13

Rolling Element Bearings

13.1 Rolling Element Bearings

The main advantage of rolling element bearings is guaranteed low friction coefficient at any rpm and at
large load. They are most suitable therefore for vehicles. Recall that film lubrication can produce low friction
coefficient only under a fully developed hydrodynamic lubrication condition so that film lubrication is ideal only for
steady high rpm applications. Because rolling element bearings are much heavier than film lubrication, rolling
element bearings are recommended mostly for supporting a rotating shaft that doesn’t move translationally.

The main disadvantage of rolling element bearings is fatigue because the rolling elements cannot be
recycled continuously unlike film lubrication. Careful design is required to ensure that the contact stress between
the rolling element (ball or cylindrical roller) and the rings surrounding it is kept relatively low to prevent
premature fatigue. The mechanics of contact between the rolling element and the rings is beyond the scope of the
course; it is sufficient to say that the number of rolling elements in contact depends on the bearing tolerance and
the load. Having a larger number would reduce the stress, but it would require a tighter tolerance and thus
increased cost. Another disadvantage of rolling element bearing is noise; hydrodynamic lubrication is quieter.

Ball bearing is recommended for very high rpm applications because the ball requires only a point contact.
Roller bearing is recommended for very large load applications because of its line contact.

Figures above show generic pictures of ball bearing and roller bearing. The rolling elements are separated
by a cage (separator) to ensure they do not touch each other when rotating at high speed. The contact prevention,
however, introduces a wear problem; hence, lubrication is needed to reduce wear. So within a rolling element
bearing, film lubrication is present. This illustrates the interconnectedness of mechanical components we study.
Wear issue also requires prevention of dust particles from entering the space between the inner and the outer
rings.

Placing the roller axis of a roller bearing at an angle not parallel with the bearing axis would allow a roller
bearing to take up an axial load. Picture below shows the resulting conic shape of the outer ring of a roller bearing
due to the oblique orientation of the rollers. Each roller can rotate and revolve around the bearing axis while
handling a load along the bearing axis.

The same idea could be implemented in a ball bearing, resulting in its ability to handle an axial load. The
design is less natural though for a ball bearing because the axial load capability requirement reduces the point
contact advantage of a ball bearing. It is almost as if the ball bearing tried to morph into a roller bearing.

13.2 Bearing Life Equation

Bearing life is basically predicted by two parameters: (i) rated capacity and (ii) load. The equation we use
summarizes the complex mechanics that determines the fatigue failure into essentially a ratio of the rated capacity
to the load:

L=K r L R (C /F e K a)3.33 ,
 7
where K r is reliability factor, LR =9 ×10 cycles, C is rated capacity of a bearing, F e is equivalent load, and K a
is application factor. The reliability factor is shown below. K r =1 for 90% reliability, implying that the 9 ×10 7
cycles is defined at the 90% reliability.

The rated capacity table is shown below. It lists 3 bearing types: radial ball, angular ball, and roller. Each
type has 3 series: Extra Light 100 series, Light 200 series, and Medium 300 series for the same bore. The 300 series
has the highest rated capacity for the same bore.
The equivalent load F e takes into account possible axial load. For the fully radial ( α =0 ° ¿ ball bearing,
 {
Ft
Fr 0< < 0.35
Fr

[
F e = F r 1+1.115
( Ft
Fr
−0.35
)] 0.35<
Ft
Fr
<10 ,

Ft
1.176 F t >10
Fr

while for the angular (α =25 ° ¿ ball bearing,

{
Ft
Fr 0< <0.68
Fr

F e = F r 1+0.87
[ ( Ft
Fr
−0.68
)] 0.68<
Ft
Fr
<10

Ft
0.911 F t >10
Fr

These formulas tell us that the basic radial ball bearings, i.e., with α =0 ° , has up to 35% axial load provision. A
roller bearing has about 20% axial load provision. In either case, the actual load with such axial load amount can be
effectively regarded as consisting of only radial load.

A ball bearing of course has additional specifications, but rated load capacity is solely determined by the
bore parameter.

Application factor K a provides an amplification factor to the load. As seen in the table, K a acts as an
impact factor and its value is larger for ball bearing because of its point contact.

Table below provides a list of acceptable expected lifetimes for different applications. The design life
basically provides a value for L so that we can find a suitable C .
Problem 27
Two ball bearings from different manufacturers are being considered for a certain application. Bearing A has a
catalog rating of 2.2 kN based on a catalog rating system of 4000 hours at 500 rev/min. Bearing B has a catalog
rating of 7.0 kN based on a catalog that rates at 1.2 ×106 cycles. For a given application, determine which bearing
can carry the larger load.

