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ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 138-149 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2011): 1.2083 (Calculated by GISI) www.jifactor.com
IJMET
IAEME
ABSTRACT
In this present work, highlights the various modes of failure and their respective causes with visual effect of appearance. The damaged bearing samples were investigated and visual inspection is done to find out the mode of failure. The component failure list to highlight the most affected bearing part and its root cause failure analysis is done. This paper described the cause and effect diagram to evaluate the most serious mode & its cause of failure. This series of articles is intended to serve as an aid in identifying the causes of bearing failures and to provide guidance on how to avoid future problems. If the machinery has been plagued by repeated bearing problems, the illustrations that complement the text can provide invaluable assistance in identifying the root cause of a bearing failure. When bearing failure occurs, consider cleaning and inspecting it and comparing the observations to the result in this series on bearing failure analysis. The first thing to look for is an illustration that depicts similar damage to the failed bearing. Read the text associated with the picture, so as to get a better understanding of why the bearing failed. Rolling element bearing life expectancy is directly related to the number of revolutions performed by the bearing, the magnitude of the load and the lubrication and cleanliness of the lubricant. Various fault detection techniques mainly infrared thermography, envelop analysis etc.; to find the different mode of failure in the component are discussed in this paper. Keywords: Condition monitoring, fault diagnosis, rolling element bearing, fault detection
1. INTRODUCTION
A bearing is a mechanical element that permits relative motion between two parts, such as the shaft and the housing, with minimum friction. The functions of the bearing is to ensure free rotation of the shaft or the
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
axle with minimum friction, supports the shaft or the axle and holds it in correct position, takes up the forces that act on the shaft or the axle and transmits them to the frame or the foundation. The term rolling bearing includes all forms of roller and ball bearing which permit rotary motion of a shaft. The rolling contact bearing has a low starting friction and thus it offers low friction hence also called antifriction bearings. A complete unit of ball bearing includes inner ring, outer ring, rolling element (balls or rollers) and the cage which separates the rolling element from each other. Rolling bearings are high precision, low cost but commonly used in all kinds of rotary machine. Sriram Pattabhiraman, George Levesque, Nam H. Kim, Nagaraj K. Arakere [1], presents Uncertainity analysis and parametric studies for estimating the fatigue failure probability of surface cracks in silicon nitride ball bearings subjected to rolling contact fatigue. Wouter Ost, Patrick De Baets and Wim De Waele [2], investigated the failure of ball bearing of a dockside crane, which had been in service for 22 years, was replaced, noise emanating from the bearing was observed. Gradually the play of the newly installed bearing increased and after 5 years this had to be replaced. Upon visual inspection a large deformation of one of the bearing rings was observed, and when the bearing was opened 5 fractured balls were found and some parts of the raceways showed extensive pitting. Analysis of the bearing showed that faulty hardening of the bearing caused pitting of the raceways, which led to failure of the bearing. Wouter Ost, Patrick De Baets [3], described the failure analysis of deep groove ball bearings of an electric motor, driving an oil-injected compressor, were periodically monitored for vibrations. Tuncay Karacay, Nizami Akturk [4], presented the Vibration measurements and signal analysis for condition monitoring of ball bearings as their vibration signature reveals important information about the defect development within them. The Time domain analysis of vibration signature such as peak-to-peak amplitude, root mean square, Crest factor and kurtosis indicates defects in ball bearings. A. Tauqir, I. Salam, A. ul Haq, A. Q. Khan [5], discuss the fatigue failure in the central main bearing (CMB) of the compressor shaft of an aero-engine resulted in an air-crash. The cage of the CMB broke due to fatigue, got stuck between the bearing balls and the outer race, misaligned them resulting in severe wear of the components and damaged the function of the engine. R. S. Dwyer-Joyce [6], investigated the solid debris particles in a lubricant can become entrained into the contacts of ball bearings. The particles damage the bearing surfaces. This can lead to rolling contact fatigue failure or material loss by three body abrasion. This work concentrates on modelling the later process for brittle debris materials. B. Liu, S. F. Ling, R. Gribonval [7], identifies a new approach to the detection of localized defects of rolling element bearings is proposed. It employs matching pursuit with timefrequency atoms to analyze bearing vibration and extract vibration signatures. In particular, this approach utilizes not only the temporal and spectral but also the scale characteristics of the vibration generated due to the presence of a defect for the detection N. Tandon, A. Choudhury [8], presents a review of vibration and acoustic measurement methods for the detection of defects in rolling element bearings. It also considered the detection of both localized and distributed categories of defect. H. Ahmadi and K. Mollazade [9], presents bearing fault diagnosis to maintain an efficient operating unit and avoid failure of mineral critical equipment, it is necessary to maintain the critical parts of that equipment. V. Sugumaran, V. Muralidharan, K.I. Ramachandran [10], has presented fault diagnostics of roller bearing through proximal support vector machine to reveals its condition and the features that show the nature, through some indirect means. Statistical parameters like kurtosis, standard deviation, maximum value, etc. form a set of features, which are widely used in fault diagnostics. Dong Wang, Qiang Miao, Xianfeng Fan and Hong-Zhong Huang [11], explain the bearing fault detection benefits decision-making of maintenance and avoids undesired downtime cost. Alan Friedman [12], describe a methodology for automatically detecting and diagnosing rolling element bearing wear.
