Bearing Data

Things break. No matter what you do, there is always a chance that products will fail. The
same holds true for bearings, but that doesn’t mean that you can’t prevent many of the
issues that result in costly downtime.
This article is a guide to the major factors that can lead to bearing failure as well as how you
can prevent the issues from happening. By learning more about these potential problems
and knowing how to stop them, you can get the most life out of your bearings and make
your application much stronger.

1. Lubrication Failure
According to a recent study, up to 80 percent of bearing failures are caused by improper
lubrication. This includes insufficient lubrication, use of improper lubricants or excessive
temperatures that degrade the lubricant.

What to Look for

Look for discolored rolling elements (such as blue or brown) and rolling-element tracks as
well as overheating or excessive wear in the bearing.

How to Fix it
Use the appropriate type and correct amount of lubricant, avoid grease loss, and follow
appropriate relubrication intervals.

2. Contamination
Contamination is caused by foreign substances getting into bearing lubricants or cleaning
solutions. These include dirt, abrasive grit, dust, steel chips from contaminated work areas
and dirty hands or tools.

What to Look for

Watch for denting of rolling elements and raceways that cause vibration.

How to Fix it
Filter the lubricant and clean work areas, tools, fixtures and hands to reduce the risk of
contamination.

3. Improper Mounting
In most instances, bearings should be mounted with a press fit on the rotating ring.

What to Look for

A number of conditions can cause denting, wear, cracked rings, high operating
temperatures, early fatigue and premature failure of bearings. These include mounting
bearings on shafts by applying pressure or blows to the outer race, mounting bearings into
a housing by pressing on the inner ring, loose shaft fits, loose housing fits, excessively tight
fits, out-of-round housings and a poor finish on the bearing seat.

How to Fix it
Follow proper mounting instructions and provide training to ensure all employees
understand the difference between a properly and improperly installed mounting.

4. Misalignment
Bent shafts, out-of-square shaft shoulders, out-of-square spacers, out-of-square clamping
nuts and improper installation due to loose fits can cause misalignment, which may result in
overheating and separator failure.

What to Look for

A wear path that is not parallel to the raceway edges of the non-rotating ring should be
noted.

How to Prevent it
Inspect shafts and housings for runout of shoulders and bearing seats, and use precision-
grade locknuts.

5. False Brinelling
Rapid movement of the balls in a raceway while equipment is idle wears away at the
lubrication. In addition, a lack of rotation in the bearing does not allow fresh lubricant to
return to the spot. Both of these conditions result in false brinelling.

What to Look for

You may see linear wear marks in the axial direction at the rolling-element pitch or no raised
edges as opposed to marks due to incorrect mounting.
How to Fix it
Eliminate or absorb external vibration that could cause the balls to move. Also, be sure to
use lubricants containing anti-wear additives.

6. Corrosion
Moisture, acid, low-quality or broken-down grease, poor wrappings and condensation from
excessive temperature reversals can cause corrosion that is abrasive to the finely finished
surfaces of ball and roller bearings.

What to Look for

Look for red and brown stains or deposits on rolling elements, raceways or cages, as well
as increased vibration followed by wear, an increase in radial clearance or loss of the
preload.

How to Fix it
Divert corrosive fluids away from bearing areas. Select integrally sealed bearings and
consider external seals for particularly hostile environments. Using the proper bearing
material, such as stainless steel, can help if you cannot avoid a corrosive environment.

7. Electrical Damage (Fluting)

Constant passage of alternating or direct current, even with low currents, can lead to
electrical damage.

What to Look for

Brownish marks may be observed parallel to the axis on a large part of the raceway or
covering the entire raceway circumference.  

How to Fix it
Prevent electrical currents from flowing through the bearing by grounding or using insulated
bearings.

8. Fatigue (Spalling)
Spalling is often the result of overloading, an excessive preload, tight inner-ring fits and
using the bearing beyond its calculated fatigue life.

What to Look for

Fatigue can be indicated by the fracture of running surfaces and subsequent removal of
small, discrete particles of material from the inner ring, outer ring or rolling elements.
Spalling is progressive and will spread with continued operation. It is always accompanied
by a noticeable increase in vibration and noise.
How to Fix it
Replace the bearing and/or consider a redesign that uses a bearing with greater calculated
fatigue life, internal clearances, and proper shaft and housing recommendations.

9. Overheating
Overheating is generally the result of excessive operating temperatures and improper
lubrication. High temperatures can cause grease to bleed (purge the oil), which reduces the
lubricant’s efficiency. In elevated temperature conditions, oxidation can lead to the loss of
lubricating oils from the grease, leaving a dry, crusty soap that can seize the bearing.
Higher temperatures also reduce the hardness of the metal, causing early failure.

