The five most common causes of bearing failure

Bearing failure is a common problem in industrial equipment and machinery, causing costly downtime and repairs. Bearings are critical components that support rotating shafts and reduce friction in mechanical systems. However, they can suffer from various forms of damage, wear, and failure due to many factors, such as improper installation, contamination, overload, lubrication issues, and corrosion. As a result, bearing failure can lead to machine breakdown, reduced performance, safety hazards, and increased maintenance costs. Therefore, it's essential to identify and prevent the most common causes of bearing failure to ensure the reliability and longevity of your equipment. In this blog post, we'll explore the five most common causes of bearing failure and discuss how to prevent them. Whether you're a maintenance technician, operator, or engineer, you'll find valuable insights to help you diagnose bearing failures, choose the right bearings, and maintain them properly. By understanding the root causes of bearing failures and taking proactive steps to mitigate them, you can avoid unplanned downtime

1. Improper lubrication or contaminated lubricants can cause bearing failure.

Improper lubrication or contaminated lubricants are one of the most common causes of bearing failure. The lubricants play a critical role in ensuring proper functioning of bearings, which are subjected to high loads and frictional forces. If the lubricant is not applied correctly, the bearing will not have enough lubrication to reduce friction and control temperature. This can quickly result in damage to the bearing, including increased wear and tear, overheating, and corrosion. Contaminated lubricants, on the other hand, contain particles that can cause abrasion, corrosion, and ultimately bearing failure. Using the correct lubricant and ensuring that it is applied in the proper amounts and at the correct frequency is crucial to prevent bearing failure due to improper lubrication.

2. Overloading or underloading the bearing can cause it to fail.

Overloading or underloading a bearing is one of the most common causes of bearing failure in industrial machinery. This can happen when the bearing is subjected to forces that exceed its designed capacity, or when the load is insufficient to create the necessary friction for proper lubrication. In both cases, the bearing is subjected to excessive wear and tear, resulting in a decrease in performance and eventual failure. It is critical to ensure that bearings are properly sized and installed to handle the expected loads and operating conditions to avoid overloading or underloading. It is also essential to monitor the bearing load and adjust as necessary to prevent damage and extend the bearing's lifespan. Regular maintenance and inspections can help identify overloading or underloading issues early on and prevent costly and time-consuming repairs.

3. Misalignment of the shaft can cause bearing failure.

The misalignment of the shaft is one of the five most common causes of bearing failure in machines and equipment. When the shaft and bearing are misaligned, they generate additional forces that exceed the design limits of the bearing, leading to premature wear, damage, and eventual failure. Misalignment can be caused by improper installation, wear and tear, heavy loads, or improper alignment of equipment during maintenance. Regular checking and maintenance are critical to ensure that the shaft and bearing remain properly aligned, reducing the risk of bearing failure and prolonging the life of the machine or equipment.

4. Improper installation or handling of the bearing can cause damage and lead to failure.

Improper installation or handling of the bearing is cited as one of the most common causes of bearing failure. This issue can arise when bearings are not handled carefully, or when they are improperly mounted or installed. When bearings are subjected to excessive force or mishandling during installation, it can cause damage that may not be immediately evident, but can ultimately lead to premature failure. For instance, loading bearings at an angle, hammering on the outer ring or inner ring, dropping bearings on a hard surface, or applying force to the incorrect bearing component can all contribute to damage and failure in a short period. To avoid installation-related failures, it is important to follow proper handling and installation procedures that are provided by the manufacturer. This includes selecting appropriate tools and equipment, applying correct lubrication and mounting techniques, and making sure that all components are properly aligned and seated.

5. Corrosion or wear caused by exposure to extreme temperatures or harsh environments can also result in bearing failure.

Corrosion or wear caused by exposure to extreme temperatures or harsh environments is another common cause of bearing failure. High temperatures can cause oil to break down, which can result in damage to the bearing surface. Similarly, exposure to chemicals, water, and other harsh environments can accelerate corrosion and wear. Bearings located in extreme environments, such as those used in mining, construction, or marine applications, are particularly vulnerable to this type of failure. It is important to select the proper type of bearing for a specific application and ensure that it is properly lubricated and sealed in order to mitigate the effects of extreme temperatures or harsh environments. Regular maintenance, inspection, and replacement of bearings that have been exposed to these conditions are also crucial to preventing failures.

In conclusion, understanding the five most common causes of bearing failure can help prevent costly downtime and equipment damage. Regular maintenance and inspections of bearings can catch early signs of wear and tear, such as abnormal noise or vibration, and allow for timely replacement. It's important to select the right type and size of bearing for the specific application and to ensure proper lubrication and installation. By following these steps, you can extend the life of your bearings and optimize the performance of your equipment.