Bearings are primarily used to reduce load friction. However, in many industry applications, the bearing may have to cope with elements not exactly aligned because of machine design and operation. For example, a shaft may flex, bend, or move under significant strain or movement. In such scenarios, spherical roller bearings are an ideal solution.
Spherical roller bearings lower component stress, limit the chance of failure and lengthen equipment life by automatically correcting misalignment without sacrificing performance. In short, it is helpful in cases where limitations in the design of normal ball bearings might create problems. They are perfect for heavy-duty use, such as in mining, construction, paper mills, and gearboxes. Let us discover effective ways to resolve misalignment problems with spherical roller bearings.
Types of Spherical Bearing Failures
Spherical bearings, normally used in heavy equipment, machines, and automotive applications, require angular movement and weight support and can experience several kinds of failures.
Below, we have mentioned a few of the common spherical bearing failures:
Wear and Scratch
One of the most common occurring failure types is abrasive wear. It happens when a foreign particle contaminates the grease in the bearing. These impurities produce scratches, grooves, and a usually dull or lapped look on the rollers and smooth raceways of the bearings. Its primary reasons are the entry of dirt, sand, metal shavings, or other abrasive particles into the bearing. It is also due to unclean work environments, tools, or hands during installation and maintenance.
Brinelling
Brinelling in bearings is a permanent deformation in their raceways. Brinelling, the persistent plastic deformation of the bearing surface, is caused by the material-generating strength of the raceway being exceeded by the rolling elements—balls or rollers. The holes in the raceways can quickly lead to ramming and extra vibration, which may accelerate other types of wear, including spalling, and ultimately cause bearing failure. Spalling is the pitting or chipping away of the bearing finish occurring in the rolling parts and the races.
Misalignment
Spherical bearings are designed to adjust when the joined parts, such as shafts, are not flawlessly aligned. However, extreme misalignment causes rough wear and early failure. One of the major reasons for fail of bearing in industrial equipment such as motors and pumps is misalignment. If the bearing is improperly placed, radial or angular discrepancies might follow. In high-speed or heavy-duty applications, operational elements such as noise and shock provide dynamic strain that may misalign bearings and shafts. Reducing errors and maximizing bearing performance and longevity calls for tackling these core causes via appropriate setup techniques, monitoring systems, and maintenance processes.
Improper Installation
Inappropriate installation methodologies could compromise component reliability, causing early wear out, decreased performance, and perhaps failures. Mistakes, poor fastening, or improper torque delivery may all result in vibrations, additional strain, and particular harm. These flaws speed up tiredness over time, producing damage or deviations that jeopardize structural integrity. Correct installation with careful handling reduces dangers, extending resilience and boosting efficiency.
Temperature Extremes
If the bearing is used in temperatures that are too hot or too cold compared to what it’s designed for, the materials inside the bearing can change. These changes may cause components to distort, wear more, and lose lubrication, and bearing failure might follow.
Spherical roller bearing failure analysis
- A bearing failure analysis follows these steps to gather data and identify the failure’s specific cause:
- When dismantling the bearing, professionals visually check it and evaluate its state.
- A lab study takes place where the oil samples and other particle sorts inside the components are studied in a laboratory.
- Every piece of operational data, including bearing temperatures, oil outlet temperatures, vibration phases, and pressure degrees, is evaluated.
- Experts can check the root cause along with the history of breakdown and current functioning changes.
- The entire process ends with a final study of what led to failure. This helps prevent future failures and improve design or maintenance.
Root Cause Analysis of Spherical Bearing Failure
Knowing the kind of bearing failure can assist one in ascertaining the main cause of the issue and carrying out sensible repairs. The following techniques help to distinguish any bearing failure:
Overheating
Measuring the bearing temperature using a temperature probe may assist in spotting overheating. Exceeding the recommended temperature can cause possible overheating problems.
Contamination
Examining the bearing surface for obvious wear or damage can be a sign of contamination. Discolored or polluted lubricant is another indication of contamination.
Inadequate Lubrication
Checking the grease or oil for indicators of wear or yellowing may help one find insufficient lubrication.
Misalignment
Using a laser alignment tool helps one to find misalignment problems by verifying the bearing and shaft alignment.
Corrosion
Looking at the bearing surface for corrosion indicators, like pitting or cracking, helps one spot corrosion challenges.
Electrical Pitting
Assessing the bearing surface for obvious cracking or pitting may enable one to figure out electrical pitting.
Improper Mounting
Using appropriate installation techniques will enable one to find the faulty mounting of the bearing.
Spherical Roller Bearing Fit Tolerance
Correct operation and its lifespan depend on spherical roller bearing fit tolerances. The bearing's fit with either a shaft or a housing affects load distribution, vibration, and wear. Depending on application need, common fits include interference, transition, and clearance fits. Tolerance zones defined by ISO 286 guarantee the best performance. Operating temperature, load direction, and rotating speed influence the fit choice. While loose fittings are easy to assemble, misalignment is a danger. Engineers have to strike a balance between flexibility and accuracy to maximize bearing life and performance. Selecting correctly reduces maintenance costs and improves dependability.
Bottom Line
Handling misalignment and guaranteeing the smooth operation of heavy-duty equipment depend critically on spherical roller bearings. Knowing the many kinds of bearing failures and investigating their underlying causes helps one to respond quickly in corrections. Industries may decrease downtime, save maintenance costs, and improve equipment dependability by choosing the right fit tolerance and following best practices in installation and maintenance.
In essence, resolving misalignment using spherical roller bearings is all about creating stronger and more effective structures over the long term.