What to Look for

Note any discoloration of the rings, rolling elements and cages. In extreme cases, the
bearing components will deform. Higher temperatures can also degrade or destroy the
lubricant.

How to Fix it
Thermal or overload controls, adequate heat paths and supplemental cooling are among
the best options to mitigate overheating.

10. Excessive Loads

Putting too much load on a bearing is another common cause of failure.

What to Look for

You may see heaving rolling-element wear paths, evidence of overheating and widespread
fatigue areas.

How to Fix it
Reduce the load or consider a redesign using a bearing with greater capacity.

11. Improper Storage and Handling

Improper storage exposes bearings to dampness and dust. Storing bearings in excessively
high temperatures can also degrade a grease’s shelf life, so always check with the grease
manufacturer for storage specifications. Handling bearings by opening boxes and tearing
wrappings prematurely can let in dirt and expose bearings to corrosive elements.

What to Look for

Watch for dampness and temperatures that can cause rust and/or uncovered bearings in a
storage area.
How to Fix it
Store bearings in a dry area at room temperature. Always cover bearings to keep them
clean while in storage and take them to the installation site before unwrapping.

12. Fit
A tight fit can be caused by excessive loading of the rolling element when interference fits
exceed the radial clearance at operating temperatures. Micro-motion between fitted parts
where the fits are too loose in relation to the acting forces may result in a loose fit.

What to Look for

For a tight fit, look for a heavy rolling-element wear path in the bottom of the raceway,
overheating or an inner-ring axial crack. For a loose fit, note any fretting (generation of fine
metal particles), which leaves a distinctive brown color. Wear at the fitting surfaces can
cause noise and runout problems.

How to Fix it
Make sure a proper clearance is selected to avoid fit issues. Refer to the manufacturer’s
installation guide.

Preventing Failures
By becoming aware of the different problems that can cause a bearing failure and the signs
to look for, you have already taken a big step toward limiting machine failures. Of course,
you don’t have to wait for the symptoms of a bearing failure to take action. Regular
preventive measures can keep your bearings at peak performance for as long as possible,
saving your business time and money. 
 Protect your ball
bearings: 8 common
problems
Identifying the primary reason for premature motor failure is
as easy as looking at the bearings.
BY DAVID MANNEY JULY 27, 2016

 Facebook
 Twitter
 Google+
 LinkedIn
 Email
 One of the more common issues that can occur
in any industrial facility is the possibility for premature motor failure. It is not only a costly
problem due to the repairs that may be necessary, but the unexpected downtime can bring
your operation to a halt until the repairs take place. Identifying the primary reason
premature motor failure occurs is as easy as looking at the bearings.

Some issues could happen and result in damage to the motor or catastrophic failure.
Identifying the problem, including the source of the issue, is half of the battle. It is then
important to protect the bearings from further damage, resulting in longer equipment life and
fewer maintenance issues along the way. Here are some common problems:

 Misalignment: The raceway ball track must be parallel to the raceway edges. If it

isn’t, bearing damage and the possibility of equipment failure could occur.
 Lubricant: If the lubricant fails, it typically results in blue or brown discolored ball
tracks and balls.
 Contamination: This issue could lead to indenting of the raceway or the balls
themselves.
 Overheating: If overheating is a problem, it may lead to a discoloration of the balls,
rings, and cages.
 Load: When excessive load is a problem, it may result in fragmentation in the ball
path.
 Tight fitting: If the bearings fit too tightly, it could lead to ball wear seen in the
bottom of the raceway.
 Loose fitting: If the bearings fit too loosely, it could result in a discoloration of
mounting surfaces or circumferential wear.
 Bearing current: When current flows through the motor bearings, it could lead to
fluting.

Methods for protecting the bearings

If you see any issues in the bearings, the root cause needs to be identified and corrected.
This helps to reduce any problems that could occur in the future. It is also important to
protect the bearings, and this can be done in some of the following ways.

 Shaft grounding brush: This prevents fluting damage by diverting shaft voltages to

ground, rather than having it run through the bearings. A grounding brush helps
 prevent damage associated with shift current and can extend the life of the motor
considerably.
 Bearing isolator: This is a two-part seal that consists of a stator (press fitted to the
housing) and a rotor (attached directly to the shaft). Since the rotor is connected to
the shaft, it revolves along with it. This creates a noncontacting seal and eliminates
wearing, helping to protect the bearings and keep them free of contamination and
properly lubricated.

