Bearing Failure Modes

Precision bearings are essential components designed to support and guide motion across a wide range of applications. These industrial parts come in various forms, with roller bearings being among the most widely used due to their reliability and durability. In fact, over 99% of roller bearings meet their expected service life under normal operating conditions, even when subjected to extreme environments. Despite their robust nature, a small percentage of bearings do fail prematurely. This issue is often attributed to several interconnected factors. Surface damage such as flaking, pitting, spalling, rusting, corrosion, creep, and misalignment are common culprits. Each of these concerns typically arises from a few preventable causes. Among the most frequent reasons for failure are: **Inadequate Lubrication** – Proper lubrication is vital for maintaining bearing performance and extending its operational lifespan. However, incorrect lubrication practices—such as using too much or too little grease, mixing incompatible lubricants, or allowing contaminants into the system—can severely impact the bearing's functionality. Bearings also have a "grease service life," which represents the optimal period between lubrication cycles. Neglecting to refresh the lubricant within this timeframe can result in bearing failure. **Improper Mounting and Installation** – The installation process demands precision. Using the correct tools and techniques is critical to ensure that the mounting pressure is evenly distributed. Applying force to the wrong part of the bearing, especially with self-aligning types, can dent the raceways and rolling elements. Additionally, a poor fit—whether too loose, too tight, or misaligned—can distort the preload weight, potentially causing the shaft to rotate improperly or creep. **Operational Stress and Bearing Selection** – While roller bearings are generally dependable, the systems they operate within may evolve over time. Changes in load conditions—either excessive or insufficient—can lead to bearing fatigue or skidding. Signs of these issues include rising temperatures and unusual noises. **Environmental Factors** – External elements like dust, dirt, moisture, and extreme temperatures can compromise bearing performance if not adequately sealed. Depending on the application, some bearings might require insulation to protect against electrical currents or sparks. Always consider external variables that could affect your specific setup and take appropriate measures to mitigate risks. Understanding the different bearing technologies available and selecting the one best suited for your application is the initial step toward preventing premature failure. By staying vigilant about these causes and their warning signs, you can preemptively address potential issues before they escalate into costly repairs. At Emerson Bearing, we bring over five decades of expertise in ball and roller bearings. Our global reach extends to serving original equipment manufacturers (OEMs) and maintenance sectors, helping clients find the ideal bearing solutions tailored to their needs. For further insights into diagnosing and resolving premature bearing failure, we encourage you to explore our comprehensive eBook, "Bearing Failure Analysis." In conclusion, while precision bearings are built to endure significant wear and tear, taking proactive steps to maintain them ensures longevity and efficiency. By staying informed and prepared, you can safeguard your investment and optimize your operations.

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