1. 1 22/02/2005Strategic's Annual Reliability Conference Bearing Damage Analysis Jonathan Brown Manager IOE & Rail Australian Timken Phone:02 9790 0039 Fax:02 9790 0057 Email:jonathan.brown@timken.com

2. 2 22/02/2005Strategic's Annual Reliability Conference Bearing Life u Theoretical (rated) Bearing Life u L10 Life Calculations u Load u Revolutions u “Actual” bearing life

3. 3 22/02/2005Strategic's Annual Reliability Conference Bearing Damage u To achieve rated life, bearings must be correctly: u Selected u Installed u Handled u set u lubricated u Maintained

4. 4 22/02/2005Strategic's Annual Reliability Conference Tapered Roller Bearing Cone Cage Rollers Cup

5. 5 22/02/2005Strategic's Annual Reliability Conference Bearing Loads u Axial and thrust loads combine to create seating force u Keeps rollers perfectly aligned u The cage keeps the rollers equally spaced around the cone

6. 6 22/02/2005Strategic's Annual Reliability Conference Bearing Clearance (Setting) Axial Clearance u Adjustable Setting u Adjust clearance between races and rollers u Maximize machine performance and extend bearing life

7. 7 22/02/2005Strategic's Annual Reliability Conference Tapered Bearing Adjustment

8. 8 22/02/2005Strategic's Annual Reliability Conference Life vs Bearing Setting at operating conditions

9. 9 22/02/2005Strategic's Annual Reliability Conference Two Types of Contact Rolling and Sliding Contact Rolling Contact

10. 10 22/02/2005Strategic's Annual Reliability Conference Bearing Damage u As many as 95% of bearing failures occur prior to achieving the design life of the bearing u You need diagnose bearing failures to recommend corrective action

11. 11 22/02/2005Strategic's Annual Reliability Conference Spalling – The end of “design” life

12. 12 22/02/2005Strategic's Annual Reliability Conference Spalling u Cyclic fatigue

13. 13 22/02/2005Strategic's Annual Reliability Conference Spalling u Occur at site of non-metallic inclusion u Dirt particle u Graphite stringer u Alumina stringer

14. 14 22/02/2005Strategic's Annual Reliability Conference Inclusion-origin spall

15. 15 22/02/2005Strategic's Annual Reliability Conference Inclusion-origin spall u Normal life criteria inclusion-origin spall

16. 16 22/02/2005Strategic's Annual Reliability Conference Inclusion-origin spall u Spall propagation

17. 17 22/02/2005Strategic's Annual Reliability Conference Inclusion-origin spall u Spall Propagation

18. 18 22/02/2005Strategic's Annual Reliability Conference Point surface-origin spall u Caused by nicks, scratches, dents

19. 19 22/02/2005Strategic's Annual Reliability Conference Point surface-origin spall u Typical, axial propagation

20. 20 22/02/2005Strategic's Annual Reliability Conference Misalignment

21. 21 22/02/2005Strategic's Annual Reliability Conference Misalignment u Even load distribution

22. 22 22/02/2005Strategic's Annual Reliability Conference Misalignment u Stress on small end

23. 23 22/02/2005Strategic's Annual Reliability Conference Misalignment

24. 24 22/02/2005Strategic's Annual Reliability Conference Misalignment u Misaligned housing bores

25. 25 22/02/2005Strategic's Annual Reliability Conference Misalignment HOUSING BORE SHAFT

26. 26 22/02/2005Strategic's Annual Reliability Conference Misalignment u Uneven wear

27. 27 22/02/2005Strategic's Annual Reliability Conference Misalignment u Uneven wear

28. 28 22/02/2005Strategic's Annual Reliability Conference Misalignment u Geometric stress concentration spall

29. 29 22/02/2005Strategic's Annual Reliability Conference Misalignment u Geometric stress concentration spall

30. 30 22/02/2005Strategic's Annual Reliability Conference Misalignment u Split housings

31. 31 22/02/2005Strategic's Annual Reliability Conference Misalignment

32. 32 22/02/2005Strategic's Annual Reliability Conference Misalignment

33. 33 22/02/2005Strategic's Annual Reliability Conference Foreign Material

34. 34 22/02/2005Strategic's Annual Reliability Conference Foreign Material u Abrasive wear

35. 35 22/02/2005Strategic's Annual Reliability Conference Foreign Material u Bruising

36. 36 22/02/2005Strategic's Annual Reliability Conference Foreign Material u Bruising

37. 37 22/02/2005Strategic's Annual Reliability Conference Foreign Material u Grooving

