Applied Failure Analysis

Service Training Meeting Guide 010 SESV8010

September 2000

TECHNICAL PRESENTATION

APPLIED FAILURE ANALYSIS

ANTI-FRICTION BEARINGS
ANTI-FRICTION BEARINGS FAILURE
ANALYSIS
MEETING GUIDE SLIDES AND SCRIPT
AUDIENCE
Service, service support and administrative staff personnel who understand the basic principles of
failure analysis, and who are or may be involved in determining root causes of anti-friction bearing
failures.

CONTENT
This presentation describes function, structure, operation, normal wear, abnormal wear and fractures,
parts problems and some root causes of anti-friction bearing failures.

OBJECTIVES
After learning the information in this presentation, the student will be able to:

1. describe functions of anti-friction bearings;

2. describe structural difference between, and correctly identify the different types of Caterpillar anti-
friction bearings;
3. describe the principle types of loading that anti-friction bearings experience during operation;
4. identify road signs of high temperatures, misalignment, impact damage, and corrosion on anti-
friction bearings and list possible root causes;
5. identify common manufacturing or installation problems of anti-friction bearings.

REFERENCES
Anti-friction Bearings Applied Failure Analysis Reference Book SEBV0562
Anti-friction Bearings Applied Failure Analysis Self-Paced Instruction CD-ROM SEGV8010

PREREQUISITES
AFA STMG 013 Failure Analysis Management SERV8013
AFA STMG 017 Basic Metallurgy SERV8017
AFA STMG 014 Principles of Fractures SERV8014
AFA STMG 015 Principles of Wear SERV8015

Estimated Time: 3 1/2 Hours

Visuals: 150 electronic images
Student Handout: 1 - Lab Worksheet
Form: SESV8010
Date: 4/2000
© 2000 Caterpillar Inc.
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TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................5

NOMENCLATURE................................................................................................................8

FUNCTIONS ........................................................................................................................11

LOADS .................................................................................................................................12

MANUFACTURE ................................................................................................................26

REMOVAL/INSTALLATION..............................................................................................32

OPERATION ........................................................................................................................47
Ball Bearings...................................................................................................................49
Cylindrical Roller Bearings ............................................................................................53
Tapered Roller Bearings .................................................................................................55

PROBLEMS .........................................................................................................................63
Contact Stress Fatigue.....................................................................................................66
Plastic Yielding ...............................................................................................................79
Adhesive Wear ..............................................................................................................100
Abrasive Wear...............................................................................................................102
Corrosion.......................................................................................................................107
Fretting Corrosion and Creep........................................................................................111
Electrical Pitting and Fluting ........................................................................................118
Handling and Installation Damage................................................................................122
Fractures........................................................................................................................139
Bearing Problems..........................................................................................................150

CONCLUSION...................................................................................................................154

SLIDE LIST........................................................................................................................155

STUDENT HANDOUT......................................................................................................158
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INSTRUCTOR NOTES
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INTRODUCTION

This presentation covers applied failure analysis of anti-friction bearings,

• Failure Analysis of
sometimes also known as rolling element bearings.
Anti-friction Bearings
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• Anti-friction bearings This presentation will first look at the nomenclature, function and loading
presentation of anti-friction bearings.
- Nomenclature
How the bearings are manufactured, properly installed and operated will
- Function then be covered.

- Loads Bearing problems will also be discussed as well as the facts and "road
signs" to look for that lead to the root causes of bearing failures.
- Manufacture

- Installation

- Operation

- Failure analysis of
anti-friction bearings
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• Anti-friction bearings There are two general categories of anti-friction bearings -- ball and roller.
include ball and roller
Within these categories, the major types found in Caterpillar products are:
- Major types used in
Caterpillar products
Ball
- Ball bearings may be
- radial contact
radial and/or angular
contact - angular contact

- Roller bearings may

be cylindrical, Roller
tapered, spherical,
or thrust - cylindrical (straight)
- tapered
- spherical
- thrust
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NOMENCLATURE

• Ball bearing The basic nomenclature of a ball bearing is shown here:

nomenclature

A. Outer ring (race)

A. Outer ring
B. Outer ring B. Outer ring raceway
raceway
C. Outer ring O.D. C. Outer ring O. D. (Outside Diameter) surface
D. Cage D. Cage
E. Balls
F. Inner ring E. Balls
G. Inner ring F. Inner ring (race)
raceway
H. Inner ring I.D. G. Inner ring raceway
I. Ring faces
H. Inner ring I. D. (Inside Diameter) or bore surface

I. Ring Faces
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• Cylindrical roller The nomenclature of a cylindrical roller bearing is shown here:

bearing nomenclature

A. Outer ring (race)

A. Outer ring
B. Outer ring B. Outer ring raceway
raceway
C. Outer ring O. D. C. Outer ring O. D. surface
D. Cage D. Cage
E. Rollers
F. Inner ring E. Rollers
G. Inner ring F. Inner ring (race)
raceway
H. Inner ring I. D. G. Inner ring raceway
I. Ring faces
H. Inner ring I. D. or bore surface
J. Ribs
I. Ring faces

J. Ribs
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• Tapered roller bearing The basic nomenclature of a tapered roller bearing is shown here:
nomenclature

A. Cup A. Cup (outer ring or race)

B. Cup raceway B. Cup raceway
C. Cup O. D. C. Cup O. D. surface
D. Cup front face D. Front face of cup
E. Cup back face E. Back face of cup
F. Cage F. Cage
G. Rollers G. Rollers
H. Cone H. Cone (inner ring or race)
I. Cone raceway I. Cone raceway
J. Cone I. D.
J. Cone I. D. or bore surface
K. Cone front face
K. Front face of cone
L. Cone front face
rib
L. Rib on front face of cone
M. Cone back face M. Back face of cone
N. Cone back face N. Rib on back face of cone
rib
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FUNCTIONS

• Anti-friction bearing Anti-friction bearings have two primary functions:

functions:

- Support shafts and

1. Support and maintain alignment of shafts and housings while
housings allowing rotation with minimum friction.

- Maintain alignment
2. Carry radial and/or thrust loads.
- Minimize friction

- Carry radial and

thrust loads
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• Anti-friction bearing LOADS

loads
Radial loads (illustrated here by the arrow pointing down) generally result
- Radial loads
from the weight of parts supported by the bearings and loads on shafts
- Part weight load required to transmit power -- such as belts, chains, gear drives, etc.

- Operating loads

- Thrust loads Thrust loads (illustrated by the arrow pointing left) result from
engagement forces of clutches, forces from wheels when machines turn
- Clutch
engagement corners, unbalanced hydraulic forces in line with shafts, weight of parts
on vertical shafts, helical gear forces, etc.
- Cornering

- Hydraulic forces

- Vertical mounting

- Helical gear
forces

- Etc
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• Ball bearings The single row radial contact bearing (also called `deep groove', `conrad',
or `non-loading groove' type) is the most commonly used ball bearing.
- Single row is most
This type bearing is essentially a radial load carrier with limited thrust
common type
load capability. Therefore proper bearing seating is necessary to avoid
- Radial load carrier abnormally high thrust loads.

- Limited thrust
capability

- Properly seated
bearing is essential
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• Single row angular Single row angular contact bearings (shown on the left in this illustration)
contact bearings (left) are designed for radial and considerable thrust loads. These bearings are
also used where precise axial positioning of a shaft is required.
- Radial and thrust
loads
Angular contact bearings can be identified by high thrust shoulders on the
- Precise axial rings. The outer ring will have the thrust shoulder on one side and the
positioning inner ring will have the shoulder on the opposite side.

- High thrust
The ring sides opposite the thrust shoulders are only high enough to make
shoulders
the bearing non-separable.
-Thrust in one
direction only Thrust can be taken in one direction only by these bearings. However,
when mounted in opposing pairs, single row angular contact bearings can
- Opposing pairs carry carry thrust in both directions.
thrust in both
directions
Double row angular contact bearings (shown on the right) are basically
• Double row angular two single row bearings built as a unit. These bearings can take thrust in
bearings (right) for both directions and provide precise axial shaft positioning.
thrust and positioning
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• Split inner race Another type of ball bearing, sometimes used in applications that require
bearings accurate axial positioning, is called a split inner race bearing. These
bearings are capable of taking thrust loads in both directions.
- Accurate axial
positioning
The split inner race makes it possible to have high thrust shoulders on
- Thrust loads in both both sides of the races and also be able to assemble more balls in the
directions bearing.

- More balls in bearing

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• Roller bearings carry Roller bearings have higher radial load carrying capacities than ball
higher radial loads bearings of the same envelope size.
than ball bearing

Cylindrical or `straight' roller bearings have the capacity to withstand

• Cylindrical bearings
carry high radial and high radial loads. Although capable of handling some thrust, these
low thrust loads bearings are not generally used to carry heavy thrust loads.
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• Needle bearings A needle bearing is a special type of cylindrical roller bearing that has
rollers with a length to width ratio of greater than 4:1. These bearings are
- Have greater than
used for radial loads on shafts where radial dimensions must be kept
4:1 length to width
ratio minimal.

- Used where radial The cage and roller assembly pictured is a type of needle bearing
size must be minimal sometimes used to support power shift transmission planet gears.

