Rolling Element Bearings

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Written by Bobby
Created: 26 July 2009
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Rolling Element Bearings

The advantages and disadvantages of rolling bearings

Rolling element bearing use Elasto-hydrodynamic lubrication

Bearing failure

Case Study

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The advantages and disadvantages of rolling bearings Advantage: Low starting torque
compact and ready to install machine members
It is generally easier to lubricate rolling bearings than plain bearings
Combined radial and thrust loads can be carried readily in a rolling bearing
High overloads can be carried for short periods without undue or adverse effects
Rolling bearings become noisy when nearing the end of their natural life.
Running clearances is less than plain bearings, preloading can reduce deflection and
increase accuracy.
Standardisation by international agreement makes replacement and servicing easier
Better electrical insulation is possible than with plain bearings
Can be multifunctional e.g. combined water pump and fan on the same shaft
Disadvantage:

1. More expensive than plain bearings with more parts to go wrong

2. They are noisier than plain bearings
3. Their use at high speeds and loads are limited by centrifugal, fatigue and brinelling
effects. Plain bearings can run faster and carry heavier loads.
4. Brinelling, fretting can occur during static conditions when the bearing is subjected to
vibration
5. All rolling bearings have a finite life. If a large number of a particular bearing are
produced for a particular application a percentage of premature failures can be
anticipated
6. Repair of rolling bearings is almost impossible in an average workshop. The entire unit
has to be replaced when worn or failed

Rolling element bearing use Elasto-hydrodynamic lubrication. That is, the surface material
deforms to assist with the formation and shape of the oil wedge.
As the roller moves over the surface the latter deforms in a pressure wave. Hertzian stress
build up parallel to the surface of the material in which defects can occur. Defects may also
form due to the pressure wave. This defects may open and close freely with the passing of
the element. Should liquid enter the defect then hydraulic lock occurs and the defect grows
to relieve the stress. When the surface defects join the subsurface hydraulic locking again
occurs and these also grow. Eventually that portion of the material become weakened to an
extent a portion is displaced. This is a generalisation of the mechanism associated to
pitting. Anouther significant mechanism for the failure of rolling element bearing is spalling
where subsurface defects lead to the detachment of sections of material

The most effective method for detection of bearing failure is by vibration monitoring. This
may be by observing the vibration velocity history. Theoretically the vibration characteristic
should have well defined nodes at such frequencies as outer race element pass. This is of
use in determining that high vibration with an assembly is specifically caused by the rolling
element bearings.

Rolling element bearings traditionally generate vibrations over a wide frequency range.
Trending of this vibration over a period of time will allow estimation of the current condition
of the bearing. A general increase in the high frequency vibration is generally associated
with the creation of microscopic cracks and spalling too small for human eye to detect.
Although this is not considered destructive in itself it is a preliminary stage that leads to
further degradation
Alternately the vibration acceleration level may be measured. In both cases deteriorating
bearing conditions is indicated by increased vibration levels. Other methods include bearing
temperature measurements and analysis of lubricating oil

Early detection of bearing failure prevents damage such as housing fretting and shaft
distortion due to overheating remedy of which far exceeds that of bearing replacement only.

Normal Life Failure

Shown is a bearing demonstrating normal wear pattern for a vertically loaded shaft with
rotating inner ring and fixed outer race. The pattern on the outer race is displaced
depending on the line of action of the loading.
Although shown unifrom the actual wear can be of a more random pattern and careful
interpretation is required.
Premature failure

Bearing failure not associated with fatigue can occur due to several reasons but most
commonly misalignment, over greasing and contamination.
Over greasing
Typically 1/3rd of the available space should be filed with grease . For some installations a
weight of grease is given by the manufacturer.
Contamination
Contamination is the most common cause of premature failure. This occurs usually during
bearing installation and typically is caused by poor house keeping or dirt loaded grease.
Excessive wear is indicated by a dulled appearance and indented running surface.

Bearings damaged due to this tend to have indentations, and scratches both on the race
and the rolling elements. This effect is sometimes referred to as Scoring.
Misalignment

Is sometimes identified by a wide contact track on the inner race and a thinner non
perpendicular track on the outer race. Misalignment by as small amount as 1/1000 can lead
to serious reductions in life expectancy
Lubrication failure
In the short term the removal of manufacturing asperities leads to a highly polished mirror
like appearance. This may progress to a surface crystalline with dark lines showing a
crystalline structure. This is caused by incorrect specification for lubrication or overheating
reducing viscosity.

Generally leads to overheating to a blue/black colour on the load surface reducing to a

straw/gold color on the edges of the bearing
Rusting

Caused by water ingress into the bearing leading to red of black patches on all surfaces.
Generally associated with inefficient sealing and poor lubricant properties.
Brinelling
This comes in two forms:
True Brinelling

this caused when the elastic limit of the race material is exceeded and a permanent
deformation occurs. Associated with a sharp impact loading sometimes occurring during
poor installation procedures. Impacts occur at rolling element pitch False Brinelling
Sometimes referred to as 'washboarding' and is caused by relative movement of the
elements without formation of an oil film. Hematite rust may be evident in the pits.

More associated with high background vibration. Damage appearance is distinctive and
different to normal pitting. Shown is that seen with ball elements, roller elements are linear.
Both are at element pitch or multiples of it. The use of quality EP additives can reduce
progress of damage.

It should be noted that false brinelling can also lead to a similar fluting appearance but the
pits are brighter and contain corrosion products, where due to the passage of electricity the
pits are generally dark.