38. 38 22/02/2005Strategic's Annual Reliability Conference Handling Damage

39. 39 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Deformed cage

40. 40 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Deformed cage

41. 41 22/02/2005Strategic's Annual Reliability Conference Handling Damage u “Spiral Bevel Bearing”

42. 42 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Roller-spaced nicking

43. 43 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Roller nicking

44. 44 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Random nicks

45. 45 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Gouging

46. 46 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Cup edge damage

47. 47 22/02/2005Strategic's Annual Reliability Conference Handling Damage u Cup edge damage

48. 48 22/02/2005Strategic's Annual Reliability Conference Brinelling u True brinnelling: Roller-spaced indents caused by incorrect handling or shock loads

49. 49 22/02/2005Strategic's Annual Reliability Conference Brinelling

50. 50 22/02/2005Strategic's Annual Reliability Conference Brinelling u Grind marks evident in indent

51. 51 22/02/2005Strategic's Annual Reliability Conference Brinelling u False brinnell (fretting)

52. 52 22/02/2005Strategic's Annual Reliability Conference Brinelling u False brinnell (fretting)

53. 53 22/02/2005Strategic's Annual Reliability Conference Brinelling FalseTrue

54. 54 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems

55. 55 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Caused by: u Insufficient lubricant u Absence of lubricant u Wrong kind of lubricant u Areas to check: u Roller ends u Cone large rib

56. 56 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Scored rollers

57. 57 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Heat discolored rollers

58. 58 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Scoring and metal flow

59. 59 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Scored cone rib

60. 60 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Discolored cup

61. 61 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Skewed rollers

62. 62 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems

63. 63 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems u Metal transfer

64. 64 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems

65. 65 22/02/2005Strategic's Annual Reliability Conference Lubrication Problems

66. 66 22/02/2005Strategic's Annual Reliability Conference Excessive Preload or Overload u Usually looks much the same as inadequate lubrication damage u Bearing components are forced tightly together u Lube film is squeezed out creating metal to metal contact

67. 67 22/02/2005Strategic's Annual Reliability Conference Excessive Preload or Overload

68. 68 22/02/2005Strategic's Annual Reliability Conference Excessive Preload or Overload u Peeling

69. 69 22/02/2005Strategic's Annual Reliability Conference u Advanced peeling Excessive Preload or Overload

70. 70 22/02/2005Strategic's Annual Reliability Conference Excessive Preload or Overload u Full race-width spalling

71. 71 22/02/2005Strategic's Annual Reliability Conference Excessive Preload or Overload

72. 72 22/02/2005Strategic's Annual Reliability Conference Excessive Endplay u Components are not seated tightly against one another u Rollers are too loose in and out of the load zone u Rollers contact cage small ends of pockets u Cage wear

73. 73 22/02/2005Strategic's Annual Reliability Conference Excessive Endplay

74. 74 22/02/2005Strategic's Annual Reliability Conference Excessive Endplay

75. 75 22/02/2005Strategic's Annual Reliability Conference Excessive Endplay u Scalloping

76. 76 22/02/2005Strategic's Annual Reliability Conference Water / Etch Damage

77. 77 22/02/2005Strategic's Annual Reliability Conference Water / Etch Damage u Condensation in the bearing housing u Temperature change u Inadequate seals u Improper washing and drying u Three stages

78. 78 22/02/2005Strategic's Annual Reliability Conference Water / Etch Damage u Staining

79. 79 22/02/2005Strategic's Annual Reliability Conference Water / Etch Damage u Etching / Rusting

80. 80 22/02/2005Strategic's Annual Reliability Conference Water / Etch Damage u Etching  Roller-spaced Spalling

81. 81 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage

82. 82 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage u Tiny arcs of electricity jump from rollers to races u Causes small burns u Electric arc pitting u Electric arc fluting

83. 83 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage

84. 84 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage

85. 85 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage u Pitting

86. 86 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage u Pitting

87. 87 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage u Fluting

88. 88 22/02/2005Strategic's Annual Reliability Conference Electrical Arc Damage

89. 89 22/02/2005Strategic's Annual Reliability Conference Long, trouble free bearing performance u Cleaning u Handling u Setting u Lubrication u Sealing

90. 90 22/02/2005Strategic's Annual Reliability Conference Understanding Damage Analysis u Get all the components and information possible u In a two-bearing system, get both bearings u Also get any gears, seals, mounting components u Lube samples are helpful

91. 91 22/02/2005Strategic's Annual Reliability Conference Bearing Damage Analysis