- Used in
transmission planet
gears
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• Drawn cup bearings Another type of needle bearing is called a drawn cup bearing. The unique
feature is the outer raceway, formed by drawing a relatively thin hardened
- Outer raceway is a
steel cup around the rollers.
thin, hardened steel
cup
Drawn cup bearings need special care during installation, which will be
- Special care during reviewed later. (Photo courtesy of The Torrington Company)
assembly
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• Tapered roller Tapered roller bearings are especially suited for carrying both radial and
bearings thrust loads. The design of the rollers and raceways form an angle with
the shaft axis.
- Good radial and
thrust load carrier
Tapered roller bearings are also useful for maintaining precise axial
- Rollers and positioning of shafts and housings.
raceways form angle
A single row tapered roller bearing can carry thrust loads in one direction
- Precise axial
only and is therefore usually adjusted toward another bearing on the same
positioning
shaft capable of carrying thrust loads in the opposite direction.
- Single row carries
thrust in one
direction only
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• Double row bearings The double row tapered roller bearing can support thrust loads from either
carry radial and thrust side as well as radial loads.
in both directions
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• Spherical Roller Spherical roller bearings are self-aligning, and as such can withstand
Bearings some shaft or housing misalignment. In addition to radial loads, this type
bearing can carry thrust loads from either direction.
- Self aligning

- Tolerate
misalignment

- Carry thrust loads in

both directions
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• Roller thrust bearings Roller thrust bearings are designed to carry pure thrust loads, as the name
only carry thrust implies.
loads
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• Cage functions Most anti-friction bearings incorporate cages to keep the rolling elements
evenly spaced, resulting in equal load distribution amongst the rolling
- Evenly spaced
elements and preventing the elements from rubbing against each other
rolling elements
during operation.
- Equal load
distribution Additionally, cages keep cylindrical rollers in line with the shaft. If
allowed to run free, rollers could skew, stop rolling, and slide causing
- Prevents contact adhesive wear and premature failure.
- Maintain roller
alignment
There are many different types of cages including riveted, stamped, brass,
and electron beam welded, which is the type shown here.
• Multiple cage types
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• Ball bearing stress High stress areas on ball bearings are indicated by the arrows on these
areas illustrations.
- Radial contact
In radial contact bearings subjected to radial only loads, stresses are
- Stationary ring concentrated in the center of the raceways.

- Load zone In most applications, one ring rotates while the other ring is stationary.
Under these conditions, the stationary ring will have constant stress only
- Rotating ring
on the portion of its circumference that is in the direction of the load
(called the "load zone").
- Angular contact
The rotating ring will have stress all the way around its circumference, as
- Off center wear it rotates through the load zone.
pattern
Load zones and resultant wear patterns will be reviewed later.

In angular contact bearings, subjected to radial plus significant thrust

loads, stresses will be off to one side of raceways and all the way around
both rings.
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• Roller bearing stress High stress areas on roller bearings are on inner and outer raceways and
areas rollers where radial rolling contact forces are applied.
- Cylindrical roller
Normal stresses in cylindrical roller bearings will be all the way around
- Inner raceways the rotating raceway as it passes through the load zone and only part way
around the stationary raceway (in the load zone).
- Outer raceways
Stresses in tapered roller bearings with high thrust loads or pre-load will
- Rollers
be all around both raceways.
- Load zone
Tapered roller bearings will also experience bending, sliding, and
compressive forces due to contact between the back ribs of cones and the
- Tapered roller large ends of the rollers. This contact (called seating force) is what keeps
the rollers aligned with the shaft.
- Seating force

- Bending

- Sliding

- Compressive
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MANUFACTURE

• Anti-friction bearings Anti-friction bearings are manufactured from top quality alloy bearing
are manufactured
steels. Some are vacuum melted and most are vacuum degassed for
from quality steel and
processes maximum cleanliness.
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• Races are cut from Race blanks are either cut from tube stock (smaller bearings) or forged
tube stock or-forged (larger bearings) from high quality steel and then machined to
approximate dimension.
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• Cylindrical and After machining, the races of cylindrical and tapered roller bearings are
Tapered Roller case hardened to RC 58 minimum and then ground to final dimension.
Bearings
Tempering temperatures are approximately 190 to 200 degrees C (375 -
- Case hardened 400 F).

- Hard case RC 58 Case hardening gives raceway surfaces good resistance to wear and
minimum fatigue while maintaining a softer (RC 25 - 40), tougher core for
increased impact load carrying capability.
- Soft core RC 25 -
40 core
This cross section is of a tapered roller bearing cone. The surface has
- Visible case depth been etched to highlight the case hardened depth.
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• Rollers are forged of Rollers are forged (cold headed) from the same high quality steel as the
high quality steel races. This cylindrical roller is an example of cold heading, before heat
treat and grinding.
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• Rollers Rollers are also case hardened (to RC 60 minimum) and then ground to
final dimension.
- RC 60 case
hardened

- Finish ground
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• Ball and spherical Ball and spherical roller bearings are manufactured in a similar manner,
roller bearings have except the raceways and rolling elements are through hardened. Hence no
similar manufacture
case depth can be seen on the ball and raceway cross sections shown here.
- Rollers and races
through hardened

- No visible case
depth
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REMOVAL/INSTALLATION
• Removal/installation
Using the correct anti-friction bearings for the application and correct
- Correct bearings
procedures for removal and installation is very important. General
- Caterpillar parts guidelines are as follows:

- Removal/installation 1. Be sure to order bearings from the Caterpillar parts system to avoid
using standard bearings where "special" bearings are required.
- "Clean" assembly

- Proper tools and

2. Bearings, shafts and housing bores must be clean and free of dirt or
procedures other debris.

- Parts alignment 3. Proper tooling and procedures should be used to avoid excessive
forces between races and rolling elements, and to avoid damaging
- Correct parts fit
races, housings and shafts.
- Accurate bearing
adjustment 4. Alignment of shafts and housings needs to be accurate.

5. The fit of bearings on shafts or in housing bores must be correct.

6. Bearing adjustments (if called for) must be accurate.

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• "Special" and Caterpillar specifies "special" as well as "standard" bearings

"standard" bearings manufactured by suppliers.
- "Special" bearings
"Special" bearings are used where loads, shaft deflection, etc. call for
may have unique
unique rolling element shape, cage design, internal clearances, etc.
- Rolling element
shape "Special" bearings may look like "standard" bearings and may be marked
by the manufacturer with similar bearing numbers, but will have different
- Cage design
load carrying capabilities.
- Internal
clearances Also, continual design changes improve and increase service life. No
other bearing supplier is up to date on all these changes.
- "Special" bearing
appearance and Therefore, it is important to order bearings from the Caterpillar parts
numbers system to be sure of designed service life and to avoid premature failures.
- Design changes
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• Various publications An excellent video tape called "Caterpillar Anti-Friction Bearings" (Form
available on No. TEVN1412) explains the importance of using Caterpillar supplied
Caterpillar bearings
bearings in Caterpillar products.

Also a booklet, "Straight Talk about Caterpillar Anti-friction Bearings"

(Form No. PEDP6124), discusses the differences between "standard" and
"special" bearings.

In addition, a handout piece (Form No. PEDP8110) is available which

discusses these differences.
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• Anti-friction bearing During installation, care must be taken to assure no dirt or other debris is
Installation present to cause premature wear or damage to rolling elements or
raceways.
- Dirt and debris can:

- Cause wear Equally important is avoiding debris or dirt from getting between bearing
race faces and shaft or housing shoulders as is illustrated here.
- Prevent seating
The debris could prevent bearings from seating properly (illustration on
- Create lose
the left) and cause them to lose adjustment or positioning during
adjustment
operation.
- Cock or deform
races If the debris is concentrated in one area of the circumference (illustration
on the right), it could cause a bearing race to be deformed or cocked
resulting in out of roundness or misalignment.
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• Proper tooling and Proper tooling and procedures are very important when removing and
procedures installing bearings.
- Use a press where
In general, races should be pressed onto shafts or into housings straight
possible
and through only the race being mounted.
- Only press on the
race being mounted The use of chisels, punches, flame cutting, and weld bead shrinking
should be avoided where possible.
• Some methods should
be avoided
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• Incorrect procedures Bearings should not be pressed or driven through their rolling elements,
i.e. removing or installing a race on a shaft or in housing by driving or
- Do not press or drive
pressing on the other race. This practice can cause chipping of ribs and/or
through rolling
elements denting (brinelling) of raceways and rolling elements that may lead to
failure. These problems will be discussed later in this module.
- Chipping or denting
may occur
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Special care needs to be taken when pressing drawn cup needle bearings
into bores since the cups are relatively thin and are easily damaged by
• Drawn cup needle
mishandling.
bearing installation
rules
General installation rules are:
- Press only on
stamped end 1. Press only on the end of the bearing that has the bearing information
stamped on it.
- Press only to
specified depth
2. Press only to a specified depth and not to an internal shoulder.
- Use service manual
and proper tooling 3. Use proper tooling and procedures specified in the service manual.

If service manual recommendations are not followed, cup distortion,

cracking and subsequent failure can occur. (Photo courtesy of The
Torrington Company)
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• Heating or freezing Heating or freezing bearings for easier installation must also be correctly
bearings for easy done.
installation

Bearings should be evenly heated with induction heaters, infrared lamps,

- Heating methods:
suspending in oil, or in ovens. All these processes should be
- Induction heaters thermostatically controlled to avoid exceeding service manual
specifications. Higher temperatures may soften bearings.
- Infrared lamps

- Suspended in oil
or oven

- Thermostatically
controlled methods
avoid overheating
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• Open flame heating Avoid heating bearings with an open flame such as a blowtorch because
has uncontrolled uneven and uncontrolled temperatures can result.
temperatures
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• Freezing bearings for Sometimes freezing outer races is required for easier installation into
easy installation housings. Again, follow service manual instructions for proper freezing
temperatures.
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• Parts alignment is Alignment of shafts, housings, and bearing seats also needs to be within
critical to proper certain tolerances. Misalignment in any of these areas can cause uneven
loading
loading and result in early failure.
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• Bearing fit The fit of bearings on shafts and in housings should also be correct.

- Tight fit can Housing bores or shafts that are too tight can cause overload conditions
overload, split races,
that could split inner races or cause tight and subsequently hot running
increase operating
temperatures bearings.

Housing bores or shafts that are too loose can cause bearing races to move
- Loose fit bearings or turn in/on them (excessive "creep") resulting in abnormal wear and
can move and
increased clearances.
increase clearances

- Machining can affect Improperly machined housing bores can cause misalignment or out of
alignment and fit round bearing races and subsequent overloading of raceways and/or balls
or rollers.
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• Tapered roller bearing Tapered roller bearings are usually adjusted with slotted nuts, shim packs,
fit can be adjusted etc.
• Design may be for
Some installations are designed to have "end play." Others are designed
"end play" or
"preload" to operate with a certain amount of "preload."

