Precision bearings are essential components in many industrial applications, designed to support loads and ensure smooth motion. 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 these bearings achieve their expected lifespan, even under harsh conditions.
While the failure rate of such bearings is low, when it does occur, it often stems from preventable issues. Common problems include flaking, pitting, spalling, rusting, corrosion, creeping, and misalignment. These issues usually arise from a small set of underlying causes that can be addressed with proper maintenance and care. Here are some of the most frequent reasons behind premature bearing failure:
**Improper Lubrication** – Lubrication is key to extending bearing life, but it must be done correctly. Using too much or too little grease, mixing incompatible lubricants, or allowing contamination can all lead to performance issues. Bearings also have a "grease service life," and failing to reapply lubricant when this period ends can result in failure.
**Incorrect Mounting and Installation** – Proper tools and techniques are critical during installation. Applying pressure to the wrong ring, especially with self-aligning bearings, can damage the raceways and rolling elements. A poor fit—whether too loose, too tight, or misaligned—can cause uneven preload and lead to shaft rotation or creep.
**Operational Stress and Bearing Selection** – Even reliable roller bearings can fail if the application changes over time. Excessive or insufficient load can cause fatigue or skidding, both of which may be indicated by unusual noises or increased temperatures.
**Environmental Factors** – Contaminants like dust, dirt, moisture, and heat can harm bearings if they are not properly sealed. In certain environments, insulation may be necessary to prevent electrical currents and sparks. Being aware of these external influences and taking preventive measures can help avoid costly failures.
Choosing the right bearing technology for your specific application is the first step in preventing failure. By understanding the causes and recognizing early warning signs, you can take proactive steps to avoid downtime and reduce repair costs.
Emerson Bearing has more than 50 years of experience in ball and roller bearings. We serve OEMs and maintenance markets globally, helping customers find the right bearing at the right price. To learn more about the causes and solutions to premature bearing failure, we invite you to download our eBook, “Bearing Failure Analysis.â€
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