Bearing analysissoftware

Vibration sensors are designed to attach to industrial assets, particularly machinery with high-speed rotating components, to monitor the amount and characteristics of their vibration. Specifically, vibration monitoring continuously measures a rotating asset’s root mean square (RMS) velocity, which provides a uniform measure of vibration over a wide range of machine frequencies, RMS high-frequency acceleration, and peak velocity. Sensor data showing these characteristics at optimal levels is indicative of good overall machine health. If a machine is vibrating abnormally compared to baseline conditions, that could indicate an imbalanced, misaligned, loose, or worn part—for example, a belt, fan blade, or bearing requiring service or nearing the end of its useful lifecycle. Increasing vibration can be a sign of increasing potential damage to the machine.

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Being able to identify failure modes and causes of rolling bearing damage is the first step towards avoiding repeat failures and improving machinery reliability.

With this in mind, the International Organization for Standardization (ISO) has published ISO 15243, a standard that provides a classification of the different failure modes that occur in rolling element bearings. For each failure mode, the standard describes the characteristics, appearance and possible causes of the failure. The most recent version of the standard was published in 2017.

Bearingdamage types

SKF’s data1 identifies the five most common ISO failure modes to be abrasive wear (26 %), surface initiated fatigue (16 %), moisture corrosion (14 %), adhesive wear (7 %) and current leakage erosion (7 %) (fig. 20). These failure modes represent approximately 70 % of all the failure modes identified in the bearing investigations, although fretting corrosion is seen in most bearings, even if minor in nature. The other ISO failure modes are observed but to a lesser extent.

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The data shows that most bearings are removed from operation because of excessive vibration and noise. Bearings are also removed from operation when maintenance is done on the machinery or when excessive temperature is experienced (fig. 2).

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Bearings are one of the most common elements in modern industrial machinery. They connect the rotating part (shaft) to the stationary part (housing) with minimal friction. They allow for the smooth running of machinery ranging from cars and aircraft to generators, conveyors, printing presses and any kind of machinery or equipment that rotates.

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ISO 15243: 2017 [Ref. 1 ] classifies the failure modes that occur while the bearing is installed in the asset/machine and during operation, meaning that it does not include manufacturing-type defects such as missing parts. The ISO failure modes are divided into six categories: rolling contact fatigue, wear, corrosion, electrical erosion, plastic deformation and cracking and fracture (fig. 4). Each of these is divided into subcategories for more specific classification of the failure modes.

Bearing analysispdf

The final ISO category is cracking and fracture. It is classified into three categories: forced fracture, fatigue fracture and thermal cracking. Forced fracture (ISO 5.6.2) (fig. 16) results when stresses exceed the tensile strength of the material. Common causes of a forced fracture are too high a hoop stress from mounting a bearing on a shaft with excessive interference fit or driving a tapered bore bearing too far up its tapered shaft seating or mounting sleeve. Fatigue fracture (ISO 5.6.3) (fig. 17) occurs when the fatigue strength of a material is exceeded under cyclic bending. Repeated bending causes a crack that propagates through the ring or cage. This can occur in a bearing if it is subject to heavy applied loads and the supporting housing does not provide uniform stiffness, subjecting the outer ring to high cyclic stresses. Thermal cracking (ISO 5.6.4) (fig. 18) occurs when two surfaces slide against one another, generating frictional heat. If the sliding is substantial, local rehardening of the surfaces in combination with the development of high residual tensile stress causes cracks, which are generally at right angles to the direction of the sliding. Thermal cracking can occur if a stationary housing, for instance, comes into contact with the rotating bearing ring.

Here we provide a summary of the ISO failure modes for rolling bearings as well as their causes. But first some basic information.