- Preload means tight Preload means the cone and rollers are adjusted to where at operating
fit at operating temperatures, they are pressed slightly into the cup.
temperature
Preload (illustration on the right) increases the capacity of the bearing by
- Preload increases
load capacity spreading the applied load over more rollers and over a larger portion of
the fixed raceway compared to bearings adjusted with end play
- Preload minimizes (illustration on the left).
radial and axial
motion Preload also minimizes radial and axial shaft motion in precision
applications.
• Wrong adjustment
shortens bearing life
If adjusted too tight or too loose, bearing life may be reduced.
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• End play adjustment It is extremely important to rotate the shaft or housing while adjusting and
checking end play on tapered roller bearing installations, to be sure the
- Rotate during
bearings are properly seated. If this step is not done, loose bearing
adjustments and
checks to seat adjustment sometimes results.
bearings
Again, service manual instructions should be closely followed to assure
- Follow service correct adjustment.
manual instructions
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• Lubricant Once bearings are properly installed, it is also important to provide the
correct quantity, viscosity, and type of oil or grease.
- Use correct quantity,
viscosity, and type
Both under filling and over filling compartments can cause excessive
for temperature
control temperatures and bearing damage.

- Use Operation and Over filling can cause "churning", churning may increase temperatures
Maintenance Guide and reduce the viscosity of the oil at the bearing.

To be safe, use Operation and Maintenance Guide recommendations for

correct lubricant quantity, viscosity, and type.
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• Operation OPERATION

- Normal operating Normal operating conditions of bearings include factors such as oil film
conditions
thickness, applied loads, surface finishes, oil viscosity, and temperature.
- High speed creates
oil film thickness During normal high speed operation, rolling elements rotate fast enough
to produce a thin oil film that separates rolling elements from raceway
- 2,070 MPa pressure surfaces. Localized pressures can be as high as 2,070 MPa (300,000 psi)
on oil film between
at the point where rolling elements are supported on the oil film. At this
parts
highly localized pressure the oil film becomes almost solid and the
- Oil film nearly surfaces of the raceways and rolling elements cyclically and elastically
becomes solid deflect or move during operation.

- Bearing surfaces For this reason, anti-friction bearings do not have unlimited life. Even if
deflect cyclically and
conditions are normal, subsurface fatigue cracking, due to cyclic
elastically
deflection, may result after many, many hours of operation.
- Limited life due to
fatigue cracking In addition to subsurface fatigue, wear from fine debris or corrosive
agents in the oil will be present. Wear on high hour bearings can also be
caused by direct rolling element to raceway contact during start-up,
before oil films are established, or in slower speed applications.
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• Slower speed In slower speed applications, the oil film may not be sufficient to keep
operation race and rolling element surfaces completely apart. Under these
conditions, some asperities penetrate the oil film, contact other asperities,
- Insufficient oil film
and reduce bearing life.
- Asperity contact
This fact is taken into account in bearing design however, so normal
- Reduced bearing life service life in terms of hours of operation is achieved.

• Designed to give good

service life
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Ball Bearings

• Ball bearing wear

Loads and resultant wear produce characteristic patterns on raceway
characteristics surfaces.

This illustration is of a normal raceway wear pattern on a ball bearing that

- Normal wear with is radially loaded. The arrow indicates the direction of the load on the
radial loading
inner race.
- Inner race rotates,
outer race stationary In this application, the shaft (inner ring) is rotating while the housing
(outer ring) is stationary.
- Inner raceway wear
Note, the wear is all around the center of the rotating inner raceway, but is
- Outer raceway load only on the load zone portion of the non-rotating outer raceway.
zone
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• Ball bearing wear This wear pattern is typical for a ball bearing that operates with radial
characteristics loads where the outer ring rotates and the inner ring is stationary. Again,
the arrow indicates the direction of the load on the inner race.
- Typical wear pattern
for rotating outer
ring and stationary Note that the wear is all around the center of the outer raceway and only
inner ring on the load zone portion of the non-rotating inner raceway.

- Outer raceway wear

- Inner raceway load

zone
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• Ball bearing thrust If a ball bearing carries consistent thrust loads in one direction, the
loading raceway wear pattern will be similar to this illustration.
- Single direction
Note: Pure thrust loads cause wear all the way around and toward one
thrust wear
side on both raceways.
• Thrust loads wear all
around on one side
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• Ball bearing carrying These raceways are from a ball bearing that was carrying both thrust and
thrust and radial loads radial loads.
- Stationary outer race
The non-rotating outer raceway has a larger wear pattern (downward) in
wear pattern
the direction of the radial load.
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Cylindrical Roller Bearings

• Cylindrical roller Cylindrical roller bearings are primarily designed to carry radial loads and
bearings carry radial will display normal wear patterns similar to ball bearings in radial
loads applications. The wear will normally be all around the rotating raceway
surface and only partially around the stationary raceway in the load zone.
- Rotating raceways
wear all around

- Stationary raceways
have load zones
AFA STMG 010 - 54 -
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50

• Cylindrical roller Ribs and roller ends in cylindrical roller bearings usually have little if any
bearing wear unless subjected to significant thrust loads.
- Ribs and roller end
wear is unusual
AFA STMG 010 - 55 -
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51

• Tapered roller bearing Tapered Roller Bearings

wear patterns
Tapered roller bearing wear patterns will vary depending on the how
- Adjustment and load
tightly they are adjusted or how much thrust load they are required to
determine wear
pattern carry.

- Loose adjustment or The looser the adjustment and the lighter the thrust loads, the more
light load result in tendency for the stationary raceway to have wear on only a portion of its
small wear area
circumference.
AFA STMG 010 - 56 -
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52

• Tight adjustment or The tighter the adjustment and the heavier the thrust loads, the more wear
heavy load result in on the total circumference of the stationary raceway.
larger wear area
AFA STMG 010 - 57 -
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53

• Tapered roller bearing Thrust loading tends to push the roller end faces into the ribs. Contact
thrust loads affect between the large ends of the rollers and the ribs of tapered roller bearings
roller ends and ribs
may cause wear; however, heavy scoring, scuffing, metal displacement,
- Normal loads cause heat discoloration, etc. would be abnormal.
wear

- Abnormal loads can

score, scuff,
displace metal and
discolor
AFA STMG 010 - 58 -
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54

• Straight and tapered Whatever the preload or applied load, if operation is normal, straight and
roller wear is uniform tapered roller bearing wear should be relatively uniform across the
if normal operation
raceway and roller surfaces.
• Normal wear pattern
This race is typical of a normal wear pattern on a tapered roller bearing
• Grinding marks can cup. The circumferential scratches seen on the raceway surface are
be seen with side light normal grinding marks that are made easily visible by side lighting and
and magnification magnification.
AFA STMG 010 - 59 -
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55

• Highly loaded In highly loaded bearings or in applications with considerable shaft

applications deflection, rollers are sometimes designed with a special crown on the
surfaces to prevent flattening, overloading and spalling of the ends of the
- Crown rollers
prevent overloading rollers.
and spalling
These bearings may have a wear pattern that is concentrated more toward
- Wear pattern the middle of the roller surface, especially if the applied loads have been
centered on roller relatively light.
AFA STMG 010 - 60 -
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56

• Lightly loaded Raceway wear patterns on lightly loaded crowned roller bearings may
applications also be concentrated toward the middle.
- Wear pattern
centered in raceway
AFA STMG 010 - 61 -
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57

• Back of races Backs of races should be free of fretting corrosion or polishing. The
machining or grinding marks should still be visible on the surfaces.
- No fretting corrosion
Fretting corrosion or polishing from turning in the bore or on a shaft (a
or polishing
condition called "creep") is abnormal.
- Visible machining
marks
AFA STMG 010 - 62 -
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58

• Race faces Light staining from the edge of the housing or shaft may be present on the
outer or inner ring faces. There should be no wear on these faces. Wear
- May have staining
would indicate races have moved relative to shafts or housings.
- No wear
AFA STMG 010 - 63 -
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59

PROBLEMS

• Problems Now that normal appearance of used bearings has been discussed some
problems caused by abnormal operating conditions will be easier to
- Contact stress
fatigue (spalling) identify.

- Plastic yielding The most common types of bearing damage (not in order of priority) due
to abnormal conditions are:
- Adhesive wear
1. Contact stress fatigue (spalling)
- Abrasive wear
2. Plastic yielding
- Corrosion 3. Adhesive wear
4. Abrasive wear
- Fretting Corrosion 5. Corrosion
6. Fretting Corrosion and Creep
- Electrical pitting
7. Electrical pitting and fluting
- Handling damage 8. Handling and installation damage
9. Fractures
- Fractures
AFA STMG 010 - 64 -
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60

Key points to remember when analyzing bearing failures are as follows:

• Failure analysis 1. Most abnormal conditions will eventually cause high loads and/or
temperatures at raceways and rolling elements. High loads and
- Abnormal conditions
create load and heat temperatures can disturb the oil film, cause abnormal wear, spalling
and/or plastic yielding and ultimate failure.
- One damage type
may generate 2. When one damage type occurs, it may further generate other damage
another
types on the same part surface. As such, at the time of investigation,
- Investigate failure there may be two or more types of damage present, with the
early secondary damage overlaid on top of the initial damage.

- Consider all facts 3. It is desirable to investigate a failure in its earliest possible stages
to most accurately determine the correct root cause.
- Eliminate
preconceived ideas
4. Be sure to consider all facts and possible conditions during analysis to
eliminate preconceived ideas about the cause of failure.
AFA STMG 010 - 65 -
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61

• Magnetic strainer If there is this much metal on the magnetic strainer in a system, chances
are the damage has progressed to where it will be very difficult to
- Severe damage
determine the specific condition that started the failure (Root Cause).
increases analysis
difficulty Careful study of all the facts will be essential to determine the most
probable root cause.
AFA STMG 010 - 66 -
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62

Contact Stress Fatigue

If overloaded with enough cool oil to keep the bearing from softening due
• Contact stress fatigue
to high temperature, raceway and rolling element surfaces can
- Overload with oil prematurely fail due to "rolling contact stress fatigue."

