7 Causes and Solutions to Bearing Failures in High-Speed Machinery

High-speed machinery is becoming the mainstay. They are usually equipped with bearings to provide smooth and efficient movement. Bearings reduce friction between movable parts, so they carry out their functions efficiently. However, bearings have the potential to fail when used at a high speed for an extended period.

When bearings fail, the consequences may be detrimental, as you can experience reduced productivity and equipment damage. As a professional or someone new to manufacturing, it is important to know the causes of bearing failures and practical solutions to mitigate them. Read on to get started! 

What Are Bearings in Manufacturing?

Bearings are mechanical structures used when manufacturing large machines and equipment. They come in varying sizes and are placed in between two movable pieces. When properly installed, bearings reduce friction and allow the components to rotate at a high speed without breaking or failing. Furthermore, these mechanical devices work with both axial and radial loads and improve overall productivity. 

There are different types of bearings you can use during part manufacturing. Some of the most common types are 

Ball Bearings: They are made up of two rings with tiny balls as the rolling element. Ball bearings are suitable for heavy-duty applications as they can handle axial and radial loads. 

Roller Bearings: Roller bearings have many subtypes depending on the element's shape. You can find them in cylindrical or spherical shapes. Roller bearings have a large surface area and accommodate more load than ball bearings. 

Plain Bearings: This type of bearings is devoid of rolling elements of any kind. They have a smooth surface and press directly against the sliding components. Plain bearings are affordable and easy to install.

Magnetic Bearings: As the name implies, this bearing type is equipped with a magnetic field. Magnetic bearings do not make physical contact with the structure. Hence, they do not wear quickly. 

Thrust Bearings: Thrust bearings exclusively handle axial loads parallel to the rotation axis. They ensure even load distribution when correctly aligned. Thrust bearings come in different sizes and designs.

7 Causes and Solutions to Bearing Failures

Bearing failures can happen when using industrial machines and equipment. The effects can be detrimental as you can experience downtime and reduced equipment lifespan. The following are the seven major causes of bearing failures and how to tackle them to improve operational efficiency. 

#1- Insufficient Lubrication

One of the reasons bearings can fail when in use is when you do not apply enough lubricants. The lubricants serve as food as they keep bearings alive and active. Bearing lubricants come in different kinds, including grease, oil, solid, and speciality. They ensure proper heat dissipation and prevent friction and wear. 

Solutions

• Use the right type and grade of lubricant to ensure compatibility.

• Have a lubrication schedule in place and follow it adequately. 

• If possible, install an automated system to ensure continuous lubrication for heavy machines. 

#2- Contamination and Debris

The effect of contaminants on bearings adds up. Contaminants include everything from dirt and dust to metal shavings and moisture. The empty spaces on the bearings house the pollutants. Dirt comes from different sources, including environmental and lubricants itself. The presence of dirt and debris causes detrimental damage. They increase friction and can wear the bearings and the structures in no time. 

Solutions

• Use good shields that can act as a barrier to entry.

• Properly filter the lubricants to prevent them from being a reservoir.

• Ensure the operating environment is clean and install a system that removes dust from the atmosphere. 

#3- Improper Installation and Misalignment

The effects can be fatal when bearings are not correctly installed. These devices must align with the shaft to function well. Improper installation and misalignment lead to uneven load distribution as a section of the bearing will be subjected to more load than the other. The result is excessive vibration and production of noise when using the machine.

Solutions 

• Align the bearings with the housing during installation. 

• Do not use force from a hammer and other heavy tools during installation. 

• Train all personnel to use alignment tools correctly and watch out for the signs of misalignment. 

#4- Overloading and Excessive Stress

Just like humans, bearings have a breaking point. When you use them beyond their capacity, they break down and lead to machine failure. Overloading bearings or subjecting them to excess stress will increase friction and wear them out quickly. They can deform permanently and will have to be replaced.

Solutions 

• The bearings you use should be of the right size and must have the capacity to handle the load.

• When using the machines, do not overload or subject them to excessive stress. 

• Additionally, install shock absorbers to reduce the effects of overloading.

#5- High Temperature and Thermal Expansion

Another cause of bearing failure is excessive temperature and thermal expansion. While most bearings work at a high speed, you should not go above the permissible limit. Using bearings at a high speed for a long time will cause overheating and thermal expansion of the components. The inconsistent heating and cooling process will introduce residual stresses and lead to cracks or spitting. 

Solutions 

• Use heat-resistant lubricants that serve as thermal insulators. 

• When utilising the machines, make sure to include cooling systems to prevent overheating.

• Regularly monitor the operating temperature when the bearings are working.

#6- Corrosion and Chemical Attack

Corrosion from chemicals and moisture can also lead to bearing failure. Moisture is usually from the operating environment and cleaning agents. Conversely, chemical corrosive substances are products of lubricants and liquids the machine processes. Corrosion can damage the surface of bearings and weaken them. It causes rust and leads to bearing failure. 

Solutions 

• When cleaning bearings, properly dry them and do not flood them with fluid.

• Make sure the lubricants are compatible with the bearings to prevent unwanted reactions. 

• Apply protective coatings to reinforce the mechanical properties of the bearings. 

#7- Poor Maintenance and Repair Practices

A poorly maintained bearing will inevitably fail beyond repair. After installing bearings, take actions to minimize degradation and ensure longevity. You must properly maintain the bearings routinely to prevent excessive breaking. This will reduce machine downtime and the cost of emergency repairs.

Solutions 

• Inspect the bearings and machine itself before every use. 

• Properly lubricate the bearings to reduce degradation. 

• Once you see signs of worn out or detect damage, repair or replace the bearings.

Conclusion

Bearings are indispensable in part assembly. They serve as a connecting mechanism between two movable parts to ease motions and prevent friction. Without adequate preventive strategies, the various types of bearings can fail and break down. It may prevent the entire system from functioning and reduce productivity. To prevent this, align and install bearings and do not use them past their limit. You should also lubricate them and avoid exposure to contaminants.