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Basics of Bearing Maintenance Course Notes

The document provides an overview of bearing maintenance, including construction, materials, and factors influencing material selection. It details common causes of bearing failure, types of damage, and preventive measures, emphasizing the importance of proper installation and maintenance practices. Additionally, it covers mounting and dismounting methods for bearings to ensure effective operation and longevity.

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13 views5 pages

Basics of Bearing Maintenance Course Notes

The document provides an overview of bearing maintenance, including construction, materials, and factors influencing material selection. It details common causes of bearing failure, types of damage, and preventive measures, emphasizing the importance of proper installation and maintenance practices. Additionally, it covers mounting and dismounting methods for bearings to ensure effective operation and longevity.

Uploaded by

testing101new
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Basics of Bearing Maintenance – Course Notes

Bearing Construction and Function


Bearings are mechanical components designed to reduce friction between moving parts. Plain
(sleeve) bearings typically support shafts that rotate or oscillate and are made as monometal,
bimetal, or trimetal structures.

• Monometal: Solid metal (e.g., bronze, aluminum), used in light-load applications.


• Bimetal: Steel backing with soft metal lining (Babbitt, copper-lead, or aluminum).
• Trimetal: Combines a hard layer (e.g., copper-lead) with a thin soft overlay for durability and
embeddability.

Common Bearing Materials


• Babbitt (lead or tin-based alloys)
• Copper-lead alloys
• Aluminum-based alloys
• Bronze and its variations
Each material is selected based on performance needs such as strength, embeddability, and
thermal conductivity.

Factors Influencing Material Selection


• Load capacity and fatigue strength
• Embeddability and conformability
• Corrosion resistance and temperature strength
• Lubrication condition and cleanliness
• Application environment (e.g., dust, heat, contaminants)

Bearing Material Requirements


• Surface Action: Resist seizure during metal contact
• Embeddability: Absorb contaminants safely
• Conformability: Adjust to geometric irregularities
• Fatigue Strength: Resist cracking under cyclic loads
• Thermal Conductivity: Disperse heat efficiently
• Corrosion Resistance: Withstand oil breakdown products

Improper Mounting or Installation


Improper crush, misalignment, debris during assembly, and incorrect torque cause bearing
fretting, distortion, and early failure. Always use clean parts, proper tools, and follow torque
specs.

Common Causes of Bearing Failure


• Contamination (dirt, debris)
• Inadequate or wrong lubrication
• Misalignment and crush issues
• Excessive load or speed
• Incorrect installation

Types of Bearing Failure & Prevention


1. Wear Damage:
Caused by contaminated lubricant (dust, metal particles), metal-to-metal contact from oil
starvation, improper filtration, Misalignment or overload. Preventive maintenance: regular
lubrication, contamination control, proper installation practices, load and speed control, routine
inspection & monitoring.

2. Indentation/Brinelling:
reasons of it are improper mounting during installation, excessive load, containing contaminated
debris.
True brinelling from static overload; false brinelling from vibration.

Prevent by using proper installation tools and correct press fit methods.

3. Cracking Damage:
Due to fatigue from cyclic stress, thermal expansion, or misalignment. Prevent by rechecking
tolerances and material strength.

🔧 Cracking Damage – Key Locations

 Raceways (Inner/Outer Ring)


o Cause: Fatigue from cyclic load, misalignment
o Location: Load zone of the ring
o Prevention: Correct fit, alignment, lubrication
 Rolling Elements (Balls/Rollers)
o Cause: Subsurface fatigue, contamination
o Effect: Radial cracks, surface flaking
o Prevention: Clean oil, avoid overload
 Cage
o Cause: Vibration, poor lubrication, misalignment
o Location: Rivet holes or pocket corners
o Prevention: Balance loads, reduce vibration

4. Cage Damage:

Due to misalignment, excessive vibration, poor lubrication, material fatigue. Prevent via balanced
loads and clean, smooth operation.
Hot-Short Phenomenon
The Hot-Short Phenomenon occurs when localized high temperatures within a bearing cause
the low melting-point elements (typically lead or tin in bearing alloys) to melt. This results in
softening, erosion, or cracking of the bearing surface, particularly in high-load, high-speed, or
poorly lubricated systems.

Causes:

 Oil starvation (no or low lubricant flow)


 Contaminated oil (abrasives causing frictional heat)
 Excessive operating temperatures
 High bearing load or speed without adequate cooling
 Inadequate heat dissipation (poor housing design or cooling system)

Effects:

 Localized melting or blistering of the bearing lining


 Cracking or flaking of the surface layer
 Loss of load-bearing capacity
 Rapid and severe bearing damage

Preventive Measures

 Ensure proper lubricant selection (temperature-resistant oils)


 Maintain uninterrupted oil flow
 Avoid oil contamination with dust or metal particles
 Improve bearing cooling systems
 Avoid operating conditions that exceed design temperatures

Cavitation
Cavitation in bearings is a damaging physical phenomenon caused by rapid formation
and collapse of vapor bubbles in the lubricant. Here's how it typically unfolds:

1. Pressure Drop in Lubricant Film

During high-speed rotation or irregular oil flow, the pressure in parts of the lubricant film
can drop below the vapor pressure of the oil. This often happens near the trailing edge of
the bearing surface where flow separates or changes rapidly.

2. Vapor Bubble Formation


When the local pressure drops too low, vapor bubbles form in the oil — much like
boiling at a lower temperature due to low pressure.

These bubbles are not filled with air, but with vaporized lubricant.

3. Bubble Collapse (Implosion)

As the shaft continues to rotate and the lubricant moves into a higher pressure region, the
vapor bubbles are suddenly crushed (imploded). This implosion creates a shock wave or
micro-jet of fluid directed at the bearing surface.

4. Surface Damage

These tiny but powerful impacts erode the metal, creating pits, craters, or a honeycomb
texture on the surface. Over time, this pitting leads to loss of load capacity, vibration, and
eventually bearing failure.

Mounting and Dismounting Bearings

🛠️ Bearing Mounting Methods

1. Press Fit

The bearing is pressed onto a shaft or into a housing using mechanical force.Common for
small- to medium-sized bearings. Requires press tools or arbor presses.

2. Shrink Fit

The shaft is cooled (e.g., with dry ice) or the housing is heated (e.g., with an induction
heater).The bearing is mounted while there is a temporary clearance; tight fit occurs after
temperature equalizes.

3. Interference Fit

The bearing bore is slightly smaller than the shaft diameter. Requires force to fit;
provides very strong retention. Common in high-load applications.

4. Adhesive Bonding

Uses industrial adhesives for mounting. Suitable for low-load, low-speed applications.
Avoids mechanical stress on components.

🔧 Bearing Dismounting Methods

1. Mechanical Pullers
Manual or hydraulic pullers apply pulling force. Used when there is access behind the
bearing. Risk of damage if not properly aligned.

2. Hydraulic Pullers

Use hydraulic pressure to exert uniform force. Ideal for larger or tightly fitted bearings.
Safer and more efficient than manual methods.

3. Oil Injection Method

Pressurized oil is injected between the shaft and bearing surface. Reduces friction,
allowing smooth removal. Requires special grooves in the shaft or housing.

4. Heating and Cooling

Heating the bearing or housing expands it for removal. Cooling the shaft shrinks it,
easing dismounting. Common in combination with pullers or injection.

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