- Cyclic flexing In rolling contact stress fatigue, high rolling stresses cause cyclic flexing
of rolling element and raceway surfaces. This surface movement initiates
- Subsurface fatigue
small fatigue cracks beneath the surface.
- "Spalling"
These cracks can grow and progress upward, eventually breaking out
large pieces of material, creating a condition known as spalling.
AFA STMG 010 - 67 -
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63

There are many possible root causes of premature contact stress fatigue in
• Contact stress fatigue rolling element bearings, including:
can result from

1. Excessive applied loads.

- Loads

- Tight adjustment 2. Tapered roller bearings adjusted too tight.

- Loose adjustment 3. Tapered roller bearings adjusted too loose.

- Tight fit 4. Shaft too big or housing too small.

- Out of round
5. Out of round housing or shaft.
- Tapered
6. Tapered housing bore or shaft.
- Misalignment
7. Misalignment.
- Lube
8. Low viscosity lubrication.

9. Etc.
AFA STMG 010 - 68 -
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64

• Too loose Correct adjustment of tapered roller bearings is essential. If the bearing is
adjusted too loose (too much end play), wear and spalling can occur due
- Fewer rollers carry
to overload from not enough rollers taking the load.
the load

- Wear and spalling In horizontal shaft applications (primarily radial load), this could result in:
occur
1. Wear and spalling all around the rotating raceway but only on a small
- Horizontal mounting portion of the stationary raceway.
will have

- Small wear area

2. Rollers can show more wear and spalling on one end than the other.
on stationary race Raceways can also show more wear and spalling toward one face than
the other.
- Off center roller
and race wear 3. Cage windows on bearings on either end of the shaft may show
lipping and an "hour glass" wear pattern.
- Damaged cage
windows
AFA STMG 010 - 69 -
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65

• Too loose This stationary cup was overloaded due to loss of adjustment of the
bearing (too much end play). Note the narrow area of spalling. The
- Too much end play
bearing had so much end play, that the rollers were not contacting the
- Narrow spalled area raceway surface across its entire width.

- Spalling not in
normal wear location
AFA STMG 010 - 70 -
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66

• Too loose These tapered rollers are from the same bearing and are spalled on the
small ends of the rollers indicating. misalignment from too much end
- Tapered rollers
play.
spalled on the end

- Cage window lipping Also note the lipping (rolling up of a burr) and the "hour glass" wear
and "hour glass" pattern on the cage windows (window is slightly wider toward the ends of
wear the rollers than in the middle). This wear pattern occurs when the rollers
are allowed to skew and rub with greater than normal force against the
- Roller alignment
cage windows. The rollers were not held in line by correct adjustment
problems
and seating force against the cone back face rib.
- Window notches are
abnormal stress In addition, the rollers in this cone have also worn sharp notches at the
raisers cage window corners. These abnormal stress raisers can cause fatigue
fractures of the cage window struts. Once the cage window struts fail,
- Check other
rollers can skew even more, stop rolling, and result in extensive bearing
bearings
damage.
- Determine reason for
excess end play Too much end play could also affect the bearing at the other end of the
shaft in the same way.

At this point, determine why the bearing had too much end play. Was the
bearing incorrectly adjusted when installed or become loose during
operation due to conditions such as debris behind races, retaining nuts
backing off, bolts loosening, abnormal wear from dirt or other debris in
the lubricant, etc.?
AFA STMG 010 - 71 -
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67

• Too tight If preload is too tight, rolling elements and raceways can be overloaded in
thrust causing premature fatigue of their surfaces, spalling, and failure.
- Excess preload
overloads in thrust
Road signs of this condition on horizontal shaft applications include:
• Road signs
1) Spalling/wear over a large portion of the circumferences of both the
- Large wear and/or rotating and stationary raceways.
spalling area
2) Rollers and raceways are worn/spalled evenly across the surfaces
- Wear/spalling evenly
across contact
from face to face.
surfaces
AFA STMG 010 - 72 -
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68

• Typical road signs of This tapered roller bearing cup has typical road signs indicating it had
excess thrust loads excessive thrust loads applied possibly from being adjusted too tight.
Note the even spall pattern on this stationary cup. This pattern can be
- Wear all around cup
found completely around the circumference of the cup.
- Deep wear location
This particular raceway also shows wear/spalling extending all the way
- Cone moved in as toward the back face of the cup indicating the cone was running very deep
spalling occurred in the cup just prior to disassembly.
- Spalling increases
end play and can
This road sign indicates that after the tight or highly thrust loaded bearing
cause misalignment spalled the thrust loads pushed the cone and rollers to this depth.

Note that as spalling continued the end play increased, unloading the
bearings on both ends of the shaft and causing some shaft misalignment
as evidenced by the heavier wear pattern and "grooving" toward the front
face of the cup.
AFA STMG 010 - 73 -
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69

• Roller and cone The rollers and cone show the same even spall pattern indicating these
spalling from tight fit parts were also running tight at one time in their life and were overloaded.
• Cage windows
Note however, the lipping and "hour glass" shaped wear in the cage
indicate loose fit after
spalling windows. This type wear implies the rollers were allowed to skew and
wear the cage windows (after the bearing loosened) due to increased
clearances from the wear and spalling. This condition was secondary to
• Investigate all the too tight/too much thrust condition which happened first.
possible reasons for
excess preload
Remember that not only tight adjustment but also excessive thrust loads,
or a shaft that is too big or a housing that is to small, can overload tapered
roller bearings and give similar road signs. Investigate all possible root
causes before arriving at the most probable cause.

If tight bearing adjustment is suspected, review adjustment procedures

with the installing service technician.
AFA STMG 010 - 74 -
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70

• Tight fitting bearings If shafts are too large or housings are too small, internal clearances can be
can become reduced to the point where rolling elements and raceways are overloaded
overloaded
at operating temperatures.

• Road signs will be Assuming temperatures are controlled, road signs would be:
similar to excess
thrust or preload 1. Abnormal wear and/or spalling on the complete circumference of both
problems the rotating and the stationary races.

2. Wear and/or spalling distributed evenly across the wear surfaces of the
rollers and raceways.

The appearance will be similar to the tapered roller bearing subjected to

too much preload or thrust shown in slides No.68 and No.69.
AFA STMG 010 - 75 -
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71

• Out of round parts will Another dimensional problem that can reduce bearing life is if the shaft or
have two or more load housing is out of round. In this case the wear/spalling pattern on the race
zones
installed in or on the out of round part will show two or more load zones.
• Load zones are at top
and bottom The illustration in this slide would indicate an out of round (oval) housing
bore. Note the two load zones (top and bottom) on the outer, stationary
race.
AFA STMG 010 - 76 -
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72

• Tapered parts can Tapered shafts or housing bores can also overload bearings. Road signs
over load bearings can usually be found on the back of the bearing race mounted in or on the
tapered part.
• Road signs are
usually found on the
back side of bearings As seen here, the contact pattern may be heavier where the race is tighter
(on the right in this example). The well defined (straight) line at the edge
- Heavier contact of the heavier contact area may indicate there was actually a step in this
areas housing bore.
- Heat discoloration
The bearing also shows heat discoloration in the heavier contact area.
- Fretting corrosion The discoloration was caused by increased temperature due to reduced
rolling element to raceway clearances.
- Fatigue cracking
Although not present on this bearing, fretting corrosion or fatigue
cracking due to flexing where races are not adequately supported by
shafts or housings is possible.
AFA STMG 010 - 77 -
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73

• Misaligned parts Misalignment can also cause unusual wear, contact stress fatigue and
have: spalling. Misalignment of shafts or housings will normally cause
wear/spall patterns to wander from one face to the other on one or both
- Unusual wear
raceways.
- Contact stress
fatigue This tapered roller bearing raceway shows a wear pattern caused by a
shaft that was out of alignment due to loss of bearing support on the other
- Wandering wear end. If allowed to run longer and if temperatures are not excessive, the
pattern
surface could eventually develop contact stress fatigue and spalling.
AFA STMG 010 - 78 -
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74

• Low oil viscosity If oil viscosity is too low, the oil film may be too thin and result in more
asperity contact than normal. This condition can over load bearing
- Thin oil film allows
raceway and rolling element surfaces. If rolling elements continue to roll
more asperity
contact (don't slide), and if temperatures are low enough for the steel to maintain
hardness, rolling contact stress fatigue cracking and spalling can occur.
- Rolling contact
stress fatigue and These fatigue cracks and spall patterns will usually have an orientation
spalling occur across the raceway, in-line with the shaft (axial orientation).
- Axial fracture and
wear patterns
AFA STMG 010 - 79 -
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75

• Plastic yielding Plastic Yielding

- Results from high Another type of damage found on anti-friction bearings is plastic yielding.
temperature,
High temperatures, insufficient oil film separating the surfaces or heavy
insufficient oil film,
or high loads loads that permanently deform bearing materials at normal temperatures
can cause plastic yielding.
- Root causes include
lube quantity, lube Root causes include oil quantity (not enough or too much oil or grease),
quality high loads
oil quality (too thick, too thin, etc.), high bearing loads, etc.
AFA STMG 010 - 80 -
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76

• Lack of lube shows If the root cause is quantity (no oil or grease), the bearing surfaces and
heat discoloration and surrounding components will usually be softened from high temperature,
no cooked on oil
show heat discoloration, and will generally be rather dry looking with
- Pinion and bearing little burned or cooked on oil.
failed without oil
This 816 dozer differential pinion bearing failed when a plug worked out
of the axle housing resulting in loss of oil to the bearing and other
components.

