Precision bearings are essential components in many industrial applications, designed to support and guide moving parts under various loads. Roller bearings, which use rolling elements like balls or rollers within a raceway, are known for their reliability and long service life. In fact, over 99% of rolling bearings achieve their expected lifespan, even in harsh environments.
While bearing failures are relatively rare, they can still occur due to a variety of preventable issues. Common causes include flaking, pitting, spalling, rusting, corrosion, creeping, and misalignment. These problems often stem from a few key factors that can be managed with proper care and maintenance. Here are some of the most frequent causes:
**Improper Lubrication** – Proper lubrication is vital for extending bearing life. However, using too much or too little grease, mixing incompatible lubricants, or allowing contamination can all lead to premature failure. Bearings also have a "grease service life," and failing to reapply lubricant at the right time can result in performance degradation and eventual breakdown.
**Incorrect Mounting and Installation** – The way bearings are mounted and installed plays a crucial role in their performance. Using the wrong tools or applying excessive pressure to the wrong ring during installation—especially with self-aligning bearings—can damage the raceways and rolling elements. An improper fit, whether too loose or too tight, can cause uneven preload, leading to shaft rotation or misalignment.
**Operational Stress and Bearing Selection** – Even high-quality roller bearings can fail if they’re not properly matched to the application. Changes in load conditions, such as excessive or insufficient stress, can cause fatigue or skidding. Early signs of these issues may include unusual noises, increased temperatures, or vibration.
**Environmental Factors** – External conditions like dust, moisture, chemicals, and heat can significantly impact bearing performance if not properly controlled. Sealing is essential to protect against contaminants, and in some cases, insulation may be required to prevent electrical damage. Being aware of environmental risks and taking preventive measures can help avoid costly failures.
Understanding the different types of bearings and selecting the right one for your specific needs is the first step in preventing failure. By being attentive to warning signs and maintaining proper practices, you can extend the life of your bearings and reduce downtime and repair costs.
At Emerson Bearing, we bring over 50 years of experience in ball and roller bearings, serving OEMs and maintenance professionals worldwide. We specialize in helping customers find the right bearing at the right price. To gain deeper insights into the causes and solutions for premature bearing failure, we invite you to download our free eBook, *“Bearing Failure Analysis.â€*
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