Bearing defects

A low speed REB test-rig

MSc Manufacturing

Simulation of bearing defects

Spark erosion defects

MSc Manufacturing

Simulation of bearing defects

Line defects

MSc Manufacturing

Simulation of bearing defects

Outer Race Defect: W1 grease

Max amplitude

Energy

Peak Amplitude: ORD and good bearing, W1 grease

Energy: ORD and good bearing, W1 grease

-4

10

0.7

ORD
Good

ORD
Good
0.6
-5

10

ORD=5.2537e-6

Energy, Joules

Peak Amplitude, Volts

0.5

0.4
ORD=0.3344

0.3

0.2

-6

10

Good=3.0248e-7

-7

10
Good=0.0873

0.1

-8

10

10

15

20
25
SW signature

30

35

40

MSc Manufacturing

10

15

20
25
SW Signature

30

35

40

Simulation of bearing defects

Inner Race Defect: W1 grease

Max amplitude

Energy

Peak Amplitude: IRD and good bearing, W1 grease

Energy: IRD and good bearing, W1 grease

-5

10

0.4

IRD
Good

IRD
Good

0.35

IRD=2.6732e-6

0.3
0.25

Energy, Joules

Peak Amplitude, Volts

-6

10
IRD=0.2308

0.2
0.15

Good=3.0248e-7

-7

10

0.1

Good=0.0873

0.05
-8

10
0

10

15

20
25
SW signature

30

35

40

MSc Manufacturing

10

15

20
25
SW Signature

30

35

40

Simulation of bearing defects

Roller Defect: W1 grease
Max amplitude

Energy

Peak Amplitude: RD and good bearing, W1 grease

RD
Good

RD
Good

0.45
0.4

-5

10

RD=4.3742e-6

0.35
0.3

Energy, Joules

Peak Amplitude, Volts

Energy: RD and good bearing, W1 grease

-4

10

0.5

RD=0.2774

0.25
0.2
0.15

-6

10

Good=3.0248e-7

-7

10
Good=0.0873

0.1
0.05

-8

10
0

10

15

20
25
SW signature

30

35

40

MSc Manufacturing

10

15

20
25
SW Signature

30

35

40

Simulation of bearing defects

Debris: W1 grease
Max amplitude

Energy

Peak Amplitude: Debris and good bearing, W1 grease

Energy: Debris and good bearing, W1 grease

-4

1.4

10

Good
Debris

Debris
Good
1.2
Debris=1.4957e-5
-5

10

Energy, Joules

Peak Amplitude, Volts

0.8

0.6

Debris=0.5429

0.4

-6

10

Good=3.0248e-7
-7

10

0.2
Good=0.0873
-8

10

10

15

20
25
SW signature

30

35

40

MSc Manufacturing

10

15

20
25
SW Signature

30

35

40

Simulation of bearing defects

Discussion: Mechanism of SW formation

The interaction of mating components under
loading condition would break and deform the
surface asperities which generate SW
The presence of the localised defects (ORD, IRD, RD
) with higher surface roughness and distortion
generated higher SW amplitude than b/g noise
ORD: more than one SW signature for every ORD
passage. Each roller had to rub against the full
3mm width of the defect
MSc Manufacturing

Simulation of bearing defects

Discussion: Mechanism of SW formation

IRD & RD: SW were only detected for a certain period of
time. SW generated when the IRD and RD were in the
loading zone
Grease contamination: SW activities random in time. SW
generated by the crushing activities of the debris particles
at the working interfaces. Debris might slide and rub
against the REB components

MSc Manufacturing

Simulation of bearing defects

Discussion: Time domain analysis

The maximum amplitude and energy of ORD, IRD , RD &
grease contamination fluctuated randomly. Attributed to
the breakage and deformation of the asperities were
inconsistent in nature
ORD: different orientation the roller struck the ORD.
IRD: the orientation of the roller struck the IRD and the
variation of the defect position in the loading zone.
RD: the orientation the defective roller rubbed the outer
and inner race. Also movement of roller in the loading zone
Grease contamination: could occur from any position and
with varying SW strength
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10

Simulation of bearing defects

All types of defects and debris: W1 grease

Max amplitude

Energy

Peak Amplitude: All defects and good bearing, W1 grease

ORD
IRD
RD
Good
Debris

1.2

Debris=1.4957e-5
-5

10

ORD=5.2537e-6
RD=4.3742e-6

Energy, Joules

Peak Amplitude, Volts

Energy: Defects and good bearing, W1 grease

-4

10

1.4

0.8

0.6

Debris=0.5429

IRD=2.6732e-6
-6

10

Good=3.0248e-7

-7

0.4

ORD
IRD
RD
Good
Debris

10

ORD=0.3344
RD=0.2774

0.2

IRD=0.2095
-8

Good=0.0873

10

15

20
25
SW signature

10

30

35

40

MSc Manufacturing

10

15

20
25
SW Signature

30

35

40

11

Simulation of bearing defects

Discussion: All types of defects and debris, Time domain
analysis
Highest max amplitude and energy are associated with
grease contamination due to crushing activities
ORD recorded the highest max amplitude and energy
among the bearing defects due to the closeness of the
defect to the sensor. Shorter transmission path
Transmission path play an important role in attenuating
the SW signature

MSc Manufacturing

12