Module 6 : Applications of Tribology

Rolling Contact Bearing

Rolling Element Bearing :

In rolling element bearings, friction and wear are low, so we require lesser quantity of lubricant.
These bearings work with elastohydrodynamic mechanism. Low friction & moderate lubricant
requirements are two important advantages of rolling bearings. Additionally, these bearings are
mass produced therefore, are cost effective. These bearings are purchased in standard sizes
instead of being customized by individual designer. The bearings are selected from catalogues of
bearing. But very large size bearings, which are specially designed, are often very costly; so
selection of bearing is important for proper life of bearing. One of the important bearing selection
criterions is retainer (Fig. 6.6), which is required to maintain constant angular distance between
rolling elements. But due to retainer, sliding (friction) increases and lesser number of rolling
elements (means lesser load carrying capacity) can be arranged.

Fig. 6.6: Retainer for rolling element bearing.

Bearing may fail due to following factors :

1. Sudden rise in bearing load.

2. Inappropriate selection of bearings.

3. Improper mounting.

4. Manufacturing faults.

Let us consider a case study to understand bearing failure.

Failure Of Four Row Cylindrical Roller Bearing :

• Two large roller bearings – (ID = 865 mm, OD = 1180 mm) failed in a cold rolling mill, each
bearing costed Rs. 35,00,000.
- One bearing failed within 105 hours (installed on 05/01/03 and failed completely on 10/01/03)
and
- Other failed within 300 hours of operation (installed on 05/01/03 and removed on 24/01/03 due
to detection of excessive vibration and metal particles).
- Expected life of bearings was approximately 40,000 operating hours. This means survival rate
was 0.5% and 1.0%.

Fig. 6.7: Layout of a 4-high rolling mill stand.

Fig. 6.8 shows different types of failure due to corrosion, excessive loads, holes, fatigue load etc.

Fig. 6.8: Failed outer ring.

To analyze these two bearing failures, finite element study was performed. Outer ring was
fixed(zero degree of freedom) and assumption was made that all rolling element participate to
bear the load.
 Fig. 6.9: Finite element analysis of bearing.

Fig. 6.10: Factor of safety obtained by FEA.

Factor of safety, as shown in Fig. 6.10, comes out to be 100 at outer ring (which failed in
operation), which clearly indicates whole of outer ring does not participate in load support, but
only a fraction of ring supports the load.

In rolling mills, the load is of constant direction and due to clearence, only a quarter of the outer
race is under load. For this reason, the side faces of the outer races are divided into four zones,
indicated by I to IV. When the bearing is mounted first time, it is usual to position zone I along
the direction of the load. After a period of approximately 1000 operating hours (Ξ 2 months), outer
race is turned by 900. This means rated life of outer ring is four times of rated life of each load
zone. In other words, if fatigue life of outer ring is 40,000 hours, fatigue life of each load zone is
10,000 hours.
 Fig. 6.11: One quarter of outer ring under Fig. 6.12: Outer ring marked with four
load. load zones.

Two important observations from intial study were :

1. Management replaced pin type bearing with brass cage bearing, which was cheaper.

2. Load capacity as function of number of rolling elements.

Fig. 6.13(a): Brass cage.

Fig. 6.13(b): Pin cage.

It is interesting to note that brass cage takes more space and accommodates only 34 roller(per
row) compared to 38 roller(per row) in pin type bearing.
 Fig. 6.14: Load capacities of brass and pin type cage bearings.

Due to lesser number of rolling elements brass cage bearing load capacities are lesser than pin
type bearings. Following equation indicates lesser life of solid brass cage bearing compared to pin
type cage bearings.

Detailed survey of failed bearing indicated placement of hole along on the line of maximum load.
Four holes of 3/8” 10 UNC 3B of 45mm depth were drilled and tapped to facilitate the handling of
outer race, Fig. 6.15.

Fig. 6.15: Holes to handle the outer ring.

It is intreasting to note that stress level increases significantly if drilled hole directly comes under
load as shown in following figure. Following figure shows stress results of outer ring. On shear
failure of outer ring near lifting holes, tensile stress was experienced by remaining roller-outer-
ring interfaces. Under tensile stress, radial fracture of outer race occurs.
 Fig. 6.16: Tensile stress in outer ring.

After understanding the drawback of existing arrangement, new arrangement for outer ring was
suggested. With new arrangement as shown in following figure and no complaint was received.

Fig. 6.17

Bearing Terminology :

In previous paragraphs, we learnt bearing failure. To understand rolling bearing fully, we must
under terminology of bearing. Rolling element bearings, as shown in Fig. 6.18 consist of four main
components: inner ring, outer ring, balls, and the cage. Inner and outer rings are hollow cylinders.
Their thickness is decided based on stiffness criteria. Rolling elements, which may be balls, rollers,
needle rollers, etc. are solids with very good surface finish.