Note the heat discoloration and the absence of cooked or burned oil on the
surfaces (dry look).
AFA STMG 010 - 81 -
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77

• Cage and rollers show The bearing cage and rollers also show signs of severe heat. The rollers
severe heat road are softened as indicated by plastic yielding. The cage was deformed
signs
allowing the rollers to skew, stop turning, skid, cause adhesive wear and
generate even more heat.
AFA STMG 010 - 82 -
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78

• Closer view of rollers A closer look at some of the rollers shows the softening, plastic yielding,
and evidence of skewing.
AFA STMG 010 - 83 -
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79

• Pinion bearing cup The outer race also shows signs of heat discoloration, adhesive wear,
with hot dry look deposits from the melted cage, and a hot, dry look (no cooked-on oil).
AFA STMG 010 - 84 -
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80

• Look for signs of heat Another road sign to look for in lubrication caused failures is evidence of
on other parts heat on seals, gears, shafts and other bearings in the same system. This
cup is from the bearing on the other end of the shaft and is temper colored
indicating high temperature was present here also.
AFA STMG 010 - 85 -
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81

• Proper cleaning NOTE: If a bearing is suspected to been hot, proper cleaning is

techniques important to determine if the discoloration is really oxide deposits
from excess heat or lacquer from oil residue and not necessarily a
- Soft bristle brush
and mild solvent road sign of high temperature. The following method will usually
removes lacquer help.

- Crocus cloth used 1. Wash the bearing with a soft bristle brush in clean solvent. If the
lightly removes discoloration is removed, the deposit is probably lacquer and not
lacquer coloring
temper oxides.

2. If the discoloration is still present after washing, rub the surface

lightly with crocus cloth. Discoloration from oil lacquer will
normally be removed with the crocus cloth. Discoloration or temper
oxide from excess heat will normally not be removed.
AFA STMG 010 - 86 -
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82

• Hot, dry look with This 910 pinion bearing also suffered from loss of oil. The bearing
plastic deformation nearest the highly loaded pinion gear failed first. Note the hot, dry look,
with much plastic yielding.
- Bearing closest to
the heat source
(gear) failed first
AFA STMG 010 - 87 -
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83

• Other parts may also The bearing on the other end of the shaft also shows distress from no oil
show distress and from misalignment caused by lack of support of the failed bearing.
- Temper colors mean
Notice the heat discolored band on the raceway near the front face of the
small end of rollers
were overloaded cone where the small ends of the tapered rollers were carrying more than
normal load with insufficient oil film.
AFA STMG 010 - 88 -
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84

• All parts show signs The rollers also show evidence of high temperature due to inadequate
of lack of lube. lubrication and misalignment. All road signs suggest there was
inadequate oil quantity in this case. The analyst now needs to determine
- Determine why there
was insufficient lube why the oil was not present in sufficient quantity.
AFA STMG 010 - 89 -
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85

• Hot, wet look Bearings can also over heat and plastically yield due to factors other than
no lubrication, namely:
- Usually caused by

1) Using oil with viscosity that is too low.

- Low viscosity oil

- High operating 2) High operating temperatures. (Ambient temperatures too high, oil
temperatures quantity marginal, too much oil or grease causing churning.

- High loads
3) High loads -- applied
- Rough surfaces -- misalignment
-- misadjustment
-- etc.
- Asperity contact
increases wear and
4) Rough surface finish.
temperatures

Any of these conditions can cause more asperity contact than normal.
Asperity contact can then accelerate wear and may further increase
surface temperatures on rollers, cages, raceways, and ribs.

If heat is not controlled to below the tempering temperatures, surfaces can

be softened resulting in plastic yielding.
AFA STMG 010 - 90 -
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86

• Asperity contact Failures caused by too much asperity contact usually start with
roughens and cracks roughening and fine axial cracking of surfaces as seen on the right of this
part surface
spherical roller bearing raceway.
AFA STMG 010 - 91 -
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87

• Cage windows Also, some lipping (rolling up of a burr) can occur on edges of the
damage relatively soft cage windows that rolling elements rub against. In this
case, however, the cage windows will usually not be worn to an "hour
glass" shape, unless bearing adjustment is lost or is set too loose allowing
rollers to skew and wobble.
AFA STMG 010 - 92 -
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88

• Glazed appearance on Rolling elements and raceways may also appear glazed from plastic roll
rollers and races down (flattening of asperities) and polishing (burnishing) of a very thin
surface layer. The glazed surfaces may also show some heat discoloration
• Material pull out on
rolling elements if surface temperatures have been high.

• Spalling will occur Next, small pieces may begin to pull out of rolling element and/or
next, as seen on these raceway surfaces forming pits. These pits may have a "frosted"
rollers. appearance.

Frosting can then progress to spalling as is seen on some portions of these

roller surfaces.
AFA STMG 010 - 93 -
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89

• Worn or broken cages If cages wear or break, rollers may get out of line, skew, etc., begin to
lose control of the slide instead of roll, generating enough heat to soften rollers and
rollers
raceways. In this case, plastic yielding and discoloration can occur.
AFA STMG 010 - 94 -
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90

• Typical hot, wet look If substantial heat is generated, the bearing and surrounding surfaces may
with cooked on oil also appear discolored and damp, with burned, cooked or carbonized oil
deposited.

Burned or carbonized oil is evidence that there was oil at the bearing, but
the heat generated was too great for the oil to control.
AFA STMG 010 - 95 -
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91

The challenge to the analyst when bearings have been hot (but not
• Analysis challenge is completely dry) is to determine:
to determine lube

1. if the quantity of oil or grease supplied was marginal,

- quantity

- viscosity 2. if the viscosity of the oil was too low due to:

- film capability a. use of the wrong oil,

• Immediate failure b. high operating temperatures (environment or too much oil or

analysis is important grease causing churning), or,

3. if the bearing oil film was disturbed or overloaded due to high applied
loads, misadjustment, misalignment, incorrect dimensional fit, rough
surface finish, etc..

There are many conditions that can give the same resultant damage in
rolling element bearings. Immediate analysis of bearing failures is
therefore very important. Gather as many background facts as possible,
such as oil quality, quantity, loading, operating temperatures, etc., before
arriving at the most probable root cause.
AFA STMG 010 - 96 -
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92

• Brinell marks are Another type of plastic yielding not usually accompanied by signs of high
dents caused by temperature is called "brinelling." Brinell marks are dents on raceway
excess load
surfaces from excessive loads being transferred through the rolling
• Forceful assembly elements.
have grinding marks
in the dents As mentioned earlier, brinelling can be caused during assembly by
forcefully driving one race into position through the other race and rolling
elements. Road signs are:

1) Dents all the way around raceways at the same spacing as the rolling
elements,

2) Grinding marks visible in the bottom of the dents.

AFA STMG 010 - 97 -
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93

• Wear pattern in the Another example of brinelling is shown here. Note the wear pattern in the
bottom of the dents bottom of the dent is undisturbed. The rolling element actually dented the
meaning:
surface, but did not rub or wear away the wear pattern that existed before
- Shock loading did the brinell mark was formed.
not happen during
original assembly This brinell mark did not occur during installation but after the bearing
operated for some time.
- Damaged while
bearing was not
High shock loads applied (such as dropping a machine) while the bearing
rotating
is not rotating cause this condition.
• Brinelling gives lube
an escape path If brinelling occurs after the machine has operated (and there has been
wear in the bearing), the wear marks will be visible in the bottom of the
dents instead of or in addition to the original grinding marks.

Brinelling can cause localized interruption of the oil film thickness, too
much surface contact and overload between raceways and rolling
elements.

Overloading can then progress to spalling, starting at the brinell marks.

AFA STMG 010 - 98 -
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• Bruises are dents Large particles in the lubricant, such as metal debris from a gear or
from large particles another bearing failure, can cause plastic yielding and surface or fragment
denting (called "bruising") of raceways and rolling elements. Hard
- Hard particles
produce sharp particles will produce sharp angular dents where softer particles will
angled dents produce smoother more shallow dents.

- Soft particles Large particles can also jam between rolling elements and raceway
produce smooth surfaces causing bearings to "lock-up." When a bearing locks up relative
shallow dents
movement between the races and shafts or housing bores will occur.
- Large particles may
cause the bearing to
lockup
AFA STMG 010 - 99 -
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95

• Bruising leads to If allowed to run long enough, bruising can lead to spalling as seen in this
spalling tapered roller bearing cup.
AFA STMG 010 - 100 -
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Adhesive Wear

• Adhesive wear can Adhesive wear, without extreme plastic deformation, can occur on race
occur with adequate
and rolling element surfaces if there is sufficient cool oil or grease to
lube for cooling
control heat and if rollers stop turning and start sliding. As mentioned
earlier, one way rollers can stop turning is if the cage is excessively worn
or broken allowing rollers to skew and start skidding on raceways.
AFA STMG 010 - 101 -
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97

• Typical surface These raceways are typical of the type of surface adhesive wear caused by
adhesive wear this condition.
• Lack of temper colors
Note the wear did not create excessive heat or soften the steel as there is
indicate oil was
present little if any discoloration or gross plastic yielding. This indicates there
was enough oil to carry away much of the heat generated by the adhesive
• Analyst should wear.
determine what
stopped the rollers
The challenge when this condition exists is to determine why the rollers
stopped turning or why the cage was worn or broken.
AFA STMG 010 - 102 -
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98

Abrasive Wear

• Abrasive wear Abrasives such as dirt or sand in lube systems can also cause bearing
failures.
AFA STMG 010 - 103 -
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99

• Fine abrasives create This bearing race had a considerable amount of fine abrasives present
a matte or satin finish during operation. Note the matte or satin finish on the raceway due to
fine pitting. The pitting is a result of the lapping action of the abrasive
material. This same condition existed on the rollers and other raceway.
AFA STMG 010 - 104 -
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100

• Heavy contamination If contamination is extensive, bearings can lock up, cause rollers or balls
leads to: to slide generating adhesive wear, and/or cause races to move in housings
or on shafts.
- Bearing lockup

- Ball or roller sliding Severe contamination can also cause rolling element and raceway wear
that can increase end play on tapered roller bearings (loose adjustment)
- Increase end play which can result in abnormal cage wear, skewed rollers, cage fracture, and
extensive damage.
- Pitting

- Fatigue cracking and

Severe pitting can lead to fatigue cracking and spalling of surfaces at high
spalling operating hours. Fatigue cracking and spalling can be due both to the
abnormal stress raiser effect of the pit and the hydraulic force exerted by
oil being forced into the pit during operation.
AFA STMG 010 - 105 -
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101

• Look at other parts in If abrasives cause bearings to progress to adhesive wear or spalling, the
the same lube system root cause will be difficult to determine by looking at only the failed
for road signs
bearing. Careful observation of other parts in the same lubrication system
however, will generally give evidence of system contamination.

