted without damage.
3.Dimensions of parts related to the bearing will be correct.
4.There are no defects inherent in the bearing.

2013-09-13 ©SKF Slide 3 [Code]

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Bearing failure analysis
Even if all the four conditions are met, the bearing may still
fail due to fatigue of bearing material.
Three major classifications of premature spalling are
lubrication, mechanical damage, and material defects.

2013-09-13 ©SKF Slide 4 [Code]

SKF [Organisation]
Bearing failure analysis

Most bearing failures can be attributed to one or more of the

following causes:

1. Defective bearing seats on shafts and in housings.

2. Misalignment.
3. Faulty mounting practice
4. Incorrect shaft and housing fits.
5. Inadequate lubrication.
6. Ineffective sealing.
7. Vibration while the bearing is not rotating
8. Passage of electric current through the bearing.
9. Transportation, storage and handling.

2013-09-13 ©SKF Slide 6 [Code]

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Load paths

2013-09-13 ©SKF Slide 7 [Code]

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Normal radial load zones…

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 Normal radial load zones…
Stationary outer ring
Rotating inner ring
Constant unidirectional loads

2013-09-13 ©SKF Slide 9 [Code]

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Normal radial load zones

Stationary inner ring

Rotating outer ring
Constant unidirectional load

2013-09-13 ©SKF Slide 10 [Code]

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Combined (radial and axial) load

Stationary outer ring

Rotating inner ring
Constant unidirectional radial and axial loads

2013-09-13 ©SKF Slide 11 [Code]

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Pure Axial load

2013-09-13 ©SKF Slide 12 [Code]

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Misalignment of outer ring

2013-09-13 ©SKF Slide 13 [Code]

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Ovalised outer ring

2013-09-13 ©SKF Slide 15 [Code]

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Out of round housing

2013-09-13 ©SKF Slide 16 [Code]

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Tight fit - preloading

2013-09-13 ©SKF Slide 17 [Code]

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Eccentric radial load

2013-09-13 ©SKF Slide 18 [Code]

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Imbalance

2013-09-13 ©SKF Slide 19 [Code]

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Failure mode classification

• Causes of failures have identifiable characteristics

• Failure mechanisms have identifiable failure modes
• Observed damage can identify failure causes

2013-09-13 ©SKF Slide 20 [Code]

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Failure modes

Subsurface fatigue
Fatigue
Surface initiated fatigue
Abrasive wear
Wear
Adhesive wear
Moisture corrosion
Corrosion
Fretting corrosion
Excessive voltage
Electrical erosion
Current leakage
Overload Indents from debris
Plastic deformation
Indentation
Indents by handling
Forced fracture
Fracture Fatigue fracture
Thermal cracking

2013-09-13 ©SKF Slide 21 [Code]

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Subsurface fatigue

Subsurface fatigue
Fatigue
Surface initiated fatigue
Wear

Corrosion

Electrical erosion

Plastic deformation

Fracture

• Repeated stress changes

• Material structural
• Micro cracks under the surface changes
• Crack propagation
• Flaking and peeling

2013-09-13 ©SKF Slide 22 [Code]

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Fatigue spall

2013-09-13 ©SKF Slide 23 [Code]

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Edge loading

2013-09-13 ©SKF Slide 24 [Code]

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True brinelling

2013-09-13 ©SKF Slide 25 [Code]

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Surface initiated fatigue

Subsurface fatigue
Fatigue
Surface initiated fatigue
Wear

Corrosion
• Surface distress 40 µm
Electrical erosion • Reduced lubrication
• Sliding motion
Plastic deformation • Severity micro cracks
Fracture

2013-09-13 ©SKF Slide 26 [Code]

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 Abrasive wear

• Progressive removal of material

• Accelerating process
• Inadequate lubrication
• Ingress of dirt particles Fatigue
Abrasive wear
Wear
Adhesive wear
Corrosion

Electrical erosion

Plastic deformation

Fracture

2013-09-13 ©SKF Slide 29 [Code]

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Wear

2013-09-13 ©SKF Slide 30 [Code]

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 Adhesive wear

Fatigue
Abrasive wear
Wear
Adhesive wear
Corrosion
• Smearing / skidding / galling
Electrical erosion • Material transfer / friction heat
• Tempering / rehardening with stress
Plastic deformation concentrations and cracking or flaking
• Low loads
Fracture • Accelerations

2013-09-13 ©SKF Slide 32 [Code]

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 Adhesive wear

Fatigue
Abrasive wear
Wear
Adhesive wear
Corrosion
• It is a material transfer from one
Electrical erosion surface to another high temperature
resulting in tempering and
Plastic deformation rehardening of material

Fracture

2013-09-13 ©SKF Slide 33 [Code]

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Temperature discoloration

150° - 177° C (300° - 350° F)

177° - 205° C (350° - 400° F)

205° - 260° C (400° - 500° F)

+ 260° C (+ 500° F)

+ 540° C (+ 1000° F)

• SKF Bearings can be used at temperatures up to

125° C (~ 250° F)
• Higher temperatures may cause loss of Hardness
• Loss of 2-4 points of Rockwell Hardness reduces life 50%

2013-09-13 ©SKF Slide 34 [Code]

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Corrosion
Rust will form if water or corrosive agents reach the in side of the bearing In
Fatigue such quantities that the lubricant can not provide adequate protection.

