1. FAILURE OF ROLLING CONTACT BEARINGS

2. Rolling Element Bearings
DEFINITION:
The medium of contact in between the rigid frame and movable parts in a machine is called bearing.
Bearings are common machine components.
Two types of bearings
Plain or sleeve bearing.
Anti-friction or rolling element bearings.

3. Types of roller bearings:
Cylindrical roller bearing.
Spherical roller bearing.
Taper roller bearing.
Needle roller bearing.
Needle roller thrust bearing.
Spherical roller thrust bearing.

4. Principle of roller bearing:
it is designed on the principle of rolling contact rather than sliding contact.
So the friction is very less in roller bearings compared to slider bearings.

5. Types Of Failures Failure by wear:
wear failure is due to the insufficient lubrication in the roller bearing.
If the lubrication is adequately and correctly applied there is no wear failure in the bearing.
In practice wear is caused by the entry of dirt,hard particles, or corrosive fluids causing increase in the running clearances of the various parts of the bearing,which may lead to noisy operation and early failure of machine.

6. Failure by dirt:
Roller bearings are very sensitive to dirt or foreign matter,because of the very high unit pressure between the rollers and raceways.
Due to the rolling action of the balls dirt particles will easily enter in to the bearing.
Foreign material may get in to the bearing during its initial assembly,during repairs or by seepage from the atmosphere in to the bearing housing during operation of the machine.due to this bearing become loose and noisy

7. Failure by hard particles:
Usually non metallic, of any size that will scratch, cut or lap the surface of a bearing are called hard particles
This failure is also known as third particle abrasive wear. This failure usually occurs on the load carrying surfaces.
Some metallic particles like iron oxide power will ailso cause failure on the load surface. since iron oxide is a good lapping compound.

8. Failure by corrosive fluids:
Water, acid, or other corrosive fluids, including corrosive formed by deterioration of the lubricant, produce a type of failure that is characterized by a reddish brown coating and very small itch points over the entire exposed surfaces of the raceways.
Usually corrosion will not occur on the ball path because of the rolling action the balls pushes the lubricant

9. Failure by electric pitting:
It is produced by passage of electrical current betweeen two surfaces.
Applications such as electric equipment,locomotives and rail way cars there is a possibility of electric current passing through the bearings.
When current is broken at the contact surfaces between raceways and rolling elements, arcing or sparking occurs, producing high temperature and localised damage.
The overall damage is proportional to the number and size of localised points.

10. Failure by cumulative material transfer:
A type of failure some times called smearing or galling results from considerable sliding between bearing contact surface.it is characterized by the formation of welded junctions between the contact surfaces.
This welding usually occurs on a localized microscopic scale and results in removable of material from one or both bearing surfaces by tearing action.

11. Failure by rotational creep:
Rotational creep occurs on inner ring of bearing.
It may result from the ring being initially loose on the shaft as a result of fitting errors or from plastic or elastic deformation due to abnormal loading conditions or severe imbalance.
Rotational creep may also occur in thrust bearings if the shaft against which the ring about is not perpendicular to the axis.

12. Failure by damage:
bulk damage failures are the result of damage to bearing components outside the contact zone.
Deterioration of the bearing results from one or more cause, inducing overheating, overloading, bulk fatigue fretting, and permanent dimensional changes.

13. Failure Mechanism Wear mechanism:
There is a limited number of modes or mechanisms by which small amounts of material can be removed from a larger body. these are ductile fracture, brittle fracture, high cycle fatigue, low cycle fatigue, and melting, chemical dissolution. hydrogen ebrittlement is an example of a hybrid mechanism in which ordinary ductile material may fracture in a brittle manner.

14. Fatigue: Electrical erosion:
Segments of a long lived bearing may fail by fatigue. A bearing may have many cycles of varying load on it, as in engines, or may have an unbalanced load, as in other machinery. Fatigue failure will be hastened by high stress and by corrosive environment.
Electrical erosion:
some bearings, particularly those in steam turbines, may have an electrical potential applied across them, usually anadvertently.

15. When the gap spacing in the bearing is small and the applied potential is high enough,
sparks will pass through the oil film and cause
Erosion. The bearing surfaces will not be reflective, but will appear frosted.
Fretting:
When oscillatory sliding occurs with an amplitude of the order of 0.05 m, fretting occurs. This may happen on the outside of the bearing backing, against the housing of the machine

16. Corrosion: Cavitation:
Several products of degradation of oil (alcohols, aldehydes, ketones, and acids) contaminants (such as water), and some anti-wear additives in oil cause corrosion. A corrosive may selectively attack an alloy, removing only one element.
Cavitation:
In certain areas of fluid flow along a solid boundary, high pressures and low pressures can develop. If the negative pressure is high, cavities can form in the fluid.

17. Foreign particles: Misalignment:
Dirt, chips, and abrasive grit cause wear by abrasion. This is a problem in all applications of sliding bearings. One insidious effect of foreign particles is that they may scratch or score the shaft surface severely, which adds move foreign particles to the system.
Misalignment:
Some bearings are improperly assembled and fracture very early in use. Some bearing-holder systems deflect excessively. The result of misalignment is a distorted wear pattern.

18. PRVENTIVE METHODS: For dirt failure: For fatigue failures:
Proper maintenance.
Grinding and polishing the journal surfaces if necessary.
Changing the oil and filters at regular interval.
For fatigue failures:
Proper lubrication
Maintenance of oil-film thickness at desired level.

19. For hot shot phenomenon:
Temperature at contact surface should not be allowed to rise more than the specified level.
Flow of oil, free from dirt should be ensured.
For fretting failure:
Mating faces of the bearing assembly should be cleared and made burr free while installation.
Attention should be given regarding load carrying capacity.

20. For excessive interference problems:
Care should be taken during mounting, specially regarding fit selection.
For corrosion problems:
oil suppliers may be consulted.
Investigation may be made for possible coolant leakage into oil.

21. THANK YOU