Look for the matte or satin finish discussed earlier on other bearings and
gears lubricated by the same oil.
AFA STMG 010 - 106 -
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102

• Abrasive wear If there is evidence of abrasive wear, the analyst needs to determine the
exact source of the abrasive material.
- First determine what
the abrasive material
Using magnification to identify what type particle caused the wear is a
is
good practice.
- Use magnification
and good lighting There are many sources such as debris built into the system, cracked
housings, dirt entry through failed seals, failure to clean grease fittings,
- Debris can be built-
contaminated grease, etc.
in or enter later

- Careful analysis If seals are failed, determine whether the seal failed first contaminating
finds the root cause the system or whether the bearing failed first causing shaft motion,
resulting in a failed seal that allowed dirt entry.

Careful observation and consideration of all facts and possibilities are

necessary to determine the exact root cause.
AFA STMG 010 - 107 -
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103

Corrosion
• Manufacturers dip and
wrap new bearings New bearings are dipped in a rust preventative solution and wrapped in
protective paper by the manufacturer.
• Bearings prepared for
inspection will rust
quickly If bearings are removed from a machine and cleaned, rust can begin very
rapidly. Therefore, protect removed bearings with oil, grease, or other
rust inhibitor.

Protected bearings should also be stored in a dry place.

AFA STMG 010 - 108 -
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104

• Unprotected bearings If these precautions are not followed, atmospheric corrosion can occur
may be unfit for reuse and result in a bearing that is not fit for use.
AFA STMG 010 - 109 -
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105

• Corrosion can affect Corrosion can occur after the bearing is installed if moisture enters the
assembled bearings lubrication system. Many times the corrosion will take place while the
machine is shut down and produce a condition known as "static
• "Static corrosion" or
"black acid etching" corrosion" or "black acid etching."
occurs during
shutdown periods Under these conditions, moisture (coupled with acids formed in the used
oil), collects around the rolling elements and produces dark, evenly
• Moisture collects spaced corrosion stains, pits, or deposits as seen on this tapered roller
around rollers and
bearing cup raceway. Deep pits can cause fatigue cracks, spalling and
corrodes
subsequent failure.
AFA STMG 010 - 110 -
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106

• Static corrosion of the This slide shows the static corrosion on the rollers of this same bearing.
rollers
AFA STMG 010 - 111 -
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107

Fretting Corrosion and Creep

• Fretting corrosion or Sometimes road signs such as fretting corrosion or creep on inner or outer
creep indicate
bearing bore surfaces will indicate movement relative to shaft or housing
movement
has occurred.
• "False brinelling"
indicates vibration The analyst may also notice fretting corrosion on raceway surfaces where
without rotation rolling elements have vibrated while the bearing was not rotating -- a
condition called "false brinelling."
AFA STMG 010 - 112 -
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108

• Fretting corrosion The outer bore surface of this race shows fretting corrosion, a road sign
indicates movement indicating relative movement.
AFA STMG 010 - 113 -
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109

• "Creep" is a product This bearing outer race turned excessively in the housing, a condition
of excessive called "creep."
movement

Road signs of creep are a smooth, polished appearance on the bearing

- Road signs are
radial marks on the race.
race
If creep occurs, housings or shafts where races are mounted will usually
• Housing or shaft may also be worn. Care must be taken to assure shafts or housings are
require replacement
salvaged or replaced, if worn to the point where new bearings will be
loose.
AFA STMG 010 - 114 -
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110

• Creep may also affect If races have moved, rib faces may also show wear from turning against
the rib faces. shoulders on shafts or in housings. Under these conditions, the grinding
marks will be disturbed or worn away as seen in this slide.
• Thrust loading can
produce similar marks
This appearance can also result from high thrust loads in tapered roller
bearings. These thrust loads can rock the cup in its bore without actually
causing it to rotate. This rocking action can then disturb or wear the
grinding marks off of rib faces.
AFA STMG 010 - 115 -
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111

• Reasons for If a bearing race moves or "creeps" in its housing or on its shaft, the
movement or creep analyst should determine if:
are:

1. the shaft was too small,

- Shaft too small
2. the housing bore was too large or,
- Housing bore too
large 3. the race moved because the rolling elements stopped turning for
reasons such as skewing or foreign material being lodged between
- Rolling element
rolling elements and raceways.
stopped rotating
AFA STMG 010 - 116 -
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112

Brinelling was discussed earlier. There is another condition which looks

• "False brinelling" similar called "false brinelling."
- Caused by vibration
False brinelling is different than true brinelling. False brinelling is not a
without rotation
result of heavy shock loads, but is actually fretting or fretting corrosion
- Can occur during caused by vibration under load while the bearing is not turning.
shipping
For example, false brinelling can occur when shipping machinery a long
- Can affect bearings
distance by rail. Under these conditions, the rolling elements that support
that do not rotate
during operation
heavy loads may vibrate and wear into raceway surfaces.

This cylindrical roller bearing supports the swash plate in a hydraulic

excavator variable displacement pump. During operation the bearing
rotates only a few degrees as the pump is required to produce more or less
flow. Much of the time it is stationary and is subjected to vibration under
normal loads. After many operating hours, it is possible to find some
false brinelling on the raceway surfaces.
AFA STMG 010 - 117 -
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113

• Closer view shows Notice on this magnified view, the original grinding marks are worn away
grinder marks worn where the roller vibrated against the raceway. This road sign indicates
away
that false brinelling occurred.

Now the analyst should follow the root cause path that identifies the
source of the vibration rather than suspecting that shock loads while the
machine was not operating caused the problem.
AFA STMG 010 - 118 -
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114

• Electrical pitting and Electrical Pitting and Fluting

fluting
Another abnormal condition that can cause bearing failures is the passage
• Two most common
of electric current through them. Two major ways this can happen are:
types are

- High current not 1. Relatively high current while the bearing is not rotating, and
rotating
2. Relatively low current over a prolonged period of time while the
- Low current rotating
bearing is rotating.
AFA STMG 010 - 119 -
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115

• High current causes High current while the bearing is not rotating usually causes arcing and
arcing and pitting pitting as seen here. Root causes can include welding on a machine with
the ground cable connected in such a manner that electric current passes
through the bearing. These pits can lead to spalling and ultimate failure.
(Photo courtesy of The Timken Company)
AFA STMG 010 - 120 -
9/2000

116

• Low current leaves Another form of electrical damage is the passage of relatively low current
small pits over a large over a prolonged period during operation.
area

Road signs are many small pits covering a large portion of the rolling
- Can increased
vibration, noise and elements and the raceway paths. If vibration is also present, these pits can
fluting further develop into fluting, noise and increased vibration.

Flutes are the axial lines on this ball bearing raceway.

AFA STMG 010 - 121 -
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117

• Closer view of flutes In this magnified view, the fluting lines are actually concentrated groups
or clusters of small pits.
AFA STMG 010 - 122 -
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118

Handling and Installation Damage

• Handling bearings Faulty handling or mounting and dismounting practices can cause
incorrectly
bearings to fail.
• Installation and
removal procedures
AFA STMG 010 - 123 -
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119

• Mishandling may If bearings are dropped or otherwise forcefully mishandled before

cause dents, cracks installation, raceways can be dented, cracked, or chipped. Fractures will
or chips
normally initiate on the exposed surfaces of the races that are vulnerable
• Races are very hard to outside forces.
and will brittle fracture
Since raceways are heat treated to a very high hardness, fractures will
• Cone has impact normally be brittle. Therefore, magnification and good lighting are
damage and brittle required when looking for evidence of crack initiation at the exposed
fracture
surface.

This cone appears to have been struck by an external force on the rib face.
Note the impact damage with local heat discoloration from the sliding
action of the impact load on the rib face surface.
AFA STMG 010 - 124 -
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120

• Bearing cage damage The bearing cage was impact damaged by dropping the cone before
can lead binding of installation. Damage such as this could crack cages, cause rollers to bind
the rollers
in the cage, skew, stop turning, begin skidding, generate heat, and lead to
a serious failure.
AFA STMG 010 - 125 -
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121

• Avoid spinning the Another way to cause handling damage to bearings is allowing the
bearing with bearing to spin while using compressed air for drying after cleaning. This
compressed air
practice should be avoided since skidding and adhesive surface damage
(scuffing) to raceways and rolling elements can occur with no oil film to
separate them.
AFA STMG 010 - 126 -
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122

• Improper installation Roller bearing ribs can be chipped or broken during installation by
driving or pressing through rolling elements.
- Brittle fractures at
the ribs and snap
Under these conditions, brittle fractures can occur which break out pieces
ring grooves
of the ribs or material outside snap ring grooves.
- Ribs fractures at the
same spacing as If there is a rib on the race, the broken pieces will tend to be at the same
rollers spacing as the rollers.

- Snap ring groove

If the rollers are retained with a snap ring, as is the case in this slide, a
fractures are random
spacing random fracture spacing will occur.

