Chapter Three
Typical damages of machine parts
Content
1. Damages of Sliding Bearings
2. Damages of Anti friction Bearing
3. Damages of Gears
4. Damages of friction surfaces
5. Damages of Shaft
6. Damages of Seals
3.1 Damages
of
Sliding
Bearings
Introduction
Sliding/Journal/plain bearings consist of a
shaft or journal which rotates freely in a
supporting metal sleeve or shell.
There are no rolling elements in these
bearings.
These Bearings operate mostly in the hydrodynamic
regime of lubrication (Hydrodynamic journal bearing), in
which the bearing surface is separated from the journal
surface by the pressurized lubricant film generated by the
journal rotation.
Cont.…
The rotating journal is displaced from the concentric
position and forms a converging gap between the
bearing and journal surfaces.
▪ The bearing surface is
separated from the journal
surface by the pressurized
lubricant film generated by the
journal rotation.
Cont…
The pumping action of the journal
forces the oil to squeeze through
the wedge shaped gap generating
a pressure.
The oil pressure creates a
supporting force separating the
journal from the bearing surface.
Operation
Damages
❖ Damage in sliding bearings is wear plus fatigue.
✓ Static loads cause wear
✓ Dynamic loads cause wear plus fatigue.
✓ Corrosion also becomes an important damage in
environments where corrosive media is present
❖ However, when dealing with damages of the system,
the whole system has to be considered especially with
respect to
✓ shape of bush hole or bore,
✓ lubrication,
✓ Deformation of shaft under applied loads. and
✓ misalignment
Cont…
Factors influencing damages of slide bearings
✓ Design of bearing, Material
and Lubrication,
✓ Manufacturing accuracy,
✓ Assembling conditions:-
Misalignment causes reduced
contact area which produces
fatigue,
✓ Bearing forces,
✓ Service and Operation
Conditions
Cont…
❖ The process of wear in sliding bearings depends on
the working velocity and operation conditions,
particularly temperature.
✓ High temperature and high working velocity
produce overheating which change the
properties of the materials.
✓ Presence of foreign substances in the lubricant
causes increased wear .
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Slide bearing lubrication
✓ Suitable lubricants for slide bearings are mineral oils and greases
✓ important property of lubricants for slide bearings is the viscosity of
the lubricant used.
✓ If the viscosity of lubricant used is low, the load-carrying capacity of
the bearing will be low;
✓ If the viscosity is too high, there will be high loss of power and the
operating temperature will be higher.
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Cont.…
✓ When good properties are sought at high and low
temperatures, synthetic oils may be used if suitable
viscosities are available.
✓ The application is however, costly.
✓The general characteristics of lubricants used for plain
bearings are shown in the table below.
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Methods for lubricant supply Vary from application to
application; some typical applications
✓ For low speed journal bearing hand oiling is possible.
✓ For journals in machine tools drip and wick feed method of
supply is used.
✓ Bath and splash lubrication is used in engines, process
machinery, etc.
✓ For high speed and heavily loaded bearings in machine tools,
engines, etc. pressure-feed supply is used.
❖ For satisfactory performance and long life, cleanliness of the oil
supply is always essential.
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Bush bearing assembly
In bush bearing assembly the following main features must be
provided.
✓ When bush bearings are installed at both ends thrust bearings or
collars should be provided to take up the axial load.
✓ The bush outside diameter must be locked in housing either by a
locking pin (Al) or locking set screws.
✓ An axial play must be ensured.
✓ For proper lubrication of the bush bearing, lubricating grooves must
be cut on the bush surface and connected with the lubricating hole.
✓ Proper fits and tolerances should be provided (basic hole/basic shaft
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systems)
3.2 Damages in Anti-friction Bearings
Introduction
Anti-friction bearings provide rolling contact rather then
sliding contact therefore the total effective contact area is
much less in anti-friction bearings as compared to plain
bearings (sliding contact bearing).
