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Analysis
J. I. TAYLOR
Gardinier Inc., This paper describes procedures for identifying defects in antifriction bearings from
Tampa, Fla. 33601 analyses of the low frequencies (up to 2,000 Hz) generated by the moving parts in the
Assoc. Mem. ASME bearing. Defects on bearing raceways, the cage, or rolling elements, as well as excessive
clearance, turning on the shaft and loose housing, cause unique vibration signals. A
unique signal is also generated when bearings need lubrication. The spectrum shape,
frequency, amplitude, and sum and difference frequencies are useful in identifying
combinations of defects and their size. Information as to whether the bearing is in a
thrust or radial loaded condition is presented.
Introduction
Data are necessary for effective identification and analysis of tape recorder was used to record the vibrations at the various
problems in rotating machines. This paper is concerned with the monitoring points. The recorded data were fed into a spectrum
identification of defects in antifriction bearings, including those analyzer. A copy of the spectrum made with an X-Y recorder
in outer race, inner race, balls or rollers, and Cage. Signatures of was analyzed to identify any problems.
bearings with excessive internal clearance and inadequate lubri- The limits of a significant change in vibration level depend
cation are also presented. Some information on bearing installa- on the type of equipment involved and the cause of the vibration.
tion can be obtained from signatures; for example, whether or For a coupled pump and motor that normally vibrate at 0.07
not the installation has imposed a thrust or radial load. Em- IPS (0.17 cm/sec) a change of 0.05 IPS (0.12 cm/sec) could be
pirical evidence suggests that defect size can be measured within significant and should be checked out. On the other hand, a
certain limits. bucket elevator that normally vibrates at a wide range on either
All of the data were obtained from on-line operating machines. side of 0.5 IPS (1.2 cm/sec) could be checked on a periodic basis
They operate at relatively slow speeds — up to 3,600 RPM —• and or when a change of 0.3 IPS (0.76 cm/sec) occurred.
include electric motors, fans, pumps and speed reducers. Each Defects in antifriction bearings can be identified at 0.01 IPS
defect has been identified repeatedly by spectrum frequency, (0.02 cm/sec), an increase of 0.1 IPS (0.25 cm/sec) in a bearing
shape, amplitude, and sum and difference frequency. Table 1 is defect could thus be important, whereas an increase of 0.1 IPS
a summary of bearing defects that have been identified by tech- in an unbalance condition might cause little concern.
niques described in the following pages. Excessive vibration can be defined as that level of vibration
The formulas for determining the various frequencies generated that experience has shown to be harmful to a particular piece of
by antifriction bearings were developed by such experimentalists equipment. For a directly coupled pump and motor excessive vi-
as Miller1 and Martin2, their publications have been helpful in bration could be 0.15 IPS (0.38 cm/sec) at a bearing frequency.
analyzing the signals generated by defects in bearings. For a fan that weighs 2,000 pounds (907 kgs) 0.25 IPS (0.68
cm/sec) at the running speed could be excessive. At the other
Data Collection extreme, a light fan (20 Lbs) (9 kgs) could vibrate at 1.0 IPS
(2.54 cm/sec) at the running speed for long periods without
Data sheets for equipment to be checked were prepared, and incident.
monitoring points were selected. The vibration velocity at the All data in this paper were gathered using a seismic pickup
monitoring points was measured in inches per second (IPS) and with a magnet base. All spectra are presented in the linear mode.
recorded each week. Although such weekly monitoring is not The average given are based on 32 samples. Amplitudes are
proposed as a standard, it is justified in hostile environments. calibrated in IPS, with each major division equal to 0.1 IPS
When a significant change in vibration occurs, a scientific quality (0.25 cm/sec). This calibration is important because more sensi-
tivity permit unwanted data to be displayed and less sensitivity
'Miller, T. D., "Machine Noise Analysis and Reduction," Sound and Vibra-
tion, S&V-4 March, 1967. eliminate desirable data. However, more calibration sensitivity
may be required when analyzing speed reducers.
»Martin, R. L„ "Detection of Ball Bearing Malfunctions," Instruments and
Control Systems, Dec. 1970. In some machines, a defective bearing frequency may be very
close to a harmonic of the rotational frequency vain pass/blade,
pass frequency, or some other available frequency. When this
Contributed by the Vibrations Committee and presented at the Design
Engineering Technical Conference, St. Louis, Mo., Sept. 10-12, 1979 of the
occurs, serious analysis errors can be made. These errors can be
AMERICAN SOCIETY OF MECHANICAL ENGINEERS. Manuscript received at ASME avoided by using a spectrum translator for detail analysis of
Headquarters May 29, 1979. Paper No. 79-DET-14. selected frequency windows.
if> .2
eo (.50)
.1 .3 .~ .1 .2 .3
FREQUENCY (KHZ> FREQUENCY (KHZ>
(a) (a)
Fig.1(b) Fig.2(b)
Fig.1(a) Outer Race Defect. This spectrum was taken from a 200 HP Fig.2(a) Inner Race Defect. This spectrum was taken from a 200 HP
electric motor. The drive end bearing is a SKF N319 cylindrical roller electric motor. The fan end bearing is a SKF 6313 ball bearing. The
bearing. The motor speed is 29.6 Hz. The ball pass frequency for a motor speed is 20 Hz. The ball pass frequency for a defect on the inner
defect on the outer race Is 172 Hz. The spectral line at 172 Hertz is the race is 98 Hz. The spectral line at 98 Hz Is the electronic representa-
electronic representation of large defect on the outer race of the tion of the small defect on the inner race of the bearing in Fig. 2(b).
bearing in Fig. l(b).