- Fractures are brittle In either case, these fractures will normally be brittle and initiate at fillets
and start at fillets or on the inside of the ribs or at the corners of snap ring groves.
corners
AFA STMG 010 - 127 -
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123

• Improper tooling Using improper tooling for removal or installation can result in uneven
and/or forceful blows on bearing races, cages, rolling elements, housings
- Damage can
or shafts. This bearing race was installed with a punch or chisel.
interfere with
performance
If deep enough, dents like this can interfere with rolling element travel,
cause localized high stress, and initiate spalling. The dent is also an
abnormal stress raiser that could initiate a fatigue crack.
AFA STMG 010 - 128 -
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124

• Improper tooling This same bearing race was also removed with a chisel. There are chisel
marks in the housing bore which could cause high spots behind the race,
- Damage can affect
reduce bearing clearances, and cause the bearing to run hot or be
the next bearing
overloaded resulting in premature contact stress fatigue and spalling.
AFA STMG 010 - 129 -
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125

• Improper tooling This tapered roller bearing cup is spalled in only a localized area of the
raceway.
- Localized bearing
damage in two areas
Although not shown in this slide, there is another similar area about 120
degrees around the cup's circumference.
AFA STMG 010 - 130 -
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126

• Close up of bearing Close inspection of the O. D. bore surface of the cup reveals two areas
O. D. where the cup was not allowed to seat properly due to a high spot on the
housing bore surface.
- High spots create
seating problems
This high spot in the housing bore caused reduced bearing clearance
- Improper tools can resulting in localized overload and contact stress fatigue and spalling.
damage housings
The two high spots in the housing bore were probably the result of using
improper tooling during bearing installation or removal.
AFA STMG 010 - 131 -
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127

• Misalignment can During assembly or disassembly, raceways can also be damaged if forced
damage bearings onto the mating roller and race assemblies without proper alignment.
• Damage will usually
This type of damage results in smear marks and possibly brinell marks on
be at roller spacing
rollers and raceways.

• This cup was forced Spacing of the marks will be the same as roller spacing and will either be
into position during all the way around or concentrated in only a portion of the race
assembly
circumference.
• One side has marks
near the front of the This tapered roller bearing cup was not properly seated (cocked) in the
wear face bore when installed. As the shaft and cone assembly was moved into
position, heavy pressure from misalignment (due to the cocked cup)
caused brinell and smear marks to be formed on the cup raceway surface.

Note the marks are concentrated toward the front face on this portion of
the cup.
AFA STMG 010 - 132 -
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128

• Opposite side shows This portion of the cup is 180 degrees opposite the previous view. Note
damage at the rear of that these brinell and smear marks are concentrated more toward the back
the wear surface
face of the cup.
AFA STMG 010 - 133 -
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129

• More damage was The O. D. bore surface near the back face of the cup also shows scuff
found indicating marks on only one portion of the circumference from the cup
misalignment
straightening in the housing bore during shaft and cone installation and
• All road signs indicate bearing adjustment.
improper seating
during assembly These road signs indicate the cup was not properly seated in the housing
bore prior to shaft and cone installation.
• Operating the
equipment would fail
If this bearing were allowed to operate with this damage, the smear/brinell
the bearing
marks on the raceways could have interrupted oil film and caused
premature pitting and spalling of the raceway and roller surfaces.
AFA STMG 010 - 134 -
9/2000

130

• Do not use a punch or This drawn cup needle bearing was removed with a punch or chisel. Note
chisel on drawn cup the indentations on the thin cup lip that doesn't have the bearing
bearings
information stamped on it. Bearings removed in this manner should not
• Damaged bearings be reused as the damage could stop rollers from turning and cause them to
should not be reused slide, resulting in adhesive wear and failure.
AFA STMG 010 - 135 -
9/2000

131

• Wrong flange angle Drawn cup bearings that are pressed in using tooling with the wrong
can damage bearings flange angle can be damaged by caving in and breaking off the lip at one
end of the cup. The other lip was broken at removal. Proper tooling is
• Use proper tooling
and press on the very important and press only on the end of the bearing with the bearing
correct side information stamped on it.

(Photo courtesy of The Torrington Company)

AFA STMG 010 - 136 -
9/2000

132

• Careful disassembly Using care when removing shafts through bearing bores is also very
will prevent bearing important.
damage

This drawn cup bearing was damaged when the corner of a key in the
• Keys and splines on
shafts can damage shaft key way caught on one of the rollers as the shaft was removed
bearings through the bearing bore.

Feeling resistance to movement, the technician decided to press the shaft

the rest of the way out of the bore. The key pushed the roller through the
cage and fractured the lip on the end of the cup.

The key also pressed down on the roller and brinelled the raceway near
the opposite end of the cup.
AFA STMG 010 - 137 -
9/2000

133

• Heating methods used Practices sometimes used in bearing removal are flame cutting of inner
to remove bearing races or weld bead shrinking of outer races.
races

When possible, these methods should avoided since uncontrolled heat is

- Should be avoided
generated and physical damage can be done to housings or shafts.
- Creates uncontrolled
heating This cup was loosened in the bore by the weld bead method. The heat
discoloration extends all the way to the outside diameter. This procedure
- May damage shafts
may have caused excessive heat to be transmitted into the housing.
and housings
AFA STMG 010 - 138 -
9/2000

134

This cone was removed by flame cutting. Note the cone is actually cut
through and into the shaft. As a result, the shaft was damaged both by:
• Flame cutting may
damage shafts 1. raising a high spot that would need to be ground off before
installing another bearing, and

2. cutting a groove in the shaft creating an abnormal stress raiser.

Consult the service manual for proper tools and procedures.

AFA STMG 010 - 139 -
9/2000

135

• Fractures Fractures

- Fractures may result Fractures in anti-friction bearing races or rolling elements that are
from overload or
properly heat treated and do not contain abnormal subsurface flaws, are
misalignment
usually due to heavy overload conditions.

If severe, misalignment can over load, wear and fracture rolling elements,
ribs and races.
AFA STMG 010 - 140 -
9/2000

136

• Fractures This group of parts is from a D3 winch with approximately 100 SMU.

- Broken D3 winch
after 100 hours
AFA STMG 010 - 141 -
9/2000

137

• Gears have road signs The gear on the shaft and the mating gear show signs of severe
of misalignment misalignment.
AFA STMG 010 - 142 -
9/2000

138

• Cylindrical roller The outer race of the cylindrical roller bearing on one end of the shaft is
bearing race fractured fractured due to over load caused by the prying action of shaft
by shaft misalignment
misalignment.
AFA STMG 010 - 143 -
9/2000

139

• Brittle fractured rib is The rib on the outer race of the bearing on the opposite end of the shaft is
a road sign of shock broken off in brittle fracture indicating a severe shock load was applied.
loading
AFA STMG 010 - 144 -
9/2000

140

• Fractured rollers Several of the rollers in this same bearing were split in half.
AFA STMG 010 - 145 -
9/2000

141

• Closer view of The broken rollers have ductile fractures in the softer core and brittle
fractured roller fractures in the harder case material indicating a sudden high load was
applied.
AFA STMG 010 - 146 -
9/2000

142

• Roller ends are The ends of the rollers are spalled and worn from unusual loading due to
spalled misalignment.
AFA STMG 010 - 147 -
9/2000

143

• Fatigue fractures on Note the fatigue fractures (spalling) on this roller start at the end and
roller end from high progresses toward the middle due to high cyclic loads from the severe
cyclic loading
misalignment.
• Need to determine
what caused The question facing the analyst at this point is "What caused the severe
misalignment misalignment?"
AFA STMG 010 - 148 -
9/2000

144

• Failed housing This housing supported the bearing outer race that was cracked. The race
supported the bearing and shaft were forced to move out of the housing at the fractured bore
outer race
multiple times.
- Subsequent damage
from misalignment The rest of the damage to the bearings and gears was the result of severe
shaft misalignment.
AFA STMG 010 - 149 -
9/2000

145

• Housing appears to Close observation of the cast iron housing with bright and angled lighting
have a brittle fracture reveals what appears to be a brittle fracture.
- Brittle fracture is
Brittle fractures are usually caused by shock loads. The analyst should
caused by shock
load now investigate the application of the D3 to see how a shock load could
have been applied.
- Fracture
identification can be Remember that fatigue fractures are sometimes very difficult to identify
difficult in cast iron
in cast iron. Looking carefully at the fracture face, there is a faint semi-
- Faint semi-circular
circular pattern radiating from the fillet in the bottom of the housing bore.
pattern could This pattern could be the road sign of a fatigue crack.
indicate fatigue
Therefore, an unusually high cyclic load or a material or process flaw
- High cyclic loading could have caused a fatigue fracture in the housing. These possibilities
or flaw are possible
would also need to be investigated prior to arriving at a most probable
causes of failure
root cause.
AFA STMG 010 - 150 -
9/2000

146

• Bearing problems Bearing Problems

- Material and Material, forming, machining, heat treat, grinding and assembly problems
manufacturing
are extremely rare in anti-friction bearings. This is due to the high quality
problems are rare
bearing steels and the strict quality control measures used in their
- One example manufacture.
available
As a result only one example of a manufacturing problem is presented
here.
AFA STMG 010 - 151 -
9/2000

147

• Bearing with early This bearing failed after only a few hundred hours of operation. The cage
hour failure is broken into many pieces.
AFA STMG 010 - 152 -
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148

• Bearing failure The outer race and balls look relatively normal. Only light scuffing is
observed which is from the cage pieces rubbing against the race and balls
- Outer race and balls
as the cage was breaking up.
look normal
AFA STMG 010 - 153 -
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149

• Bearing failure The inner race, however, shows considerable plastic deformation. The
notch on the outer edge of the raceway was easily cut with a file causing
- Inner race is
the analyst to question the material hardness. When tested, the hardness
plastically deformed
and soft (RC 20) was found to be less than RC 20.

