Aug 28,2024
Many things rely on needle roller bearings, including industrial goods and automotive transmissions. They can meet high radial loads while being compact in shape. However, like every other mechanical component, they are prone to degradation, damage, and failure.
To ensure the equipment works, it's essential to know how to fix these common problems with needle roller bearings. Below, some repeated problems concerning needle roller bearings are discussed, and a possible action or way to avoid them is provided.
The most typical problem with needle roller bearings is the failure to lubricate them. It is advisable to ensure that the bearing is well lubricated to minimize the friction between the moving parts of the bearing. Lack of adequate lubrication or contaminated lubricants causes increased friction, overheating, and early failure of the components. This can cause early bearing failure, usually accompanied by noise, vibration, or outright failure.
One significant cause of lubrication failure is the user applying the wrong type or quantity of lubricant that the manufacturer recommends. It is also recommended that the bearing be adequately greased during installation and function. Grease lubrication is required in some applications, while oil lubrication is required in others.
This requires periodic inspection of the lubricants and replacement of old or contaminated ones. Various methods can avoid this error, such as installing automated lubrication systems to ensure the bearings are correctly lubricated at the right time.
Needle roller bearings can be contaminated with materials and substances like dirt, dust, metal particles, and even moisture if the equipment is subjected to severe conditions. When these contaminants harm the rolling elements and raceways, wear, pitting, and corrosion are observed. Over time, friction and heat will increase, leading to bearing failure.
To prevent contamination of needle roller bearings, high-quality seals and shields must be used to avoid letting in contaminants. It is also good practice to regularly clean and inspect the bearing housing, as this can also point out any contamination source. Proper sanitization of the surrounding area can also help minimize particles' intrusion within the bearing's reach. However, suppose the bearing is to function in hostile environments that expose it to high temperatures or corrosive substances. In that case, bearings with more robust sealing systems or surface treatments that help shield it from contaminants can be used.
It happens when the shaft and bearing housing are not parallel or straight. This issue can lead to situations where some rolling elements of the bearing are more stressed than others. Over the time, this will lead to wear and tear or increased friction and material failure. Misalignment commonly results from wrong mounting practices, a wrongly machined shaft or housing, or distortion of the bearing housing.
To correct such misalignment problems, the shaft and the bearing housing must be correctly aligned during assembly. Some solutions include precision alignment tools and following the manufacturer's installation instructions.
Ensure it is checked frequently for any indications of misalignment, like worn-out tires or increased vibrations. If misalignment is identified, adjust the shaft and housing to bring them back in alignment whenever necessary. Furthermore, they said it is possible to incorporate self-aligning needle roller bearings as these can cope with more minor misalignments in the system.
Needle roller bearings are manufactured to withstand particular load ratings. When loads applied to a bearing are more significant than its design loads, overloading may occur. This results in increased temperatures, early fatigue of the rolling elements, and even forming bearing ring cracks. Overloading is usually a consequence of incorrect load estimates, variable operating conditions, or unsuitable bearings.
To avoid overloading problems, selecting the correct bearing to suit the application is essential. This includes estimating the loads the bearing will undergo during its use and identifying a bearing that can handle such loads. It is also possible to monitor the system for a tendency to overload by observing its normal operating status.
Occasionally, replacing the bearing with a larger one or one that can handle larger loads is beneficial. Moreover, installing load monitoring systems assists in identifying loads before they lead to extensive damage.
Fatigue failure may happen when the rolling elements or raceways of the bearing crack up due to cyclic loading. These cracks advance further until structures develop spalling, the physical signaling of a bearing surface that has degraded or pitted, and final failure. Fatigue failure is inevitable with usage, but usage can be hastened by overloading misalignment or lack of proper lubrication, among other things.
Thus, the best way to address the fatigue failure problem is to ensure proper selection and fitting of bearings and regular maintenance. When choosing a bearing, ensuring it has enough load rating to support a given application will increase its fatigue life.
Routine maintenance, such as lubrication and alignment checking, can also prevent fatigue-related conditions. In cases where the bearing operates under very stringent conditions, a high-fatigue capability bearing may be required, preferably made of high-quality material or heat-treated.
Inadequate installation is one of the significant causes of fatigue failure of needle roller bearings. This can be due to poor mounting methods, using too much force during mounting, or even not consulting the manufacturer's manual. Poor installation can result in misalignment, uneven loading, and interior bearing damage.
In the case of installation, there is always the right way to go about it: by following the manufacturer's instructions keenly. Exercise care and use the proper tools and methods to avoid mishandling the bearing upon installation.
In press-fit installations, use the correct degree of force and distribute the force around the circumference of the bearing rings to avoid bending the rings. If you have doubts about the proper procedure for installing the bearing, consult an expert technician or use hydraulic presses or Induction heaters to carry out the exercise effectively.
Needle roller bearings can be subjected to vibration and shock loads in many applications, such as automotive and industrial machinery. These conditions cause the rolling elements to apply more force on the raceways than is desired, resulting in either brinelling or wear. In the long run, this increases friction, noise, and bearing failure, so it must be minimized.
Properly mounting and balancing the equipment can minimize vibration and shock loads affecting needle roller bearings. Using the new mounts or pads will reduce the shocks that distort the bearing, thereby reducing the force exerted on it.
Also, choosing bearings with higher shock load capacity or hard-surfaced raceways will enhance their ability to perform well in challenging conditions. Moreover, routine checks and appropriate machinery services also contribute to discovering the causes of vibration and shocks that may adversely affect the bearings.
Needle roller bearings are often used in various machines and equipment, but they can develop several issues if they are not well maintained or even when wrongly installed. These are some regular issues that most users encounter. Your needle roller bearings may last longer and work better if you take the right precautions and use the right solutions. The best way to reduce downtime, it is significant that the machinery is properly maintained and installed and proper bearing is used for the particular job.