The pitch diameter (Pd) is the diameter measured across the narrow band spikes at the ball pass frequency and at the ball
bearing from center ball (or roller) to the center ball (or roller). pass frequency plus or minus the RPS. As the defect becomes
The contact angle is the angle me/tsured from a line perpendicular even larger the ball pass frequency sometimes disappears; the
to the shaft to the point at which the balls, or rollers, contact the spectrum then can be a series of spikes. The frequency differ-
race. The contact angle of a deep groove ball bearing is zero. ence between the spikes equals the RPS of the rotating unit. An
It has been found that the computed frequency does not always outer race defect is shown in Fig. 1; Fig. 2 shows an inner race
equal the spectral frequency. The reasons might be that some defect.
slippage occurs in the bearing and that the measuring equipment The formulas indicate the value of the ball pass frequency is
is not entirely accurate. Computations of frequencies by the equal to a percentage of the balls or rollers passing over the defect
percentage. method is sufficiently accurate for most applications. each revolution.
If more accuracy is required the frequencies can be computed. Empirical evidence indicates a sip.gle spectral spike is gener-
An appendix of commonly used bearings and t.he various fre- ated at the ball pass frequency when the defect is not large
quencies is in reference. 8 enough to permit movement of the rotating unit. When the defect
becomes large enough to allow movement of the rotating unit
Defects the ball pass frequency becomes modulated with the speed of
rotating unit. This modulation generates a side lobe to the ball
Defects in antifriction bearings can occur on the raceways, the pass frequency. The difference frequency between the ball pass
cage, or the rolling elements. Such defects cause unique vibration frequency spectrum and the side lobe will equal the speed of the
signals. Excessive clearance and inadequate lubrication can also rotating unit. As the defect increases in size more side lobes are
be identified by their unique vibration signals. generated and at some point the ball pass frequency may no
Raceways. Defective raceways can be identified by a narrow
longer be generated. Instead as series of spikes - the difference
band spike at the ball pass frequency of the race on which the frequency of which is equal to the RPS - is generated by various
defect exists. As the size of the defect increases the band width movements of the rotating unit during each revolution. This
of the spectrum can increase and become modulated with the phenomenon seems to occur when the length of the defect is
RPS. At this point the spectrum could be wide band, with greater than the length required to generate one or two ball pass
frequencies, and applies to both radial and axial loads.
3Taylor, J. 1., "Determination of Antifriction Bearing Condition by Spectral Defects on the inner and outer races tend to behave in a
Analysis," Presented at a Vibration Instt'tute sponsored Seminar, Feb. 1978. similar manner except that the amplitude of the spectrum of an
>-
t:: 1::
~ .1
> <'25)
S .1
~ (,25
.2 .3
FREQUENCY (KHZ> FREQUENCY (KHZ>
(a) (a)
Flg.3(b)
Flg.4(b)
Flg.3(a) Ball Defects. This spectrum was taken from a 60 HP electric
motor. The drive end bearing Is a SKF 6314 ball bearing. The motor Fig. 4(a) Excessive Internal Looseness. This spectrum was taken
speed Is 29.6 Hz. The ball spin frequency Is 61 Hertz and the funda- from the Inboard bearing of a 50 inch (127 em) scrubber fan. The fan
mental train frequency Is 11 Hz. The sectral line at 182 Hz Is three rotates at 29.6 Hz. The bearing is a SKF 22222. The fundamental fre.
times the ball spin frequency. The three spectral lines at 232, 244 and quency of 29.6 Hz and the string of harmonics is characterlsitic of
154 Hz indicates modulation by the fundamental train frequency. looseness of rotating unit. Fig. 4(b) shows the excessive wear on the
The spectral lines In this figure are the electronic representation of one outer race.
defect on the outer race, the defects on the three balls In Fig. 3(b).
thrusting hard against the cage. Normally, defects on the balls
inner race defect is much less than that of the outer race for a or rollers are accompanied by a defective inner race and/or outer
given size defect. The reasons might be that (1) a defect on the race.