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secondary failure. The types of bearing failure may be classified as follows: (1) Primary Failure- It comprises of: Wear, Indentations, Smearing, Surface Distress, Corrosion and Electric Current Damage, (2) Secondary Failure- It comprises of: Flaking (spalling), Cracks, Cage damage.
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fact that the rolling elements are marked as well as the raceways. Bearings with vibration damage are usually found in machines that are not in operation and are situated close to machinery producing vibrations. Examples that can be cited are transformer fans, stand-by generators and ships' auxiliary machinery. Bearings in machines transported by rail, road or sea may be subject to vibration damage too. Where machines subject to constant vibration are concerned, it is essential that the risk of damage to the bearings be taken into consideration at the design stage. Consequently, where possible, ball bearings should be selected instead of roller bearings. The ability of ball bearings to withstand vibrations without being damaged can also be considerably improved by applying axial preloading with the aid of springs. An oil bath, in which all rolling elements in the load zone are immersed in the oil, has also proved to provide satisfactory protection. A vibration-damping base helps to prevent damage too. The bearings in machines that are to be transported can be protected by locking the shaft, thus preventing the small movements that have such a damaging effect on the bearings.
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formation of fluting (corrugation) in bearing raceways. Rollers are also subject to fluting, while there is only dark discolouration of balls. It can be difficult to distinguish between electric current damage and vibration damage. A feature of the fluting caused by electric current is the dark bottom of the corrugations, as opposed to the bright or rusty appearance at the bottom of the vibration induced fluting. Another distinguishing feature is the lack of damage to the rolling elements of bearings with raceway fluting caused by vibrations. Both alternating and direct currents cause damage to bearings. Even low amperage currents are dangerous. Non-rotating bearings are much more resistant to electric current damage than bearings in rotation. The extent of the damage depends on a number of factors: current intensity, duration, bearing load, speed and lubricant. The only way of avoiding damage of this nature is to prevent any electric current from passing through the bearing.
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4. Method for failure detection in rolling element bearing 4.1 Infrared Thermography
Infrared Thermography is a fast and non-intrusive method to detect the presence of abnormally warm zones on the surface of the bearing. We propose here to establish a link between the temperature rise and the rise of the vibratory level of a mechanical component in the course of degradation. The method particularly concerns the detection of the appearance of a defect of spalling on a rolling bearing. The damping of the vibration has the effect to transform a part of the damping vibratory energy into heat. This heat creation induces a rise in the ring temperature, more particularly on its external surface.
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normal lifespan can be addressed before repeated failures occur. Vibration analysis has been used in fault diagnosis of rotating machines with rolling bearings for decades. Recent evidence shows that vibration condition monitoring technique provides greater and more reliable information, thereby resulting in a more effective maintenance program with large cost benefits to industry. Vibration analysis in particular has for some time been used as a predictive maintenance procedure and as a support for machinery maintenance decisions. As a general rule, machines do not break down or fail without some form of warning, which is indicated by an increased vibration level. By measuring and analyzing the vibration of a machine, it is possible to determine both the nature and severity of the defect, and hence predict the machine's useful life or failure point. The overall vibration signal from a machine is contributed from many components and structures to which it may be coupled. However, mechanical defects produce characteristic vibrations at different frequencies, which can be related to specific machine fault conditions. By analyzing the time and frequency spectra, and using signal processing techniques, both the defect and natural frequencies of the various structural components can be identified.
