Listen Up! How to Diagnose 3 Weird Tire Noises - tire noise at low speed

2024-10-23 22:02:49

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Bearings are a critical part of any operating machine in a facility, so when you hear an awful noise coming from one of your most important pieces of equipment, you need to act fast.

It's vital that the bearing is properly mounted to an accurately sized shaft. If it isn't, it can cause issues in two ways:

Regardless if your facility has experienced bearing failure recently, it's not a surprise to say that bearings are being worn down every minute of active process operation.

Speaking of wobbliness, you can also check the wheels and see if one of them wobbles or seems loose. A bad wheel bearing might loosen its attached wheel, making your car less responsive to your inputs through the steering wheel.

External heat - Ambient operating temperature mandates many choices in radial internal clearance, high-temperature lubricants, intermittent or continuous running and other factors that affect bearing life. [source]

The key to preventing downtime and lost productivity in your facility is to prevent premature failure, which stems from damage that occurs to the bearing that usually could have been halted.

The consequences of bearing failure are far-reaching for your facility. These can include increased downtime, high-maintenance costs, missed deliveries, loss of revenue and, in some extreme cases, may injure workers.

Reliable Plant says to be sure to watch out for dampness and temperatures that could cause rust or uncovered bearings in the storage area.

An erratic wheel bearing can also lead to loose brakes. When you hit the brakes, your vehicle will pull into the same direction as the side with the bad bearing if the bearing is worn to the point of being loose.

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These contaminants reduce viscosity which causes corrosion to the bearing surfaces, disrupts the oil film, and causes erosion, leading to the creation of countless abrasive particles.

Through failure analysis testing and the understanding of normal/ abnormal wear path, one can correctly assess if the bearing has been run under the ideal conditions.

Simply put, a bearing failure occurs whenever a bearing fails to meet its expected lifespan or calculated performance levels.

Finally, a bad wheel bearing might make clicking sounds. When your vehicle accelerates, the clicks usually get louder and faster. You can narrow down which wheel bearing makes the clicking noises by gently turning the steering wheel from side to side while driving at a safe speed. If the clicking becomes softer when your car turns in one direction, one of the wheels on the opposite side has a faulty wheel bearing.

But sometimes this examination process ends up becoming complicated quickly thanks to the fact that one failure mode can trigger another.

Once you reach stage two of failure, you will commonly find that the bearing's defects begin to ring at its natural frequencies, which ranges from 500 to 2,000 Hz.

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It's important to note that bearing temperatures usually increase with start-up and level off at a temperature slightly lower than the start-up (ranging from 10 to 40 degrees Celsius higher than room temperature).

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"Amplitudes of both high-frequency noise floor and HFE may actually decrease, but this is a sign that the bearing is about to fail." [source]

Bad wheel bearings often make strange noises like grinding, rumbling, and clicking. If you listen carefully, you can figure out the direction where the noise comes from, making it easier to narrow down which bearing needs replacement.

While fatigue may occur at the end of the bearing's normal life expectancy, it frequently occurs before then due to an excessive loads, according to AST Bearings.

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Fortunately, you can use your knowledge of bad wheel bearing symptoms to help you tell which part has developed an issue. You don’t need specialized tools—you can perform these tasks yourself. But realize that determining which bearing is bad may be tricky, and sometimes a tire noise will sound exactly like a bad bearing, so be aware of what you might be getting into.

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If not taken into consideration, there are numerous operating environments that can bring down even the best bearing and cause a failure. Here is a list of the primary issues you should have on your radar...

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Bearings that operate smoothly keep the manufacturing processes moving. They are often the overlooked parts of the process, despite the fact that they carry the weight and production load. Bearings often remain invisible until there is a bearing failure in the facility.

When there is a bearing failure, that means that the bearing motion becomes ineffective. Without proper bearing motion, the machine shaft can ultimately fail, therefore, the machine itself can be damaged and break down.

Simply put, improperly storing bearing causes issues later on because they're exposed to outside elements like dampness, dust, and varying temperatures.

As we've discussed already, high temperatures do not fare well for bearings and can cause other problems already listed as in lubrication and internal friction.

Furthermore, bearings (in both critical and non-critical machinery) that reach this stage of failure should be replaced, if they're not already.