Ensuring that the bearings are not experiencing any problems can be part of a preventative
maintenance program. They can be checked daily using an IR scanner or stethoscope. The
surface temperature of the bearings can also be checked with a thermometer or through
electronic sensing devices. Stick-on labels are also available for that purpose.

As part of the maintenance program, the installation of bearing protection rings and isolators
can play a vital role in keeping your facility up and running by avoiding equipment failure.
Knowing the causes and
solutions for bearing
issues
Improving the performance and longevity of bearings begins
with understanding the most common causes of bearing
failure and malfunction.
BY DAVID MANNEY, L&S ELECTRIC OCTOBER 24, 2017
With the right application, proper installation, and good maintenance practices, ball bearings
have a longer lifespan. On the other hand, premature bearing failure arises from poor
handling practices and unfavorable operating conditions. This can include contaminated
areas and areas where moisture persists.
If the bearing malfunctions and fails, it is best to identify the cause of the problem. By doing
so, you conduct proper techniques and utilize necessary adjustments to address the issue.
In fact, it is easier to determine the underlying problem when you examine the failure mode.
However, it is quite complicated to go through this procedure since a single failure mode
tends to lead to another.
In the case of corrosion in the ball race, an abrasive material such as rust is left, which
results in wear. This, then, leads to greater radial clearance or preload loss. If a bearing is
grease-lubricated, the wear debris may hamper lubrication. Over time, successive
overheating issues and lubrication failure arise.
There are several ways to identify the main reasons why bearing failure occurs. However,
there are instances when imperfections may not be noticeable. In some cases, the problem
is quite evident, even to the naked eye. Also, we present specific techniques and remedies
for each issue with ball bearings.
Overheating
The signs of overheating include discoloration of the cages, balls, and rings, which turn from
gold to bluish.
Exposure to temperatures that exceed 400ºF anneals the ball and ring materials. This
process leads to a loss in hardness and a reduction in the bearing capacity. If left
unresolved, early failure may occur.
Deformation of the rings and balls also arises in extreme cases. It is possible for the rise in
temperature to destroy or degrade the lubricant.
Common overheating causes

 Insufficient heat paths

 Inadequate lubrication and cooling
 Heavy electrical heat loads.

A lack of proper lubrication where there is excessive speeds and loads is detrimental to the
life and performance of the bearing.
Corrective procedures
Be sure to provide adequate heat paths, supplemental cooling and overload, and thermal
controls to prevent this problem.
Excessive loads
One of the most common reasons why premature fatigue happens is an excessive load.
However, other factors affect early fatigue failure in bearings such as improper preloading,
brinelling, and tight fits. Although premature failure has the same symptoms as normal
fatigue, the clear signs of a shortened bearing life span include:

 A more advanced case of spalling

 Evidence of overheating
 Severe ball wear paths.

Corrective procedures
To prevent this issue, minimize the load. It also helps to redesign and use a bearing with
greater capacity.
True brinelling
When the loads go beyond the ring material’s elastic limit, brinelling occurs. True
brinelling appears as indentations that form in the raceways, which results in further bearing
vibration.
Brinelling often results from severe impact or static overload. This overload is why it is best
to avoid practices leading to brinelling. These practices include:

 Striking or dropping the assembled equipment

 Applying excessive force to the outer ring whenever you press a bearing onto the
shaft
 Installing or removing bearings with the use of a hammer.