(a)
Race Width Lubrication 22mm Grease (Shell) Failure mode Failure Causes Inner Race Crack Due to overload Failure mode Failure Causes
(b)
Smearing of Raceway Due to Lack of Lubricant
Sample-2
Bearing No.: Type Inside Diameter Outside Diameter Material Max.Speed 6208 Single Row Radial ball bearing 40mm 80mm Crome Steel 7000rpm (a) Cage Fracture Due to Misalignment (b) Due to Misalignment Due to improper tooling
Bearing specification
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
Sample-3
Bearing specification Bearing No.: Type Inside Diameter Outside Diameter Material Max.Speed 6203 Single Row Radial ball bearing 17mm 40mm Crome Steel 17000rpm (a) Ball Path Widened Due to Misalignment (b) Smearing of Raceway Improper Lubrication
12mm Grease
Sample-4
Bearing No.: Type Inside Diameter Outside Diameter Material Max.Speed 6304 Radial Deep groove ball bearing 20mm 52mm Crome Steel 10,000rpm (a) Fretting Corrosion Due to loose/tight fits. (b) Failure mode Failure Causes Corrosion Etching Due to contamination
Bearing specification
15mm Grease
Sample-5
Bearing No.: Type Inside Diameter Outside Diameter Material Max.Speed 6206 Deep groove ball bearing 30mm 60mm Crome Steel 10,000rpm (a) Fretting Corrosion Due to passage of electric current (b) Failure mode Failure Causes Burning tends to scuffing Due to Lack of Lubricant
Bearing specification
16mm Grease
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
Sample-6
Bearing No.: Type Inside Diameter Outside Diameter Material Max.Speed Race Width Lubrication 6203 Deep groove ball bearing 17mm 40mm Crome Steel 17,000rpm 12mm Grease (Shell) Failure mode Failure Causes (a) Wear around the Raceway. Lack of cleanliness during mounting. Failure mode Failure Causes (b) Rusting around the Raceway Due to Loose fitting
Bearing specification
Sample-7
Bearing No.: Type Inside Diameter Outside Diameter Max.Speed Bearing specification Material Race Width 6203 Deep groove ball bearing 17mm 40mm 17,000rpm Crome Steel 12mm Failure mode Failure Causes (a) Fretting Corrosion on outer surface Due to moisture or corrosive substance. (b) Failure mode Failure Causes Corrosion Etching Due to contamination
Lubrication
Grease
Sample-8
Bearing No.: Type Inside Diameter Outside Diameter Material Race Width Max.Speed Race Width Lubrication 6205 Deep groove ball bearing 25mm 52mm Crome Steel 15mm 10,000rpm 15mm Grease Failure mode Failure Causes (a) Discoloration of Inner Race Due to inadequate lubrication. (b) Failure mode Failure Causes Overheating Due to overload.
Bearing specification
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The major causes of bearing component failure may be overloading, lubrication, mishandling, poor mounting practices. The failure analysis of bearing samples has been done regarding the failure component with their percentage of Failure mode. Results shows the most encounter failure component is inner ring which depicts 90% of failure mode while rolling element depicts the least one with 30%.
Failure Analysis of Bearing Samples
Percentage of Failure Mode
Failure Component
(A) Improper mounting; (B) Inadequate lubricant; (C) Electric current; (D) Contamination; (E) Moisture/chemical action; (F) High temperation; (G) Poor handling; (H) Misalignment; (I) Improper lubrication; (J) Over loading/ axial loading
Another analysis has been done based on the number of failure causes with the percentage of failure mode. Results shows the maximum percentage of failure mode is due to Overloading; Axial Loading while 10% of the failure mode is due to electric spark which is the least one. The other causes depicts likewise improper mounting 60%, inadequate lubricant 30%, contamination 50%, moisture/chemical action 30%, failure cause due to high temperature 40%, poor handling 50%, misalignment 20% , improper lubrication 50%.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
showing that the major trends of failure cause is due to loading either overloading or axial loading while the least one is due to misalignment. For proper life expectancy of bearing these parameters must be considered.
Conclusion
The rolling element bearing problems and determining their root cause of failure is often difficult, because many failure types look very similar. This is because bearing failures are almost always precipitated by spalling or flaking conditions of the bearing component surfaces. Spalling occurs when a bearing has reached its fatigue life limit, but also when premature failures occur. For this reason, it is important to be aware of and able to recognize, all of the common failures of rolling element bearings. This ability to correctly recognize the root cause of bearing problems will lead the analyst to the right conclusions with regard to the bearing failure. Manufacturing defects in rolling element bearings make up less than one percent of the millions of bearings in use today around the world and this small defect percentage is being reduced continually by improvements in manufacturing techniques and bearing materials. Bearing manufacturers use ultrasonic inspection devices to detect surface and subsurface bearing material defects, eliminating poor quality products during the production process. Eddy current testing is used to evaluate surface hardness and detect cracks to ensure 100% product conformance to bearing specifications. Only a small fraction of all the bearings in use fail because they have reached their material fatigue limit. The vast majority of bearings outlive the machinery or component in which they are installed. According to many bearing experts, the following statistics apply to rolling element bearings failures, no matter in what type of rotating equipment they are installed (electric motors, pumps, fans, gear drives, etc.) Fail prematurely due to mechanical vibration, excessive temperatures, electrical discharge caused by static electricity or current flow, or by operating conditions which allow overloading and/or over speeding. These bearing life percentages may vary from industry to industry depending on operating conditions, maintenance practices and industry operational culture. For example, in the pulp and paper industry, poor lubrication or contaminated lubricants are the main causes of failure.