Starting friction of anti-friction bearings is therefore
considerably less than in plain or sleeve bearings
Some damages
of
Anti-friction
Bearings
Damages
❖ Ball and roller bearings normally fail by fatigue.
❖ In the case of tightening and lubrication problems, wear also
can occur.
❖ Rarely failure can occur by random damages like overload.
❖ Bearing tracks and rolling elements are loaded with periodic
reversed loads which cause fatigue of these elements.
❖ This loading condition causes cracks (which are detected only
after a long time) .
❖ The cracks develop to form pitting which in turn leads to
abrasion of parts.
Cont…
➢ High contact pressure causes damage of inner and outer races.
➢ In case of over load and assembly problems failure takes place
in a short time.
➢ Wear of bearing elements increases axial and radial play,
which can be a cause for vibration leading to increased fatigue.
➢ Contamination of lubricants causes abrasion.
➢ Impact loads in standstill produces chatter marks causing
vibration.
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Analysis of damages:
- Due to damages bearings, will either get heated up or
will run with abnormal noise and/or vibration.
- Heating can be felt by touching with hand.
- Abnormal noise can be detected by taking a rod
(screw driver of length 200-300 mm) and placing one
end on the bearing housing and listening from the other
end.
A good bearing runs noiselessly, and a defective bearing will
run with a continuous knocking or rubbing sound.
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Rolling bearing defects.
i. Bearing inner race loose on shaft:
Bearing running with such a defect gets heated up.
Correction: -
- Knurling of shaft (temporary repair only);
- chromium plating;
- metal deposition by welding
- installing of a sleeve
- welding a new shank at the end sections
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ii. Housing bore loose on shaft:
The bearing gets heated up.
Corrections:
- housing bore knurled (temporary)
- installing a sleeve.
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iii. Bearing running dry
- In the absence of lubrication bearing gets heated up.
iv. Misalignment
v. Damage of one or more balls/rollers
vi. Damage of running race
vii. Deformed separation
- Due to one of these defects bearing runs with a
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continuous knocking sound.
viii. Radial play
❑ Radial play causes vibration of the system on which the
bearing is mounted.
✓ Correction:-
➢ Angular contact bearings, taper roller bearings, and
ball/roller bearings with conical-bore can be corrected
by tightening the regulating nuts.
➢ Other types have to be replaced.
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Typical damages of rolling bearings
Rolling bearing lubrication
Grease is used for
- low temperature up to 120oC,
- lower speed factors
- low to moderate loads,
- radial ball and roller bearings, and
- relatively simpler housing design.
When grease is applied,
balls and roller bearings are packed with grease.
Generally, the grease should not fill more than three-
quarters of the total available free space in the cover
with the bearing packed full.
For dirty environments with low to medium speeds, the
grease must completely fill bearing and cover.
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Oils are used
- for bearing temperature up to 200oC,
- with higher speed factors,
- for all types of loads,
- for all types of bearing designs, and
- complex housing design.
When oils are applied to lubricate bearings,
❖For low speed :- bath or splash; oil flingers or drip-feed
lubrications are used.
❖ For high speed :- pressure circulating and oil mist systems
are used.
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3.3 Gear Damages
Gear
Gear are toothed wheels used in combination to
transmit motion and power.
Gears can be used to transfer rotation.
➢ From one axis to another
➢ With a change of direction
➢ With a change of speed
➢ With a change of torque
Different types of gears
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Gear failures
- Gear failures occur rarely
- A gear pair has not failed until it can no longer be run.
- This condition is reached when:
- One or more teeth have broken away preventing
transmission.
- Teeth are so badly damaged (worn-out) that
unacceptable vibration and noise are set up when
the gear runs.
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Cont.….
Gear failures can be any or combination of
a. Surface fatigue (pitting)
- Pits start forming with the running of the gear.
- The cause is over stressing of gear material.
- The remedy is removing the causes of over stressing.
b. Scuffing
- This is the result of disruption of the lubricant filter.