Early fatigue failure usually happens when there are severe and extensive brinell marks.
Corrective procedures
To extend bearing life, avoid pushing the outer ring as you place the inner ring onto the
shaft. Applying the right amount of force to the ring that is being press-fitted when you install
bearings is also advisable.
False brinelling
False brinelling refers to the elliptical wear marks set in an axial direction located at each
ball position. The marks also have sharp demarcations and a bright finish. There can be
seen a ring of brown-colored debris surrounding them. In most cases, too much external
vibration causes false brinelling.
External vibration also occurs with non-rotating types of ball bearings. Once the bearing
fails to turn, this prevents an oil film to form, thus exposing it further to raceway wear. The
debris that collects in this area contributes to the acceleration of the wear process.
Corrective procedures
Make it a point to apply lubricants that contain molybdenum disulfide or other anti-wear
additives. These additives isolate the bearing from external vibration. Use these greases for
bearings in actuator motors that tend to reverse or oscillate rapidly.
Reverse loading
Angular contact bearings are capable of accepting an axial load in only one direction.
However, loading in the opposite direction causes truncation on the elliptical contact area,
found on the outer ring by the lower shoulder located on that part of the outer ring.
Besides the rise in temperature and excessive stress, look for early failure and increased
vibration. The failure mode resembles tight fits, and the balls appear to have a grooved
wear ring due to the riding of the ball over the raceway’s outer edge.
Corrective procedures
The best way to correct this issue is proper bearing installation:
Install the angular contact bearings with the resultant thrust (marked “thrust”) on the wide
face of the outer ring, as well as the inner ring’s opposite face.
Normal fatigue failure
Spalling or fatigue failure refers to the fracture or damages to the running surface, as well
as the removal of discrete and small particles of the material.
The balls, outer ring, and inner ring are susceptible to spalling. Once this type of failure
arises, it progresses into something more severe. A significant increase in vibration occurs
due to spalling, a sign of an abnormality.
Corrective procedures
If you observe this issue with the bearing, you need to replace it immediately. Another
solution is redesigning that allows you to use a bearing with a maximum calculated fatigue
lifespan.
Tight fits
It is easy to detect a tight fit when you notice a severe ball wear path located at the bottom
of the raceway. The wear path is around the outer and inner ring’s entire circumference.
Excessive loading of the ball occurs when the interference fits end up exceeding the radial
clearance at the operating temperature. Thus, an increase in temperature occurs, along
with high torque. Rapid wear and premature fatigue arise with continued operation.
Corrective procedures
Reduce the total interference by matching the bearings according to the housings and shaft,
which addresses the issue.
Consider the differences both in the operating temperature and the materials when you cut
the total interference.
Loose fits
Relative motion between the mating components is often due to loose fits. Fretting occurs
as a result of a continuous relative motion between these parts. Fine metal particles that
oxidize generate over time (fretting). This material tends to worsen the looseness because
of its abrasive quality.
Once the looseness becomes severe, this leads to an increase in the movement of either
the outer or inner ring. Then, the mounting surfaces in due course heat up and wear out,
leading to run out and noise.
Contamination
A bearing failure could also arise from contamination. Some of the signs of contamination
include high vibration and wear issues with balls and dents on the bearing raceways. Once
abrasive substances, including dirt or airborne dust, get into the bearing, contamination
failures occur. Contamination is a common problem with:

 Contaminated work areas

 Foreign matter in cleaning solutions
 Lubricants and dirty hands or tools.

Corrective procedures
Minimizing the occurrence of contamination failures is possible by

 Making sure the fixtures, tools, hands, and work areas are clean
 Ensuring all grinding operations are far from the bearing assembly areas
 Storing the bearing in the original packaging, removing them only when ready to use
or install
 Keeping in mind that seal damage no longer prevents the bearings from
contamination.

Corrosion
Signs of corrosion include red or brown areas on ball bearings’ bands, as well as the
raceways, balls, and cages. Bearings exposed to a corrosive atmosphere or corrosive fluids
are prone to this issue. Over time, an increase in vibration rises, followed by fatigue, wear,
preload loss, and greater radial clearance. Early fatigue failures result from extreme cases
of corrosion.
Corrective procedures

 Utilizing stainless steel bearings and external and integral seals

 Using these techniques particularly in a hostile operating environment
 Keeping corrosive fluids far from the bearing areas.

Lubricant failure
Lubricant failure appears as brownish or bluish colors on balls and ball tracks. When this
issue persists, excessive wear of the cages, ring, and balls occur. Lubrication failure leads
to overheating and catastrophic failure.
Corrective procedures
Since ball bearings rely on proper lubrication of critical areas such as between the bearing
rings, balls, cage, and races, it is imperative to lubricate these parts well. Excessive
temperatures and restriction to lubricant flow, however, impacts the lubricant’s properties.
Misalignment
Spotting a ball wear path on the nonrotating ring raceway is a symptom of misalignment.
This wear path is not parallel to the edges of the raceway.
An abnormal temperature increase occurs once the misalignment goes beyond 0.001
inch/inch. This slight misalignment impacts the bearing, as well as the housing. Common
contributing factors of the misalignment include

 Dirt or burrs on the housing shoulders and shaft

 Shaft threads not square with the soft seats
 Bent shafts.

Depending on the applications, the maximum acceptable misalignment varies.

Corrective Procedures
Some of the corrective techniques include:

 An inspection of the housings and shafts to check for run out of bearing seats and
shoulders
 The use of precision-grade locknuts
 Utilizing single point-turned on non-hardened shafts
 Ground threads for hardened shafts.
These are the most common causes and solutions to bearing failure. Paying attention to
what your bearings are telling you is vital to ensuring your facility runs efficiently. 51% of all
electric motor failures are a direct result of bearing failure.
Take advantage of a predictive maintenance program. Utilizing an excellent program is the
best thing you can do for your bottom line.