Bearings may be small, but they play an inestimable role in keeping industrial machinery running smoothly.

Improper lubrication, pollution, corrosion, overload, and improper handling, installation and storage are the main causes of bearing failure. Here are five steps to avoid common problems and future process interruptions.

Avoid improper handling, installation and storage. Bearings should be stored horizontally in the original packaging in a clean, dry and room temperature environment. When bearings are treated unnecessarily, for example, if their packaging is removed prematurely, this may expose them to corrosion or contaminants. Even if they are stored on shelves, the bearings will still be subjected to harmful vibrations due to the daily operation of the facility. Therefore, it is important to store the bearing in an area free from vibration.

Bearings are precision parts and should be handled with care. Therefore, dropped components should not be used, as this may lead to premature failure. In addition, proper equipment should be used when handling and installing bearings. Tools not specifically used for the bearing installation and removal process may cause damage, dents, and wear. Bearing pullers or induction heaters; for example, specially designed for bearings. Ensuring that the bearings are installed correctly will avoid equipment imbalance and misalignment.

Don't overload the bearing. When choosing the best bearing that meets your needs, it is important to remember that improper loading can lead to increased fatigue and the risk of bearing failure. In order to obtain the best life rating for your bearing, limit the actual load to between 6% and 12% of the bearing's rated dynamic load. The load rating does vary depending on the bearing material. For example, stainless steel bearings will support approximately 80% to 85% of chrome steel bearing load data.

The more the bearing is overloaded, the shorter the bearing life. Overloaded bearing components will wear out prematurely. These bearings should be replaced to protect surrounding equipment.

Although the overload may be the result of incorrect specifications at the design stage, some overload may occur due to changes in production requirements, environmental conditions, or operator errors.

For example, if a steel bearing is heated beyond its design limit, this can permanently deform or soften the bearing material, resulting in reduced load-bearing capacity and equipment failure. Before installation, be sure to check the manufacturer's specifications to make sure it meets your requirements.

Avoiding contamination in the form of dust or dirt entering the bearing raceways is problematic. It is important to choose a closure that prevents these foreign objects from entering the bearing and maintains internal lubrication. According to the operating environment, the shutdown should match the application specialty. Although it is recommended to seek advice from bearing experts, please keep the following suggestions in mind.

Choose enclosures that can withstand environmental and operating conditions. Regularly check whether the bearing seals are hardened or worn. Check for lubrication leaks. When performing maintenance, try to avoid using steam cleaning methods or high-pressure sprays. This can be difficult in the food and beverage industry, so it is recommended to use sealed bearings with anti-scouring lubricants.

If it is not properly maintained, the disadvantages outweigh the benefits. In fact, if not handled properly, it is easy to damage the seals and force contaminants into clean equipment. Here, condition monitoring such as vibration analysis can provide important insights into the operating conditions of the bearing and alert the operator to any changes without intrusive operations.

Limiting corrosion Wearing gloves can ensure that sweat or other liquids will not affect the bearing in a low-corrosive environment. However, in applications where corrodible materials are insufficient to meet the requirements (food processing, chemical manufacturing, pharmaceutical production, and marine applications bearings), corrosion-resistant bearings will be required.

Corrosion mainly occurs when the bearing is exposed to water or more corrosive liquids. In some cases, it can cause surface etching and eventually rust. This is followed by spalling and cracks in the bearing. Common signs of corrosion are dark or reddish brown areas on the ball and raceway. Eventually, you may see pitting on the surface of the raceway. Although material selection is a key first step in the fight against corrosion, it is recommended to take preventive measures, such as the use of lubricants containing rust inhibitors.

Using the correct lubrication standard lubrication for the bearing will play a role in reducing friction and heat dissipation. However, this lubricant may not meet the maximum operating speed, torque level, and temperature requirements of your application. May require professional lubrication.

If the amount of lubrication is insufficient, metal-to-metal contact will occur between the balls, cage and raceway, and friction will wear the bearing. In contrast, if the bearing is filled with too much grease, the heat cannot be dissipated, causing the bearing to overheat.

In both cases, this will reduce the efficiency of the equipment and the entire process. The selection of the correct lubricant should start from the application conditions, but the amount and viscosity of the lubricant suitable for the load should also be considered, to avoid excessive temperature of the specified bearing, and to prevent the entry of dust or other contaminants.

Although these five steps provide a good starting point for reducing bearing failures and extending service life, proper design engineering and early intervention are the key. __________ Chris Johnson is the managing director of SMB Bearings.

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