inner race is in the load zone only once per revolution, and (2) Excessive Internal Looseness. Excessive internal looseness is
the signal must travel through more structural interfaces to usually a problem in spherical roller bearings mounted with
reach the surface. t,apered bushings. Internal looseness can occur for a number of
reasons: the bushing has become better seated on the shaft, the
Roiling Elements, Balls and Rollers. Defects on rolling elements
lock nut has come loose or abrasives in the lubricant are causing
can generate a ball spin frequency or some multiple of it and the excessive wear. Whatever the cause, the spectrum will contain a
fundamental train frequency. The spectrum can be either of two
one times RPM plus several multiples of RPM (see Fig. 4). Other
types: a narrow band spike at one of the above frequencies or a
characteristics of looseness include low amplitude, a broad band
combination spike in which one of the three frequencies modulates
spectrum of random noise, and a drastic change in balance
a natural frequency, gear mesh frequency, ball pass frequency, or
sensitivity. Care should be exercised in diagnosing this looseness
some other available frequency. When this occurs, the spectrum
because several multiples of RPM can also be caused by a bearing
can be a broadband consisting of a series of narrow band spikes; turning on the shaft. Pumps and electric motors, using ball
the frequency difference between the spikes is equal to the ball
bearings multiples of RPM indicates looseness of rotating unit-
spin frequency and/or the fundamental train frequency. When bearing turning on the shaft. A spectral plot that has a spectral
one ball or roller is defective a BSF is usually generated. It can line at the rotating speed and four times the rotating speed
appear in the spectrum as a narrow band spike or as a sum or usually means the bearing is loose in the housing.
difference frequency. When more than one ball or roller is de-
fective, sums of the ball spin frequency can be generated. The Cage. As has already been stated, some defects on the cage
number of sums is equal to the number of defective balls or rollers. show up at the ball spin frequency. Cage defects can also gen-
For example: If the BSF is 61 Hz and three balls are defective erate the units that are contained in both antifriction and sleeve
a frequency spike should appear at about 183 Hz. If these de- bearings because oil whirl and the fundamental train frequency
fects are large enough to affect the rotation of the cage, an FTF both occur at roughly 40 percent of the RPM for some bearings
can be generated. (See Fig. 3). at particular speeds.
The appearance of a ball spin frequency does not always mean Except for defects that occur in components during manu-
a defective ball or roller. The ball spin frequency could be facturing, the cage is usually the last component to fail. The
generated if the cage is broken at the rivet, and if the balls are typical failure sequence is as follows: defects on the races, the
.3
~(5)
is
~do)
~
u
r::
u
'3 .1
~ <.25) ~ ,1
><.(5)
1.2
Fig. 5 Inadequate Lubrication. This spectrum was taken from the (a)
bearing housing of a dust blower. The bottom spectrum was gen-
erated by inadequate lubrication. The top spectrum was generated
after the bearing was lu bricated.
balls, and finally the cage. A severely damaged cage can cause
constant frequency shifts that cannot be shown in a still picture
but are observable if the tape is played on a real time analyzer.
When the cage is broken in enough places to allow the balls or
rollers to bunch up, wide shifts in frequencies accompanied by
loud noises will occur. When these signs are present, siezure is
imminent.
Inadequate Lubrication. The unique signaturell generated by
inadequately lubricated bearings are characterized by three or
four peaks in the frequency range of 900 to 1,600 Hz. The dif-
ference frequency between the peaks ranges from 80 to 130 Hz.
Some signatures of properly lubricated bearings contain these
frequency components; however, the amplitude is very low -
about 0.0.5 IPS (0.12 cm/sec) or less. The amplitude increases
to as much as 0.2 IPS (0.50 cm/sec) when the lubrication is in-
adequate. See Fig. 5 for a typical signature of a bearing that Fig.6(b)
needs lubrication. Prompt lubrication of the affected part can
Fig. 6(,,) Sum and Difference Frequencies. This spectrum was
reduce the amplitude to a normal level, and the part may not be taken from a 300 HP electric motor. The motor rotates at 29.6 Hz and
damaged. Caution is necellsary because bearing damage can has a SKF 6313 bearing installed on each end. The broad banded
spectral line a 740 Hz Is 5 times the BPF•• This spectral line Is modu.
occur very quickly as a result of inadequate lubrication. lated with the speed of the unit. Fig. 6(b) is the Inner race of the bear-
Empirical evidence indicates that frequencies from 900- Ing that generated this spectrum. Tho failure was caused by inade-
1,600 Hz are natural frequencies of the installed bearing. Similar quate end play in tho motor.
signatures can be produced by preloading and heavy thrust.
Lubrication of preloaded or heavy thrust bearings will not
necessarily help the bearing. When a bearing has a defect(s) Spectral analysis of bearings with multiple defects and units
and is not adequately lubricated the frequency spectrum con- containing more than one defective bearing are usually complex,
tains the frequencies generated by the lubrication problem and and many problems have not yet been resolved. For example,
the frequencies generated by the defect. does a difference frequency of 60 Hz equal two RPS or a ball spin
frequency? It is hoped that experience, more in-depth analysis,
Multiple Defects and more accurate measurements will provide the solution.