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If you're looking for background on what bearing failure means, different types of failures, common reasons why bearings fail, and actionable tips to prevent bearing failures, you'll love this guide.

Avoid driving your vehicle if one of its wheel bearings has a problem. It’s best to replace both sides even if only one side has a bad bearing. Replace the bad bearing as soon as your schedule and budget permits.

Usually, the tires on your vehicle wear out at roughly the same rate. However, a really bad wheel bearing can change how its wheel spins, leading to issues like wobbling, although you’ll have heard noise a long time before the wheel starts to wobble.

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How does the bearing's fatigue limit and life expectancy factor in to being used for the correct application? It all starts with the original equipment manager (OEM).

According to Vibralign, defects appear around 20,000-60,000 Hz and while this isn't a cause for replacing a bearing, Stage 1 may indicate a lack of lubrication between the races and rolling elements.

1. If the shaft is oversized or expands, it will result in too tight of a fit, reducing the bearing's internal clearance (see more on this below).

Examining the "failure mode", known as the ways, or modes, in which something might fail, will help you determine the exact cause of failure.

Gently swerving back and forth on an empty smooth highway will usually point you in the right direction. If you swerve to the right, you’re loading the left. But usually this works better when chasing noises on front wheels than on the rear, although you can sometimes isolate rear bearing noise the same way. The best first thing to do is swap the tires around to see if the noise changes. This doesn’t cost anything and it may prevent you from buying and replacing bearings you don’t need to.

If your car starts pulling to one side when engaging the brakes, run a thorough check of the brake system first. Only look for a bad wheel bearing if you don’t find any evidence of a broken brake part.

These stages are based on the types of frequencies produced by the bearing's rolling elements impacting defects in the inner and outer races.

The tire attached to the wheel with a faulty bearing will wear out at a different rate than the vehicle’s other tires, and its tread might display uneven wear.

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Pro Tip: That being said, if you’re looking for a noise, you might not be able to hear a bearing that isn’t loaded by the weight of the car even if you can hear it when you’re driving.

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Normally, the first sign of issues like these is unusual noises and/or elevated temperatures. The desirable bearing temperature is somewhere below 100 degrees Celsius.

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Often referred to as "spalling," fatigue failure occurs when there's a fracture of the running surfaces, which leads to the removal of tiny, detached particles of bearing material.

Thanks to preventative maintenance (like the other measures we've mentioned above), facilities can detect potential failures earlier.

Pro Tip: Realize that a noisy wheel bearing can telegraph noise to a different wheel and cause you to misdiagnose which bearing is bad. Professionals even experience this.

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If bearings don't receive occasional rotations, it can cause false brinelling to occur, which is a premature failure we discussed in Chapter 3.

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This type of failure occurs when loads exceed the elastic limit of the ring material and can be identified as permanent indentation marks in the raceways, which cause increased vibration.

When a wheel bearing makes a grinding or growling noise, it indicates that the wheel bearing’s unlubricated metal parts are directly touching each other. The noise gets louder when your vehicle picks up speed. Listen to the grinding sound when you step on the gas pedal, and you can tell if the noise comes from your car’s front or rear.

2. If the shaft is undersized or has too loose of a fit, the bearing will creep on the shaft and will wear and create heat, which eventually will result in vibration and runout problems.

You would clearly see defects on the raceways if you were to remove it, and it's key to determine a deterioration rate at this point.

According to Machinery Lubrication, when applied correctly and effectively, lubrication helps reduce issues like friction and abrasion, transports heat generated by friction, prolonging service life, prevents rust and corrosion, and keeps foreign objects and contamination away from rolling elements.

This should be one of the first reasons considered when inspecting a bearing that has failed. To ensure proper lubrication, adequate viscosity at operating temperature is a must.

If you have a bearing failure in your facility, it is critical to thoroughly assess the situation at hand so you can determine the source of the failure, with the ultimate goal of preventing it from occurring again.

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Also known as "Electric Arc Erosion," this failure occurs when an electric current passes through the bearing and is broken at the contact surface between races and rolling elements, producing high temperatures at localized points. [source]

This means facilities can order and replace the damaged bearings before an entire machine breaks down, making the need for spare bearings to sit on shelves practically obsolete.