- The tooth surface are severely roughened and torn as a result of
unchecked adhesive wear.
- Cause is the rise of temp. for contacting surfaces above the
48 critical temp. for the lubricant.
c. Abrasive Wear
- During normal operation, if hard foreign material dimensionally
larger than the film thickness (0.6 µm) contaminates the
lubricant, the tooth surfaces are affected by abrasive wear.
- The remedy is protection of oils from contamination.
d. Plastic deformation
- the remedy is to avoid overloads.
e. Tooth breakage.
- If a whole tooth breaks away the gear has failed.
- The cause of fracture has to be assessed for the future
49 performance of the gear.
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❖Gear Lubrication
i-Functions of gear lubricants
o Lubrication
➢ separation of moving surfaces
➢ Reduction of friction
➢ reduction of wear
o Cooling
➢ Particularly important in enclosed gears
o Protection
➢ Against corrosion
o Maintaining cleanliness
➢ Removal of wear debris or external contamination
ii. Properties of gear lubricants.
▪ The most important property of gear lubricants is their
viscosity.
▪ The viscosity must be high enough to maintain adequate
lubricating film between meshing teeth under all conditions.
However, high viscosity oils may not always be desirable as they
- increase drag and give rise to increased power losses;
- are less effective as coolants;
- are prone to overheating and become oxidized.
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Cont.…
Other important gear lubricant properties are
- anti-wear and extreme pressure carrying property,
- oxidation resistance,
- anti-corrosion property,
- anti-foaming property,
- disability, i.e. good property to separate from water.
These properties are attained by use of suitable additives to
the base oil.
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iii. Gear lubricant selection
❑ Lubricant selection for gears must be based on
manufacturer’s recommendations.
❑ The influencing factors for lubricant selection are:
✓gear type, speed, and speed reduction ratio;
✓gear material and surface finish;
✓operating temperature; and
✓load characteristics.
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iv. Lubrication application
❖Application of lubricant to meshing gear teeth is
preferably applied at the parting pair in which the oil is
used for cooling and at the same time reduces amount of
oil at the next engagement cycle.
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Repair of transmission gears
a. Uniform tooth wear on one side
For gears running in one direction only, if uniform wear on
the gear occurs, Such gears are turned over by 180o so that
the other face would be the working face.
b. Uniform tooth face wear on both sides
The smaller of two meshing gears is comparatively worn-out
more, and should be replaced by a new one.
❖ To achieve normal gap between meshing teeth, the depth of
cut on the new ( smaller) gear is taken slightly less than the
other and the outside diameter of the old gear is reduced in the
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same proportion.
c. Broken teeth
Cont…
If there is no impact load on the gear, it is recommended to repair
the broken teeth by welding.
d. Cracked/damaged rim or bore of gear wheel
The defective rim or bore portion is machined away and fitted by
a new machined part. This new part is locked in position by
welding or set screws installed at the mating periphery.
➢ The final boring and spline cutting is done after fitting. If the rim is
replaced the final turning and milling is done after securing in
position.
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Gear assembly
Spur and helical gears
✓ These gears must be assembled in such a way that the
gear axes are parallel with the correct center distance.
✓ The correct meshing of such gears is decided by applying
blue paste on the teeth of the driving gear and checking
the blue marks on the driven gear after several turns.
✓ For correct meshing the blue bark on the driven gear
covers the tooth face about 70 - 80% and is centrally
created Otherwise the gear assembly is incorrect.
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4. Friction surfaces
-
3.4 Damages on Friction Surfaces
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Friction surfaces of clutches and brakes usually fail by
➢wear, and/or
➢ deformation.
- Damage of the friction surfaces
- affects the performance
- shortens the life of the component and
- in exceptional cases results in
complete failure.
Brake damages
Both the metallic and friction surfaces
are considered.
Brake metal surface damages
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Brake friction-lining failures
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Clutch failures
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Thank you!
Questions