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Banner provides condition monitoring technology that provides powerful, real-time insight into machine health, including vibration. Consider Banner Monitoring Solutions, end-to-end IIoT networking systems that can be installed in your facility easily and deployed in minutes—without any necessary coding or programming. Start by selecting one of two available Asset Monitoring Gateways, and then choose sensors to monitor the health of your machines. The QM30VT is a sensor that can be connected to measure both vibration and temperature of monitored assets. It outputs actionable data such as RMS velocity, RMS high frequency acceleration, and peak velocity, which are pre-processed from the vibration waveforms in the sensor. Its compact housing fits in tight locations, increases surface contact with machines, and reduces vibration resonance. This sensor is ideal for use with the wired Asset Monitoring Gateway with SNAP ID. The Q45VAC  all-in-one vibration and temperature sensor collects the same data points as the QM30VT, but it is designed exclusively for wireless use. Part of the Q45 Series of wireless sensor nodes, it is fully compatible with the Asset Monitoring Gateway with CLOUD ID. Q45 sensor nodes are ideal for deployment on machines in remote or hard-to-access locations, and they can each run for more than two years on a C-cell lithium battery.  Upon activation, Asset Monitoring Gateways identify connected sensors and immediately begin collecting actionable data. In addition, you can select sensors to monitor many other asset performance variables, including differential pressure, humidity, tank level, and more. You can access metrics from all your facility assets simultaneously for a holistic view of machine health. To create your own custom monitoring solution, Banner offers a handy Bundle Builder tool. This website feature gives you a straightforward, guided process to (1) select the appropriate gateway; (2) decide which specific sensors would be best to use for your individual machine assets; and (3) add related connectivity, if applicable (such as cabling for SNAP ID networking).

The ISO classifies plastic deformation into two categories: overload deformation and indentation from particles. Overload deformation (ISO 5.5.2) (fig. 14) is mechanical damage caused by static overload such as from improper handling (bearing dropped from height), improper mounting (hammering on bearing), peak loads from the machinery operation, etc. It can manifest itself as raceway indentation or nicks on rolling element spacings, damages to cages, seals and shields, etc. Indentations from particles (ISO 5.5.3) (fig. 15) occurs when solid particle contaminants or debris are overrolled in the bearing’s rolling contact area, thus causing indentations (deformations) in the raceways and rolling elements. The size, type and hardness of the particles influences the scope of the damage. Subsequent overrolling of the indentation can lead to surface initiated fatigue (ISO 5.1.3).

In summary, the ISO 15243 is useful to classify the failure modes of rolling bearings that have operated in assets and can be helpful to identify the failure causes. By acquainting oneself with the common bearing failure modes and their causes, one can take corrective actions to avoid a repeat of the failures. This can greatly reduce the risk of unplanned and catastrophic failures and potentially improve the reliability and availability of the assets. Bearings that are removed from operation for maintenance reasons can be inspected for reuse or possibly for remanufacturing.

The next category, corrosion, is classified into three categories: moisture corrosion, friction corrosion and false brinelling. Moisture corrosion (5.3.2) (fig. 9) is a classic issue of moisture ingress into the bearing. The high hardness bearing material has low corrosion resistance. The moisture will cause damage on rolling element spacings when the bearing is at a standstill. The surface deterioration can lead to surface initiated fatigue in subsequent operation. Moisture greatly degrades the capability of the lubricant to develop a film thickness in an operating bearing. Fretting corrosion (ISO 5.3.3.2) (fig. 10) occurs when there are micromovements in an interface between mating surfaces, such as between the bearing inner ring and shaft and bearing outer ring and housing. This can be due to incorrect fitting of the bearing on the shaft or in the housing, depending on the applied load. For instance, a bearing with a rotating inner ring and a steady applied load requires a certain minimum interference fit of its inner ring on the shaft to avoid fretting corrosion. Likewise, a bearing with a rotating inner ring and a rotating applied inner ring load requires a certain interference fit of the bearing outer ring in the housing to avoid fretting corrosion. Fretting corrosion appears as a red/blackish oxidization in the interface. False brinelling (ISO 5.3.3.3) (fig. 11) occurs in the contact area between the rolling elements and raceway subject to small oscillatory motion or vibration. The wear occurs on rolling element spacings. The wear removes the original manufacturing finishes of the surfaces and can also have a red/blackish oxidization on the surfaces, similar to fretting corrosion. The amount of wear is dependent on the intensity of the applied load, intensity of the oscillation and vibrations and the lubrication conditions.

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If needed, a full bearing damage analysis can be made by an SKF application engineer to provide recommendations for reliability improvement. The SKF engineers can use artificial intelligence (AI) [Ref. 3] to augment their bearing damage analysis. The AI uses a computer vision system that can evaluate bearing damage using digital photographs. The system uses artificial intelligence in the form of a neural network image-recognition algorithm that has been trained using thousands of images of damaged bearings from SKF’s archives.