On the plus side, you can take advantage of this behavior to identify the side where the faulty/loose wheel bearing can be found. If the bad bearing displays other symptoms, such as making noise or causing its wheel to wobble, you can quickly narrow down the malfunctioning part.

Whether or not your facility has recently experienced a bearing failure, this guide has everything you need to know regarding bearing failures.

To gain a better idea of the conditions a bearing was operated, it is best to examine the wear path pattern of the dismantled bearing that's already been in service.

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In short, the goal is to prevent bearings from reaching this stage, but if they do, it's imperative that they're replaced immediately.

There are numerous causes for cage damage. Some of the more common ones include vibration, excessive speed, wear, or blockage.

Just like with wobbling wheels, you must jack up your vehicle first to check for stiff wheels. Once you’ve raised your car with a floor jack, you can test each wheel assembly for stiffness.

Dust and dirt, which can contaminate a bearing at an aggressive rate. Be sure to use proper sealing techniques to prevent this type of contamination.

When you need to have bearings being stored in your facility and sitting on shelves, be sure to store them actively. This can be accomplished by rotating or spinning them frequently.

The majority of bearing failures we've discussed above (think pitting, spalling, unusual wear patterns, rust, corrosion, etc.) trace back to a small group of causes that are not only interrelated but are fixable too.

Bearing failures are more common than you think, and even with careful planning and normal maintenance, they can still fail unexpectedly or prematurely in an application.

Doing so can not only help you prevent premature failure, but it can also help keep your process moving smoothly as well.

However, broken wheel bearings aren’t the only possible reason for your car pulling to one side while braking. Usually, it’s bad brake parts that cause the brakes to become looser. It’s more likely for a brake rotor or brake equalizer to be the problem.

Lubrication is used on bearings to cover the rolling completely and sliding surfaces with a thin oil film to prevent metal-to-metal contact.

In the first stage, you will see small pits begin to appear in the bearing race as well as impacts of rolling elements that show up at ultrasonic frequencies in the spectrum.

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There are many contaminants that can cause problems with a bearing. Dirt, sand, and water are the most common ones that you run into, but chemicals and corrosives can also damage bearings.

Finding a bad wheel bearing means you’ll have to replace it sooner rather than later. For this, it’s best to go with a quality replacement to ensure it lasts a long time. Fortunately, CarParts.com has you covered.

Pro Tip: Note that this won’t always be the case though. In most cases, you’ll only see tire wear issues if the bearing is so worn out that the tire wobbles or runs out of line.

Handling becomes an issue when boxes are opened, or wrappings are torn prematurely because it can expose the bearings to dirt and corrosive elements.

Once you've completed installation based on manufacturer's instructions, a best practice to keep in mind is giving the bearing a solid flushing and cleaning out with lubricant. Additionally, be sure to apply the final proper amount of lubrication before the machine is used.

Be considerate of avoiding misalignment or shaft deflection, as this is significant in mounting bearings with separate parts. Without proper alignment between components, the bearings will end up experiencing abnormal wear.

Take hold of each tire and spin the wheel assembly. If the part rotates without issue, you have nothing to fear from its wheel bearing. A tire that resists your attempt to spin it could have a bad bearing but further checks need to be done to make sure there are no other causes.

Grease is more commonly used because it's easy to handle, while oil lubrication is frequently used with high-temperature or high-speed applications.

Since this type of fatigue is progressive, once it begins, it will continue to spread as the bearing operates. A key indicator of fatigue to keep an eye on is an increase in vibration.

A wheel bearing usually shows warning signs that it has worn out or broken down, and usually the first indicator is noise. But how can you tell which bearing has developed a problem? Your vehicle has four wheels, and each one has a wheel bearing. If you replace the wrong bearing, you’ll waste time and energy without resolving the issue. In the worst-case scenario, the wheel that you mistakenly tinkered with might also develop a problem.

Bearings reach this stage when they're at the end of their lifespan, and you will notice that the noise floor is increased at all levels, which in turn produces a random, broadband spectrum.

Current passage or electrolytic corrosion - Sparks can create pitting or fluting on bearing surfaces if current is allowed to flow through the bearing's rolling elements. You can fix this by using insulation on or within the bearing or creating a bypass circuit for the current.

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Last but not least, this failure impacts friction, load zone size, and fatigue life of a bearing. If the clearance of the bearing is inadequate, excessive heat will build up.