Future Scope
The future scope of this study will be to improve bearing life expectancy ratings, defined as the number of revolutions or number of operating hours at a given constant speed which a bearing is capable of, before the first sign of fatigue spalling occurs on one of the rings or rolling elements. This dissertation work can be extended to employ different optimization technique to find the exact probability of failure so as to improve the service life of the bearing.
References
[1] Sriram Pattabhiraman, George Levesque, Nam H. Kim, Nagaraj K. Arakere Uncertainty analysis for rolling contact fatigue failure probability of silicon nitride ball bearings International Journal of Solids and Structures, Volume 47, Issues 18-19, September 2010, Pages 2543-2553. Wouter Ost, Patrick De Baets and Wim De Waele, Failure of a large ball bearing of a dockside crane Laboratory Soete, Ghent University, August 2003. Wouter Ost, Patrick De Baets, Failure analysis of the deep groove ball bearings of an electric motor Engineering Failure Analysis, Volume 12, Issue 5, October 2005, Page 772-783.
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[4] [5] [6] [7] [8] Tuncay Karacay, Nizami Akturk, Experimental diagnostics of ball bearings using statistical and spectral methods, Tribology International, Volume 42, Issue 6, June 2009, Pages 836-843. A. Tauqir, I. Salam, A. ul Haq, A. Q. Khan, Causes of fatigue failure in the main bearing of an aero-engine, Engineering Failure Analysis, Volume 7, Issue 2 , April 2000, Pages 127-144. Izzety Onel, K Burak Dalci and Ibrahim Senol, Detection of outer raceway bearing defects in small induction motors using stator current analysis, Sadhana Vol. 30, Part 6, December 2005, pp 713-722. B. Liu, S. F. Ling, R. Gribonval ,Bearing failure detection using matching pursuit NDT & E International, Volume 35, Issue 4, June 2002, Pages 255-262. N. Tandon, A. Choudhury, A review of vibration and acoustic measurement methods for the detection of defects in rolling element bearings, Tribology International, Volume 32, Issue 8, August 1999, Pages 469480. H. Ahmadi and K. Mollazade, Bearing Fault Diagnosis of a Mine Stone Crasher by Vibration Condition Monitoring Technique, October 2009. V. Sugumaran, V. Muralidharan, K.I. Ramachandran , Feature Selection using Decision Tree and classification through Proximal Support Vector Machine for fault diagnostics of roller bearing Department of Mechanical Engineering, Amrita School of Engineering, Coimbatore, Tamil Nadu, May 2006. Dong Wang, Qiang Miao, Xianfeng Fan and Hong-Zhong Huang, Rolling Element fault detection using an improved combination of Hilbert and Wavelet transforms, Journal of Mechanical Science and Technology 23 (2009) 3292-3301, August 2009. Alan Friedman, Automated Bearing Wear Detection, Vibration Institute Proceedings-2004. Neville Sachs, Root Cause Failure Analysis-The Case of the Frequent Bearing Failures, Reliability Magazine, October 1999. E. Mendel, T. W. Rauber1, F. M. Varejao, and R. J. Batista, Rolling Element Bearing Fault Diagnosis in rotating machines of oil extraction rigs,17th European Signal Processing Conference (EUSIPCO 2009) Glasgow, Scotland, August 24-28, 2009. Pratesh Jayaswal, A.K.Wadhwani and K.B.Mulchandani, Machine Fault Signature Analysis, International Journal of Rotating Machinery, Volume 2008. R.CELIN, D.KMETIC, Cracks in a Roller-Bearing, Metalurgija 47 (2008) 1, pp 69-72. Viktor Gerdun, Tomaz Sedmak, Viktor S inkovec, Igor Kovse, Bojan Cene, Failure of bearings and axles in railway freight wagons, Trzaska 19a, p.p. 355, SI-1001 Ljubljana, Slovenia, November 2006.
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