Rolling contact fatigue is classified in two subcategories: subsurface initiated and surface initiated fatigue. Subsurface initiated fatigue (ISO 5.1.2) (fig. 5) is caused by the cyclic loading of the rolling contact surfaces, which over time causes a material structural change where microcracks initiate. The microcracks develop below the surface, often at an inclusion in the material, and propagate to the surface as spalls. The fatigue is influenced by the bearing quality, applied loads, lubrication and cleanliness. This is akin to the bearing rating life, L10mh. The subsurface fatigue can be accelerated if the bearing is subject to high stresses due to, for instance, temporary overload or another event that weakens the material. In these cases, the fatigue life is short (5 % to 10 % of L10mh). Surface initiated fatigue (ISO 5.1.3) (fig. 6) is fatigue initiated on the rolling surface and is typically caused by surface distress due to poor lubrication or poor cleanliness. Inadequate lubricating film and overrolling of solid contamination can result in metal-to-metal contact, causing the surface asperities to shear over each other. Thereafter microcracks can occur, followed by microspalls and finally surface initiated fatigue.

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BearingfailureanalysisPDF

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The SKF BART software is deployed to SKF engineers and is now available to SKF customers. The customer is provided basic training on bearing knowledge, bearing inspections techniques and the use of the SKF BART software. The customer works closely with an SKF application engineer or specialist to complete the inspection report. The BART Inspection report is approved by the SKF expert. The inspection can reveal whether the bearing should be replaced, can be reused, is a potential for remanufacturing or must be scrapped. It can also be used to document the inspection of a new bearing before it is placed in service. This can be helpful if a bearing has been in storage for a long time.

The handbook Bearing damage and failure analysis [Ref. 2] can be useful to identify the bearing failure mode and causes.

Bearing failure mode and cause data and other related data are being collected to gain better insights on bearing operations. The SKF BART software is used by SKF and is available to customers to make bearing inspection and damage analysis reports.

The next category is wear. The ISO classifies wear into two subcategories: abrasive wear and adhesive wear. Abrasive wear (ISO 5.2.2) (fig. 7) is the progressive removal of material, usually in the presence of abrasive material such a particle contaminant. Abrasive wear can also occur because of inadequate lubrication. Abrasive wear is generally characterized by the dull appearance of the surfaces. Abrasive wear is a degenerative process that can eventually destroy the microgeometry of a bearing’s rolling surfaces. Abrasive particles can quickly wear down the raceways of rings and rolling elements as well as cage pockets. Abrasive wear can be caused by the ingress of contaminated material into the lubricant and bearing and a starvation of lubricant in the rolling contact.

SKFbearingfailureanalysispdf

Vibration sensors should be positioned as close as possible to a rotating asset. In the case of a motor, for example, the sensor should always be mounted to a casted or structural surface of the asset, with one axis mounted radially (in line with the path of rotation), and with the other axis mounted axially (in line with the shaft of the motor). The sensor should never be mounted on guards, shielding, boxes, covers, or other indirect surfaces. The most effective mounting location is typically at the top and center of the motor, close to the  bearing. There are many different approaches to mounting Banner vibration sensors, using brackets with screws, thermal tape, epoxy, or magnets. Vibe-IQ is a Banner machine-learning technology that takes the complexity out of setting the warning and alarm thresholds for vibration levels on your rotating assets. Built into gateways, this feature allows you to spend time on profit-driving production rather than on sensor adjustments and calibration. It automatically interprets data from vibration sensors to accurately characterize the vibration of rotating assets. Vibe-IQ determines an asset’s normal operating vibration and temperature and sets these levels as baseline operating values. This automated process configures the gateway to send alerts whenever a monitored asset’s vibration characteristics deviate from the baseline values.

Keep in mind that the lubricant (oil or grease) from within the damaged bearing can also provide insight in the bearing investigation. A lubricant sample should be taken for comparison with the fresh sample. A lubricant analysis can be made to consider particle and moisture contamination content, changes in viscosity, change in grease consistency, etc.

