How to Minimise the Likelihood of Metal Fatigue-induced Bearing Failures
Machine downtime can be very disruptive because it affects how quickly you can deliver client orders. Some mechanical failures can be traced to bearing failures in the moving parts of machines. This article discusses how you can limit the frequency of such bearing failures at your manufacturing complex.
Choose Quality Bearings
Some bearings have subsurface microscopic cracks. Those cracks widen as the bearing is subjected to the stress of carrying the loads moved by the machine. Overtime, the subsurface cracks can expand until they reach the surface of the bearing. This can result in pitting. You can avoid machine failures resulting from bearing pitting by buying bearings made by reputable manufacturers. Examine the warranty provided with the bearings to confirm that they will perform as expected. A metallurgy analysis can also confirm the structural integrity of bearings before they are installed.
Ensure There Is Adequate Lubrication
Some bearings fail because they were not given adequate lubrication as the machine was in operation. That limited lubrication causes metal-to-metal contact between the bearings and the raceway. The resultant heat from that contact can cause tiny cracks to develop on the surface of the bearings. Particles will begin breaking off the surface of the bearings as the surface cracks enlarge. Eventually, the machine will seize up once the bearings are no longer able to rotate. This problem can be avoided if the lubrication of the machine is constantly monitored. Old lubricant should be immediately replaced and the lubricant level should be checked on a daily basis so that the machine isn't used when lubricant levels are low.
Monitor the Lifespan of Bearings
Everything has a limit to its useful life; bearings are no different. Some machines break down just because bearings were not replaced when they reached the end of their lifespan. Once the expected lifespan is exceeded, bearings rapidly deteriorate because of metal fatigue. They are no longer able to withstand the intense heat generated as the machine is operated. They also easily succumb to the stresses of the loads they carry. It is therefore very important for you to take bearings out of service once they reach the end of the maximum service hours indicated by their manufacturer. This will prevent your equipment from sustaining additional damage when the bearings fail.
Always invite metallurgy experts to conduct an engineering investigation when you experience machine breakdowns. This will enable you to isolate the cause of the failure so that similar events can be prevented in future.
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