The two bearings we are comparing have different lifetime benchmarks and also different load ratings.
Because we want to maximize the load both can carry, we need to apply a constraint to them, i.e., a common
benchmark with which we can compare their maximum load fairly. A common constraint we should use is their
lifetimes. Thus, we want them to have the same lifetime.

The lifetime L is based on the following bearing life equation

b
L=L R ( C /F R ) ,

where LR is bearing lifetime benchmark, C is bearing load rating, and F R is radial load. The exponent b is 3 for
ball bearing or 10/3 for roller bearing. For the two bearings, we impose a common L and want to maximize F R ,
i.e., we use the following formula

F R =LR1 /b C .
From the table below

Bearing LR (cycles) C (kN) 0.33

LR C
A 4000 × 60× 500=120 ×10
6
2.2 1019.9
B 1.2 ×10
6 7.0 710

we can conclude that bearing A carries the larger load.

Problem 28
Figure below shows a cantilevered chain idler sprocket driven by a roller chain that applies a 1200-lb force. Select
identical 200 series ball bearings for A and B. The shaft rotates at 350 rpm.
 The sprocket does not introduce a torque to the shaft. The shaft only experiences a 1200 lb downward
force. Taking the moment balance about A (left bearing),

B∙ 1.75−1200∙ ( 1.75+0.75 ) =0 ,
we get B=1714.3 lb directed upward. The force balance for the shaft in the vertical direction,

A+1714.3−1200=0 ,
we get A=−514.3 lb, i.e., directed downward. Because we ought to use identical 200 series ball bearings, we
use the larger force, i.e., 1714.3 lb, to determine the bearing size.

There are two ways to determine the bearing size. The first method is to simply use the next available
rated capacity based on the 1714.3 lb load, or 7629.3 N load. Because we need not worry about thrust loading, we
choose radial ball bearing with α =0 ° . The next available rated capacity for the 200 series ball bearings is 8.50 kN
with 35 mm bore. The expected lifetime is
3.33 6 3.33 7
L10=K r L R ( C / K a Fr ) =1 ∙ 90× 10 ( 8.5/ 1.2∙ 7.6293 ) =7.03 ×10 cycles,

where K a =1.2 is assumed for gearing. Given that the shaft rotates at 350 rpm, the lifetime in hours is thus
3347.6 hours. This seems on the low end of lifetime when compared to representative bearing design lives in Table
14.4. For machines intermittenly used, where reliability is of great importance, the lifetime in hours range between
8 and 14 thousands.

The second method is to use

C=F e K a ( L/ K r LR ) 0.3 ,

where the design lifetime L needs to be estimated using Table 14.4. Given that the 35 mm bore gives 3347.6
hours, any design lifetime increase therefore will demand the next larger bore of 40 mm in the 200 radial ball
bearing series, with a rated capacity of 9.40 kN.
Problem 29
Figure below shows a printing roll driven by the gear to which the 1.20-kN force is applied. The bottom surface of
the roll is in contact with a similar roll that applies a uniform (upward) loading of 4 N/mm. Select identical single-
row 02-series deep-groove ball bearings for A and B, if the shaft rotates at 350 rpm.

The 20 ° pressure angle causes a radial load of 1.2 kN at the shaft along the 20 ° direction. This shaft load
is then transferred to the bearings A and B. The 1.2-kN load from the gear also generates a torque of
1200 cos 20 ° ∙ 0.06=67.66 N-m magnitude. Because the shaft rotates at a constant angular velocity, the 67.66
N-m torque has to be counterbalanced by the torque of equal magnitude produced by the lower roll. This
counterbalancing torque produces a tangential force of 67.66 /0.075=902.1 N force directed tangentially at the
contact points of the two rolls to the left in the diagram so as to produce a clockwise torque to the shaft. The
contact with the lower roll produces a 902.1 N force left-directed and 4 ∙300=1200 N force upward-directed to
the upper roll (visible in the diagram).

Taking a moment equilibrium about A due to forces in the horizontal (left or right) direction will yield

902.1 ∙ ( 0.06+0.15 ) + Bx ∙ ( 0.06 +0.3+0.06 )

+1200 cos 20 °∙ ( 0.06+0.3+ 0.06+0.1 )=0

yielding Bx =−1847.2 N, i.e., directed to the right. Taking the horizontal force balance of the shaft gives us

A x + 902.1−1847.2+1200 cos 20° =0 ,

giving A x =−182.5 N, i.e., directed to the right.

