Bearings Failure Analysis: A Step-by-Step Approach

As they minimize friction between moving elements, bearings are essential for many industrial applications. But even with their resilience, bearings can malfunction for several reasons. To ensure operational efficiency and prevent the recurrence of bearing failure, it is imperative to comprehend its underlying cause. This extensive guide offers an organized strategy for bearing failure analysis that is appropriate for business-to-business.

Step 1: Assessing the Data

Assessing the situation and compiling relevant information is the first stage in bearing failure analysis. This stage entails:

• Compiling Operational Data: Compile information on the load, speed, lubrication, temperature, and environmental parameters that affect operation. Gaining knowledge of the bearing’s operating environment can help identify possible stressors.
• Visual Inspection: Examine the bearing and any nearby components from a distance. Keep an eye out for overt indications of harm, such as discoloration, wear, or contamination.
• Documenting the Failure: Keep a full record of the failure event, including the time it happened, the method used to find it, and any odd observations that were made before the incident.

Step 2: Disassemble to Clean

It is essential to disassemble the bearing to prevent further damage correctly. Take these actions:

• Careful Disassembly: Use the proper instruments and methods to disassemble the bearing. Refrain from using too much force, which could conceal or cause additional harm.
• Cleaning: Use an appropriate solvent to thoroughly clean the bearing and related parts. This procedure aids in exposing minor damage that may be covered up by lubricant or dirt residues.

Step 3: Examine and Inspect

After the bearing has been cleaned, examine it carefully with a good light source and magnification:

• Identify Damage Patterns: Keep an eye out for distinct damage patterns including spreading, cracking, pitting, or spalling. Certain failure types may be indicated by these patterns.
• Inspect for Contamination: Look for indications that moisture, corrosive materials, or foreign particles have contaminated the bearing.
• Evaluate Lubricant Condition: Look for any discoloration, changes in viscosity, or contamination that could point to a lubricant problem.

Step 4: Quantitative Examination

Objective data is obtained through quantitative examination of the bearing and its constituent parts.

• Dimensional Measurements: Determine the size of the cage, rolling elements, inner and outer rings, and other bearing components. To determine wear or deformation, compare these measures with the original specifications.
• Hardness Testing: To identify alterations in material characteristics brought on by heat or stress, perform hardness tests on a range of bearing components.
• Material Analysis: Use metallurgical analysis to look for microstructure alterations or material flaws. Methods like energy-dispersive X-ray spectroscopy (EDX) and scanning electron microscopy (SEM) can be used.

Step 5: Test and Inspect

Determine the main failure mode based on the findings of the tests and inspection:

• Fatigue: Keep an eye out for material flaking or spalling, as these conditions are common in fatigue failure brought on by repetitive stress cycles.
• Wear: Look for indications of fretting, sticky, or abrasive wear. Wear is frequently brought on by contaminants, misalignment, or insufficient lubrication.
• Corrosion: Look for signs of corrosion or its byproducts. Chemical exposure or moisture intrusion can cause corrosion.
• Electrical Damage: Look for cratering or pitting, which are frequently brought on by the effects of electrical discharge machining (EDM).
• Overheating: Look for signs of thermal damage brought on by an extreme temperature, such as discoloration, melted lubricant, or softened metal.

Step 6: Root Cause Analysis

After identifying the failure mode, ascertain the underlying causes by conducting a root cause analysis:

• Operating Factors: Determine if the bearing’s design limitations were met by operating circumstances like load, speed, or alignment. 
• Lubrication: Assess the lubrication system, taking into account the choice, use, and upkeep of lubricants.
• Environmental Factors: Take into account the effects of environmental factors such as humidity, temperature swings, and pollution.
• Installation and Maintenance: Check for possible problems like incorrect mounting or inadequate lubrication by going over installation guidelines and maintenance protocols.

Step 7: Corrective Measures

Create corrective measures to deal with the found core reasons and stop upcoming failures:

• Design Improvements: If the failure was caused by the bearing’s design, suggest design modifications such as improved sealing, upgraded materials, or higher load capacities.
• Operational Modifications: Make suggestions for modifications to the bearing’s operation to make sure it stays within its designated parameters.
• Lubrication Practices: To guarantee sufficient and clean lubrication, suggest enhancements in lubricant selection, application, and maintenance. 
• Environmental Controls: Make suggestions for ways to regulate the working environment, like better sealing or contaminant-resistant barriers.
• Procedures and Training: Give staff advice on how to be properly trained in installation, maintenance, and monitoring techniques.

Step 8: Documentation

Write a thorough report outlining the conclusions and suggestions:

• Executive Summary: Highlight the main conclusions, failure modes that were found, and suggested courses of action.
• Detailed Analysis: Give an in-depth explanation of the procedures used for testing, inspection, and analysis.
• Photographic Evidence: To bolster the conclusions, provide captioned photos.
• Data and Measurements: Provide the numerical results of tests and measurements.
• Suggestions: List the remedial steps along with any ideas you may have for observation and follow-up.

Wrapping Up

In addition to pinpointing the failure’s immediate cause, a methodical approach to bearing failure analysis offers insightful information about how to avoid such problems in the future. Businesses can improve the longevity and dependability of their bearing applications, which will ultimately result in increased operational efficiency and decreased downtime, by carefully adhering to these steps: initial assessment, detailed inspection, measurement, failure mode identification, root cause analysis, corrective actions, and comprehensive documentation.

Investing in thorough failure analysis of bearings is a proactive approach that pays off by reducing unplanned breakdowns and preserving the seamless functioning of vital equipment. If you need help, don’t hesitate to contact S. Goel Bearings Distributor.