Much like with grinding noises, you can tell which side of your car has the bad wheel bearing by listening to the rumbling sound that it makes. If the rumbling sound gets louder when you make a turn, the faulty bearing is on the opposite side of the vehicle. The outer wheels must cover greater distances during turns, so they compensate by spinning faster. But more pointedly, the outer bearing is loaded more due to the dynamics of the turn and that amplifies the noise a bad bearing will make. If one of those outer wheels has a bad wheel bearing, the rumbling noise made by the faulty part will get louder.

Bearings are typically very reliable, even under the most rigorous conditions, and under normal running conditions, a bearing's service life is substantial.

You must raise your car with a floor jack to Inspect the wheels for wheel bearing-related wobbling. Put your vehicle in neutral and set down wheel chocks to prevent the other wheels from moving.

It's imperative that the proper tools, ovens, and induction heaters are used during the mounting and installation process of bearings.

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Now that you know more about the most common types of bearing failures you can witness in your facility, how exactly can you prevent a bearing failure?

At the third stage, the bearing defect frequencies levels become much more apparent and harmonics show up on the spectrum.

Utilizing these four stages and identifying which stage a bearing is in is critical because not only will it help you foster an accurate predictive maintenance plan, but it will also help you keep your machines operating efficiently and prevent costly, unplanned downtime.

Speaking of failures, let's move on to discussing in detail the most common reasons why bearings fail that you should keep in mind...

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When a bearing fails, it negatively impacts your facility, your reputation and your bottom line. That said, there are some preventative measures you can take to increase the lifespan of your bearing and prevent improper wear on them.

A $50 bearing that fails can cost as much as $25,000-$50,000 per hour when it halts production in a multi-million dollar process, according to IBT.

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When a bearing does fail prematurely, it's often due to causes that can be avoided. For this reason, it's crucial to be able to identify the root causes to prevent future failures with preventative measures and the issues that follow them.

According to Flow Control Network, "the OEM selects bearings for each application in conjunction with the manufacturer's designed life expectancy based on a fatigued spall failure."

You can troubleshoot overloading by reducing the load on the bearing or considering using a bearing with a greater capacity.

According to Bearing Failure: Causes and Cures, the most commonly found causes of misalignment include: bent shafts, dirt or burrs on shaft or housing shoulders, shaft threads that are not square with shaft seats, and locking nuts with faces that are not square to the thread axis.

A bearing failure occurs when the bearing fails to meet their expected life or performance levels, often causing a machine shaft to fail, and the machine it is apart of can break down.

Next, test each wheel assembly to see if it moves between the 3 and 9 o’clock positions. If the wheel wobbles, its wheel bearing might need replacement. If the assembly seems firm, try to move it between the 6 and 12 o’clock positions. Again, replace the bearing if the wheel feels loose.

Look for highly polished or discolored bearing raceways when troubleshooting to determine if working surfaces are lacking adequate viscosity at operating temperature.

Accurately diagnosing and troubleshooting bearing failures in order to get ahead of them will help prevent repeat failures and additional pain-points your facility might be experiencing, such as decreased operating efficiency, increased downtime and lost revenue.

That is why it's crucial to make sure vibrations are isolated in associated equipment because if they're not isolated, they can cause unusual noises and uneven running.

Actually, less than 1 percent (0.35 percent specifically) of rolling bearings do not reach their expected life. [source]

Alternatively, a bad wheel bearing might produce a rumbling noise. You can hear the noise when you drive in a straight line. When you make a turn in your vehicle, the rumbling gets louder.

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As we've stated already, bearings do not last forever. They can be damaged and have a shortened lifespan if the right preventative measures aren't followed through in the facility.

Under normal operating conditions, bearings have a substantial service life, but since they do have a fixed lifespan, it's inevitable that a bearing will eventually fail.

It's important to note that this stage is still considered within the normal operation, so here your bearings are functioning normally.

Often these frequencies are actually the resonances of the bearing's components (like the races or rolling elements) or the bearing support structures.

Let's dive into further detail about these 13 common reasons why bearings fail as they relate to your manufacturing process.

"Under-lubrication risks metal-to-metal contact, over-lubrication causes heat build-up and friction as the rolling elements continuously try to push extra grease out of the way." according to IBT.

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