People working with industrial machinery would do well to gain a better understanding both of how they work and how they sometimes fail prematurely in operation.

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With sensors, gateways, connectivity solutions, and Cloud Data Services, Banner provides comprehensive solutions for maximizing the potential of manufacturing facilities and other industrial operations. Our vibration monitoring devices are specifically designed to be deployed with ease, to start working for you without tedious programming, saving you valuable time and money. To learn more about how to get started using vibration sensing for predictive maintenance, or to get a personalized virtual or on-site demonstration, contact us today at 1-888-3-SENSOR (736767).

There are two classifications of electrical erosion: excessive current erosion and current leakage erosion. Excessive current erosion (ISO 5.4.2) (fig. 12) occurs when current passes through one bearing ring, through the rolling elements and through the other bearing ring. At the contact surfaces, the process is similar to electric arc welding (high current density over a small contact surface). The material is heated to temperatures ranging from tempering to melting levels. This leads to the appearance of discoloured areas that vary in size, where the material has been tempered, rehardened or melted. Craters form where the material has melted and consequently broken away due to the rotation bearing. The excess material wears away. Excessive current erosion can be caused by lightning strikes on the machinery, when weld repairs are made on machinery with improper grounding of the welding equipment, etc. Current leakage erosion (ISO 5.4.3) (fig. 13) occurs when somewhat low intensity current passes through the bearing. The damage is typically small craters positioned near one another, and a grey/washboard pattern appears over time. The rolling elements can have a grey, dull appearance and the lubricant can become discoloured. The extent of the damage depends on the current intensity, duration, bearing load, speed and lubricant. Current leakage erosion is common in electric motors having stray currents when the shaft is not properly grounded and the motor is controlled by a variable frequency drive.

As well as understanding the characteristics and appearance of a failure mode, it is important to understand what caused the failure. With this understanding, recommendations for corrective actions to help avoid the failure in the future can be taken. Of course, if the bearing is run to failure and seizure occurs, then it may be impossible to identify the failure mode and causes.

A vibration sensor allows you to observe how a machine vibrates under normal conditions, set that behavior as a baseline, and arrange to receive real-time alerts when the amount or intensity of vibration changes. This notification is a bit like a “check engine” light but sent directly to you as an immediate text or email. Responding to early warning signs from networked devices to make informed decisions and conduct proactive maintenance is a prime application of the Industrial Internet of Things (IIoT). If a motor, pump, compressor, fan, blower, gearbox, or other crucial piece of equipment breaks down during production, the result is unplanned downtime, which can be catastrophically expensive. By monitoring equipment for changes in vibration, potential problems can be detected and resolved before they become severe. This proactive approach is known as predictive maintenance, and it is by far the most effective way to maintain the long-term health of your machines and thereby maximize production efficiency.

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There are different answers to this question, depending on whom you ask. SKF does many bearing inspection and damage analysis investigations for customers and for our own research. SKF documents the investigations in a cloud-based software – Bearing Analysis Reporting Tool (BART). The reasons bearings are removed from operation and the causes for a bearing’s removal are tracked, along with a score of other data. With this data, SKF can give some answers to the question: Why does a bearing stop operating?

Predictive maintenance or condition-based maintenance techniques such as vibration analysis, thermography, oil analysis, etc., can be used to detect faults before severe bearing damage occurs and possible damage to the asset the bearing was operating in also occurs. This can allow for improved failure mode identification. Removing larger size bearings (bore > 200 mm) from operation before extensive damage occurs might allow them to be remanufactured. This can restore the bearing to a “like new” condition, reducing maintenance costs and environmental impact (fig. 19).

Rolling element bearings are high-precision machine elements made of high-hardness bearing steel and, in more cases now, with ceramic rolling elements. A bearing comprises inner and outer rings, balls or rollers and a cage and, optionally, is capped with seals or a shield. Figure 1 shows the common parts of a rolling bearing. Capped bearings are grease-filled by the manufacturer. Lubrication, grease or oil is crucial to the development of the lubricating film thickness needed to separate the rolling elements and raceways. A bearing must be selected specifically for the machine, fitted and installed properly and well lubricated and free of contamination. A proper understanding of bearing internal geometry and how the bearing is meant to operate is important when looking for signs of damage.