Wear
Moisture corrosion
Corrosion
Fretting corrosion
Electrical erosion

Plastic deformation • Oxidation / rust

• Chemical reaction
Fracture • Etching (water / oil
mixture)

2013-09-13 ©SKF Slide 35 [Code]

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Ineffective sealing

2013-09-13 ©SKF Slide 36 [Code]

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False brinelling…

Fatigue

Wear
Moisture corrosion
Corrosion
Fretting corrosion
Electrical erosion

Plastic deformation
• Rolling element / raceway
Fracture • Micro movements / elastic deformations
• Vibrations
• Corrosion / wear: shiny or reddish depressions
• Stationary: Damage at rolling element spacing
• Rotating: Damage exhibits parallel flutes

2013-09-13 ©SKF Slide 37 [Code]

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Fretting corrosion

Fatigue

Wear
Moisture corrosion
Corrosion
Fretting corrosion
Electrical erosion

Plastic deformation
• Rolling element / raceway
Fracture • Micro movements / elastic deformations
• Vibrations
• Corrosion / wear: shiny or reddish depressions
• Stationary: Damage at rolling element spacing
• Rotating: Damage exhibits parallel flutes

2013-09-13 ©SKF Slide 38 [Code]

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Advanced fretting…

2013-09-13 ©SKF Slide 39 [Code]

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Advanced fretting

2013-09-13 ©SKF Slide 40 [Code]

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Electrical erosion
Fatigue
• High current = sparking
• Instant localized heating Wear
leads to melting and/or
welding Corrosion
Excessive voltage
• Craters up to 100 µm Electrical erosion
Current leakage
Plastic deformation

Fracture

2013-09-13 ©SKF Slide 41 [Code]

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Electrical erosion – excessive voltage

2013-09-13 ©SKF Slide 42 [Code]

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Electrical erosion

Fatigue
• Low current intensity
Wear
• Shallow craters
Corrosion closely positioned
Excessive voltage
Electrical erosion
Current leakage
• Development of
flutes on raceways
Plastic deformation
and rollers, parallel
Fracture to rolling axis

• Dark gray
discoloration

2013-09-13 ©SKF Slide 43 [Code]

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Vibration

2013-09-13 ©SKF Slide 44 [Code]

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Current leakage

2013-09-13 ©SKF Slide 45 [Code]

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Electric current passage solutions

Hybrid deep groove Insocoat

ball bearing

2013-09-13 ©SKF Slide 46 [Code]

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Overload

Fatigue • Static or shock loads

Wear
• Plastic deformations
• Depressions at rolling element spacing
Corrosion • Handling damage
Electrical erosion
Overload
Plastic deformation Indents from debris
Indentation
Fracture Indents by handling

2013-09-13 ©SKF Slide 47 [Code]

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Installation damage

2013-09-13 ©SKF Slide 48 [Code]

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Debris denting

Fatigue • Localized overloading

Wear • Over-rolling of particles = dents
Corrosion • Caused by soft / hardened steel / hard mineral
particles
Electrical erosion
Overload
Plastic deformation Indents from debris
Indentation
Fracture Indents by handling

2013-09-13 ©SKF Slide 49 [Code]

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Handling damage…

• Localized overloading
• Nicks caused by hard /
sharp objects

Fatigue

Wear

Corrosion

Electrical erosion
Overload
Plastic deformation Indents from debris
Indentation
Fracture Indents by handling

2013-09-13 ©SKF Slide 50 [Code]

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Handling damage

2013-09-13 ©SKF Slide 51 [Code]

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CRB roller damage

2013-09-13 ©SKF Slide 52 [Code]

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Forced fracture…

Fatigue

Wear
• Stress concentration exceeds tensile strength
Corrosion • Impact / overstressing
Electrical erosion

Plastic deformation Forced fracture

Fracture Fatigue fracture

Thermal cracking

2013-09-13 ©SKF Slide 53 [Code]

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Forced fracture…

2013-09-13 ©SKF Slide 54 [Code]

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Fatigue fracture

Fatigue • Exceeding fatigue

strength under
Wear bending

Corrosion
• Crack initiation /
Electrical erosion
propagation

Plastic deformation Forced fracture • Finally forced fracture

Fracture Fatigue fracture
• Rings and Cages
Thermal cracking

2013-09-13 ©SKF Slide 55 [Code]

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Thermal cracking

Fatigue • High sliding and / or

insufficient lubrication
Wear • High friction heat
• Cracks at right angle to
Corrosion sliding direction

Electrical erosion

Plastic deformation Forced fracture

Fracture Fatigue fracture

Thermal cracking

2013-09-13 ©SKF Slide 56 [Code]

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Securing evidence

• Collect operating data, monitoring data

• Collect lubricant samples
• Check bearing environment(s)
• Assess bearing(s) in mounted condition
• Mark mounting position(s)
• Remove, mark and bag bearing(s) and parts
• Check bearing seats

2013-09-13 ©SKF Slide 58 [Code]

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Conducting the analysis

Examine Bearing(s) and Parts

• Record visual observations
• Use the Failure Modes to eliminate improbable possible causes and
determine the original cause of the failure.

• Contact external resources for assistance, if needed

• Initiate corrective action, if desired

2013-09-13 ©SKF Slide 59 [Code]

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False brinelling

2013-09-13 ©SKF Slide 60 [Code]

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