- No temper colors on No evidence of excessive operating temperature (no heat discoloration)

parts was found on the bearing or adjacent parts that could have softened the
race. As mentioned earlier, the outer race and balls looked relatively
- Other bearing parts
normal and were of normal hardness.
were normal
hardness
Therefore the analyst concluded that the inner race most probably missed
- Inner race missed the heat treat operation during manufacture. The race was soft and could
heat treatment not carry the normal radial and thrust loads applied. The race deformed
and allowed more end play than normal causing cage interference and
subsequent failure.
AFA STMG 010 - 154 -
9/2000

150

• Anti-friction bearings CONCLUSION

- Support and This concludes the anti-friction bearing module. The functions of
maintain alignment
bearings are to support and maintain alignment of shafts and to carry
- Carry radial and radial and/or axial loads. As such, races and rolling elements are
axial loads subjected to constant cyclic loads. If oil film is not adequate either due to
high loads, low viscosity, or no lubrication, bearings can fail prematurely.
- Subjected to cyclic
loads
Getting all the facts when analyzing a bearing failure and to catch the
- May fail prematurely
failure in its earliest possible stages is very important. Otherwise, damage
can be extensive and the root cause may be very difficult to find.
- Require careful
analysis to find root Be very careful in analyzing anti-friction bearing failures since many
cause of failure different root causes can produce similar resultant damage.
- Manufacturing
Most bearing failures are not due to manufacturing problems because of
problems are rare
the high quality steel and control practices used in production.
- Perform all of the
steps of Applied After gathering facts and arriving at the most probable root cause,
Failure Analysis remember to complete steps 6, 7, and 8 of the Eight Steps of Applied
Failure Analysis. These steps help "get the payoff" by communicating
with the responsible party, taking appropriate corrective action, and
performing follow-up visits to assure user satisfaction.
AFA STMG 010 - 155 -
9/2000

SLIDE LIST
1. Anti-Friction Bearings title slide 33. Bearing installation on shaft diagram,
2. In This Presentation incorrect method
3. Categories / Types 34. Drawn Cup Bearing Installation Tool
4. Nomenclature - Ball bearing diagram
5. Nomenclature - Cylindrical roller bearing 35. Thermostatically controlled bearing heater
6. Nomenclature - Tapered roller bearing 36. LP blow torch drawing
7. Functions 37. Bearing freezer drawing
8. Loads 38. Bearing and parts alignment after assembly,
9. Single row ball bearing diagram
10. Angular contact bearing loading diagram 39. Fit
11. Split inner race bearing 40. Tapered Roller Bearing Adjustment,
12. Roller bearings diagram
13. Needle bearing 41. Tapered Roller Bearing Adjustment,
14. Drawn cup bearings instructions
15. Tapered roller bearing 42. Lubricant
16. Double row tapered roller bearing load 43. Operation / Normal Wear, load diagram
diagram 44. Rolling element, oil film and asperities
17. Spherical roller bearing diagram
18. Roller thrust bearing 45. Ball, radial load with rotating inner ring
19. Weld on bearing cage diagram
20. Radial and angular contact ball bearing 46. Ball, radial load with rotating outer ring
stress areas diagram
21. Cylindrical and tapered roller bearing stress 47. Ball, thrust load diagram
areas 48. Ball, radial and thrust load diagram
22. Manufacture 49. Cylindrical, radial load diagram
23. Races 50. Cylindrical roller bearing, view of rib and
24. Tapered roller bearing race, etched cross roller ends
section shows case hardened surface 51. Tapered Roller, light load diagram
25. Roller, cold headed during manufacturing 52. Tapered Roller, heavy load diagram
26. Rollers, etched cross section shows case 53. Tapered roller bearing, large end of rollers
hardened surface 54. Tapered roller bearing outer race, normal
27. Ball bearing and race, cross section of wear pattern
through hardened elements 55. Crowned roller bearing, wear pattern
28. Removal and Installation centered on roller surface
29. Anti-Friction Bearings 56. Crowned roller bearing outer race, light
30. Caterpillar anti-friction bearings wear pattern centered on race wear surface
informational booklet 57. Back of outer race, normal appearance
31. Dirt / Debris, diagram of location and affect 58. Angled view of outer race, normal
on bearing appearance with no wear
32. Bearing installation on shaft diagram, 59. Damage Due to Abnormal Conditions,
correct method contact stress fatigue
AFA STMG 010 - 156 -
9/2000

SLIDE LIST
60. Key Points 83. Closer view of rear pinion shaft bearing,
61. Magnetic strainer, heavily contaminated road signs of heat and misalignment
with metal debris 84. Rollers from the bearing in slide #83, road
62. Rolling Contact Stress Fatigue, roller signs of heat and misalignment
diagram 85. Other Factors - Plastic Yielding
63. Contact Stress Fatigue, list of reasons 86. Spherical roller bearing outer race,
64. Tapered Roller Bearing - Too Loose roughness and axial cracking
65. Tapered roller bearing cup, spalling in the 87. Tapered roller bearing cone, lipping at cage
load zone windows without "hour glass" shape
66. Tapered roller bearing cone, small end of 88. Three bearing rollers, glazed appearance and
rollers shows heavy contact and spalling temper colors present
67. Tapered Roller Bearing - Too Tight 89. Deformed roller bearing rollers, 13
68. Tapered roller bearing cup, spalling across plastically deformed rollers
entire wear surface 90. Tapered roller bearing outer race with four
69. Tapered roller bearing cone, even spall deformed rollers, dark, cooked on oil
pattern on roller and inner race deposits
70. Shaft Too Big or Housing Too Small 91. Possible Causes
71. Out of Round, diagram and road signs 92. Tapered roller bearing outer race, brinell
72. Tapered roller bearing race, wear pattern dents on raceway
from heavy contact of tapered bore 93. Tapered roller bearing inner race, brinell
73. Tapered roller bearing cup, wandering wear dents on top of existing wear pattern
pattern 94. Close view of tapered roller bearing inner
74. Tapered roller bearing inner race, race is race, bruising and spalling present
spalled and fatigue cracking 95. Tapered roller bearing cup, bruising and
75. Damage Due to Abnormal Conditions, spalling present
plastic yielding 96. Damage Due to Abnormal Conditions,
76. Differential pinion shaft with inner bearing adhesive wear
race, temper colors without cooked on oil 97. Tapered roller bearing inner and outer
77. Tapered roller bearing cage and rollers, raceways, significant adhesive wear
severe temper colors and plastic yielding 98. Damage Due to Abnormal Conditions,
78. Closer view of rollers in slide #77, plastic abrasive wear
yielding and evidence of skewing 99. Tapered roller bearing cup, considerable fine
79. Tapered roller bearing cup from bearing in abrasive wear
slide #77, temper colors, adhesive wear and 100. Extensive Contamination
deposits from melted cage 101. Look at Other Parts
80. Tapered roller bearing cup, temper colors 102. Determine Source
indicate high temperature operation 103. Damage Due to Abnormal Conditions,
81. Cleaning Overheated Bearings corrosion
82. Pinion shaft and bearing, "hot, dry look" 104. Ball bearing, heavily corroded
105. Tapered roller bearing cup, corrosion pits
and black acid etching
AFA STMG 010 - 157 -
9/2000

SLIDE LIST
106. Tapered roller bearing cone, mating part of 129. Tapered roller bearing cup O. D., scuff
slide #105 with corrosion on rollers marks on one portion of circumference
107. Damage Due to Abnormal Conditions, 130. Drawn cup bearing, indentations on cup lip
fretting corrosion and creep 131. Drawn cup bearing, broken lips on each end
108. Tapered roller bearing cup O. D., fretting 132. Drawn cup bearing, broken lip and three
corrosion needles removed
109. Tapered roller bearing cup O. D., evidence 133. Tapered roller bearing cup, weld bead
of creep 134. Tapered roller bearing inner race, flame
110. Tapered roller bearing cup rib face, evidence torch cutting marks
of creep 135. Damage Due to Abnormal Conditions,
111. Creep - Possible Causes fractures
112. Cylindrical roller bearing outer race, false 136. D3 winch parts, housing and parts of broken
brinnell marks bearings
113. Closer view of slide #112, grinder marks 137. Close view of gear, damaged teeth from
missing in the bottom of dents misalignment
114. Electrical Pitting & Fluting 138. Cylindrical roller bearing outer race, cage
115. Close view of roller bearing elements, and rollers still intact but the race is
pitting from arcing fractured
116. Roller bearing raceway, large area of small 139. Cylindrical roller bearing outer race, brittle
pits and fluting fracture at the snap ring groove
117. Closer view of slide #116, pits and fluting 140. Cylindrical roller bearing outer race and
118. Damage Due to Abnormal Conditions, fractured roller
handling and installation damage 141. Cylindrical roller, fractured
119. Tapered roller bearing cone rib close-up, 142. Cylindrical rollers (9), worn and spalled
impact damage to the rib roller ends
120. Tapered roller bearing cone, dented cage 143. Cylindrical roller close-up, fatigue fracture
121. Ball bearing, spinning with compressed air on end
122. Roller bearing outer race rib, brittle fractures 144. Winch housing, fractured
at snap ring groove 145. Closer view of fractured cast housing
123. Tapered roller bearing cup, dent in outer 146. Anti-Friction Bearing Problems
edge of race 147. Ball bearing, inner and outer races with the
124. Housing that held bearing in slide #123, balls and broken cage
chisel damage in bearing bore 148. Ball bearing outer race and one ball, normal
125. Tapered roller bearing cup, localized appearance
spalling 149. Ball bearing inner race, plastic deformation
126. Tapered roller bearing cup from slide # 125, but no temper colors
O. D. showing seating problems in bore 150. In This Presentation
127. Tapered roller bearing cup, brinell marks in
localized area at small diameter of cup
128. Tapered roller bearing cup in slide # 127,
brinell marks 180 degrees opposite
AFA STMG 010 - 158 - Student Handout
9/2000

Applied Failure Analysis Laboratory Worksheet

What do you see? What does it mean? Where do you go next?

10
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INSTRUCTOR NOTES
SESV8010 Printed in U.S.A.
9/2000