Taking a moment equilibrium about A due to forces in the vertical (upward or downward) direction will
yield

1200 ∙ ( 0.06 +0.15 ) + B y ∙ ( 0.06+ 0.3+0.06 )

−1200 sin 20 °∙ ( 0.06+ 0.3+0.06+0.1 ) =0 ,

yielding B y =−91.9 N, i.e., directed downward. Taking the vertical force balance of the shaft gives us
 A y +1200−91.9−1200sin 20°=0 ,

giving A y =−697.7 N, i.e., directed downward.

Therefore, the total radial force acting on A is √ 182.52+ 697.72=721.2 N, while the total radial force
acting on B is √ 1847.22+ 91.92=1849.5 N. Because we ought to select the same 200 series ball bearings for A
and B, we use the higher load as a loading specification. The higher load common specification also ensures that
the total reliability of the two bearings does not drop significantly.

A printing roll is expected to have no impact during its service, but because the force is transferred to the
shaft using gears, the appropriate application factor is between 1.0 and 1.3. We'll use K a =1.2 to allow for
reasonable allowance for impact loads when gears are not running smoothly. The closest larger-than-the-load
rated capacity is 5.07-kN capacity with a 10-mm bore. Thus, the 90%-reliability lifetime is
6 3 6
10 ( 5070/(1.2 ∙ 1849.5) ) =11.92×10 cycles
for bearing B, while for bearing A the lifetime is

106 ( 5070/(1.2 ∙ 721.2) )3=201.1 ×10 6 cycles .

Bearing A has a significantly longer expected lifetime due to the lighter load.

Another way to choose the bearing size is as follows. We expect a printing service to be used for 8-hour
service, every working day, so each roll should last at least 20-30 thousands of hours. If we pick 30,000 hours
lifetime, then the equivalent number of cycles is
 6
30,000 ×60 ×350=630 ×10 cycles.
Using the formula
0.3
C 10=Fe K a ( L/L10 ) ,
we get

( )
1
630 ×106 3
C=1849.5 ∙1.2 =19.03 kN .
106
Thus, the required rated capacity for the 02-series is 19.5 kN with a 30-mm bore. We see that this second option
will make the overall system more expensive as the bore has to increase from 10 mm to 30 mm, but the lifetime is
improved by almost a factor of 53.

Problem 30
A ball bearing carries a 1200 lb load at 900 rpm for 45% of the time and a 2500 lb load at 1800 rpm for the
remainder of the time. The ball bearing is designed to have a 10 year lifetime with a 99% reliability. The average
daily use is 4 hours per day. Find the minimum bore for the ball bearing if a 300 medium series radial ball bearing is
used. Loads can be assumed steady. Use the exponent b=3.33 in the bearing life equation for the calculation:
L=K r L R (C / F e K a)b .

The number of cycles the ball bearing will have over the 10-year lifetime for the 900 rpm is
6
N 900 =900 × 60× 4 × 365 ×10 ×0.45=354.78× 10 ,
while for the 1800 rpm it is
6
N 1800 =1800× 60 × 4 ×365 ×10 × 0.55=867.24 × 10 .
They are combined in the Palmgren’s rule

N 900 N 1800
+ =1 ,
L900 L1800
where
3.33
L900 =K r LR ( C / F e K a ) ,

1200
K r =0.21 for a 99% reliability, LR =90 ×10 6 , F e = =5340.45 N, and K a =1.0 for steady loads.
0.2247
Hence,
−6 3.33
L900 =7.30512× 10 C ,
where the bearing rated capacity C is unknown. Using the same parameters for L1800 except of course now
2500
F e= =11,125.95 N, we obtain
0.2247
−7 3.33
L1800 =6.34102× 10 C .
Combining these two results in the Palmgren’s result,

4.8566 ×1013 1.3677 × 1015

+ =1 ,
C3.33 C 3.33
or
3.33 15
C =1.41627 ×10 ,
yielding C=35,472.7 N. We note that the second term is more dominant than the first term, so that we can
approximate it with
15
1.3677× 10
=1,
C 3.33
which will yield C=35,102.9 N. which is close to the exact result. From the table below, we will find that the
required minimum bore for a 300 medium series ball bearing is 95 mm.