Roller bearings are generally more susceptible to this type of damage thus ball bearings
are preferred in high vibration areas, part submersion in oil bath also reduces this effect.
Overloading

Leads to overheating and spalling (surface material loss) of the running surfaces typically in
the direction of overload. May be remedied by more appropriate selection of bearings
Indentations
Typically uneven craters and pits. Associated with contaminated or harderned grease but
also occurs with oil lubricated bearings containing wear debris
Cracking

Associated with incorrect fit, uneven race support or severe overloading

Poor Fit
Loose fit
This leads to fretting between the contact areas of the bearing/housing or bearing/shaft.
Indication that this is occurring is by the presence of black or dark red coloration or deposits
on the landing areas. As this worsens the inner or outer race may begin to creep or rotate
relative to the adjacent landing area

The initiator for this is often the increased vibration from the bearing as it begins to reach
the end of its life. This vibration is destructive before noise, heat or vibration level reach is
detectable without the use of an instrument. Once the fit is lost in this manner the bearing
no longer can offer reliable load bearing capacity. The use of 'Loctite Bearing Fit' can solve
minor fit problems. The technique of raising the surface, for example using a centre punch
has very limited benefit

Tight fit
Where the interference fit is greater than the radial fit very high bearing temperatures are
generated due to overloading and premature failure results Discoloured wide contact areas,
at the extremes leads to very heavy overloading, high temperatures and cracking. May lead
to restriction in movement of the rolling elements and lead to scuffing of the running areas
through welding
Cage Wear
Associated with poor lubrication or incorrectly specified bearing type. Worsens to a point
that the cage fails, the elements move allowing the relative positions of the outer and inner
races to change.
Smearing
This is caused by lack of lubrication and relative sliding motion between the element
surfaces. It is commonly seen on the ends of roller bearings where they have been
subjected to axial forces.

The material is generally heated and some transfer occurs between the parts. Surface
rehardening can occur with tear fractures evident.

This effect may be seen where rollers are subject to high accelerations when entering the
load zone ( this occurs as the elements are not driven out when out of the load zone and
can be remedied by reducing bearing internal clearance), excessive preloading for taper
bearings, or even in ball bearing where load is too light in relation to the speed of rotation.
Careful selection of lubricant can avoid this damage.

Roller bearings may be subject to smearing on assembly due to poor assembly allowing
the elements to 'scrape' the surface on the race

Smearing may occur on the non running outer edges of the races due to relative
movements between housing/shaft and the bearing. This may be remedied by increasing
the interference fit.
Electrical discharge
This causes either deep cratering or thin pits containing dark product ( refered to fluting).

Installation
Installation of rolling element bearings should be done in as clean an environment as
possible. The leading cause of premature bearing failure is contamination.

Care should be taken not to cause impact lading to the bearing which may lead to
brinelling. It is preferable that the bearing be preheated by oil bath or induction heater
before fit. Where not possible then the bearing should be evenly pressed

The correct quantity and type of grease should be used.

Although not common it is not unusual for bearings to initially run with high temperatures or
increased load. This may be associated to stresses left over from when the bearing was
pressed onto the landing areas Care should be taken that the bearings are not allowed to
overheat.

For smaller motors this may be successfully compensated by light tapping of the shaft I
opposite directions until and 'tightness' is reduced. For larger assemblies a sequence of
running to a limited temperature nofollowed by a period of cooling generally leads to a
stabilization and then normal running temperatures.
Improving Bearing Life
Improved bearing life may be gained by the use of better or more appropriate greases.
Where possible the grease should be replaced to remove wear particles and restore levels
of EP additives. For Oil lubricated bearings the use of very fine filtration is essential

It is understood that 'Hybrid' bearings consisting of a relatively standard steel rolling

element bearing into which is inserted a single ceramic element. The ceramic element is
believed to polish the running surface removing surface defects.

For bearing used in electrical installations the use of Teflon coatings to the outer race
landing surface prevents electrical discharge through the bearings.

Case Study- Running in rolling element bearings

Despite good alignment one bearing out of four on a gas freeing fan shaft was found to
overheat within 10 minutes of first start up. The bearing was allowed to cool, from 100 to
65'C then restarted. On the second instance the fan run for 30 minutes before a
temperature of 100'c was reached. After a cool down and restart this was extended to over
one hour. After repeating this procedure several more times the bearing temperature
stabilized and the fan was found to operate reliably.

A second instance was on a thruster motor where zero pitch amps was found to be 500
amps against 340 amps normal after motor overhaul. The bearing temperature and
vibration where monitored and the unit run off load. The amps were found to reduced
steadily over a period f 24hours until normal currents where experience. Again the unit
entered into service successfully.
Case Study - Electrical discharge through bearing
There are benefits to inspecting all ball bearings removed from a machine to ascertain that
no abnormalities exist within the installation

A vessel had experienced a history of failure over a 25 year period in its horizontal twin
screw Cargo pumps. Inspection after one such failure of the intact bearing set indicated an
unusual form of damage.

This took the form of axial deep grooves ( sometimes referred to as Cratering) of a form not
normally associated with false brinelling. A very similar form of failure is seen in electric
motors caused by electrical discharge through the bearing. It should be noted that the
pump was driven by a diesel engine which was also coupled to a generator. It was possible
although not proven due to the vessel sale soon after that this was a partial cause.

It should be noted that false brinelling can also lead to a similar fluting appearance but the
pits are brighter and contain corrosion products, where due to the passage of electricity the
pits are generally dark.