The purpose of cage is to maintain the rolling elements (i.e. balls or rollers) a fixed distance apart,
as they roll around the ring tracks. Some cages are made from steel pressing, in two halves which
are finally riveted together(Fig. 6.19), and are shaped to freely locate on the balls.
 Fig. 6.18: Bearing terminology.

Fig. 6.19: Splitted cage with balls.

For correct function, it is necessary for the ball to make point contact only with the rolling tracks
in the inner and outer rings and to achieve this, the track radius is approximately 4% greater than
ball radius. Cylindrical roller bearings, Fig. 6.20, are mainly designed to bear radial load.

Two different arrangements (arrangements A & B) are shown in Fig. 6.20. The basic difference
between two arrangements is the sketches of inner ring. In second arrangement, the inner ring
has a groove at outer surface and rollers are guided by this groove. With such arrangements, roller
bearings are able to support a part of thrust load.
 Fig. 6.20: Sectional view of cylindrical roller bearings.

Fig. 6.21 illustrates a fully complemented needle roller bearings. The word needle itself indicates
the large value of length to diameter ratio. The ends of these needles have smaller diameter,
which is required to locate the needle in outer/inner ring. Major disadvantage of this arrangement
is higher coefficient of friction because of relatively larger value of sliding to rolling motion. This
arrangement is advantageous from space point and load capacity point of view.

Fig. 6.21: Fully complemented needle bearing.

Other than straight roller and needle roller bearings, taper roller(Fig. 6.22), spherical roller(Fig.
6.24) and self aligning roller(Fig. 6.23) bearings are common. Taper roller bearing can sustain
axial + radial loads with appropriate positioning of shaft. Spherical roller and self aligning roller
bearings can handle misalignment.
 Fig. 6.22: Sectional view of taper roller bearing.

Fig. 6.23: Self aligning roller bearing.

Fig. 6.24: Single-row spherical roller bearing.

Designation–International Organization for Standaradization :

Each rolling bearing is designed by a code that clearly indicates construction, dimensions,
tolerances and bearing clearance. Bearings codes comprising only the basic code without prefixes
and suffixes indicate normal bearings. Deviations from the normal construction are indicated by
prefixes or suffixes.

Fig. 6.25: Bearing designation as per DIN 623 standard.

Basic code consisits of "Series Code". Series code contains number(i.e, 0,1,2.....) or combination
of letter(i.e, BK, HK, .....) & numbers. Following table illustrates first part of "Series Code", which
indicates the type of bearing.
 Table 6.1: Series code.

A second and sometimes a third letter are used to identify the configuration of the flanges, e.g.
NJ, NU, NUP; double or multi-row cylindrical roller bearing designations always start with NN. It is
interesting to note that for same bore diameter, load capacity of rolling bearings can be increased
by increasing diameter of rolling elements(Fig. 6.26) and outer ring(Fig. 6.27).

Fig. 6.26: Diameter series.

 Fig. 6.27: Extra light to heavy series of rolling bearing[1].

• After defining bearing type, the width (B or T) or height (H or T) series and the second the
Diameter Series (D); is defined in "Series Code".

• Bearings "Bore diameter code" is defined by two numbers(i.e, 05, 06, 15, ...), which when
multiplied by 5, the bore diameter in millimetres is obtained.

For bearings, which have a bore diameter smaller than 10 mm and equal to or greater than 500
mm, the bore diameter is generally given in millimetres, e.g. 618/8 (d = 8 mm) or 511/530 (d =
530 mm). This is also true for bearings, which have bore diameters of 19, 28 and 33 mm, e.g.
322/28 (d = 28 mm). Bearings with bore diameters of 10, 12, 15 and 17 mm have the following
size identifications :

00 = 10 mm

01 = 12 mm

02 = 15 mm

03 = 17 mm

Series designations often include a suffix A, B, C, D or E or a combination of these letters e.g. CA.
These are used to identify differences in internal design, e.g. contact angle.

Contact angle α = 400 is designated by suffix B. Similarly, contact angles of 25 0 and 300 are
designated with suffixes AC and A respectively.

Bearing designation can be explained by considering deep groove bearing of 10 mm bore diameter.
Table 6.2 lists outer diameter (D), bearing length (B), dynamic load capacity (C), static laod
capacity (Co), Fatigue load capacity (Pu), rated speed for grease(as lubricant) and oil(as lubricant)
and designation.

If applied load is lesser than Pu, then bearing shall have infinite life. Limiting speed with liquid
lubricant is higher compared to bearings with grease lubricant, as liquid lubricant provides better
cooling and effective operating temperature shall be lesser. Bearing column of table 6.2 lists
bearing series(i.e, 6000, 6200) with suffix(i.e, 2RSH, 2Z).

Table 6.2: Deep groove ball bearing(bore dia = 10 mm)[2].

Suffix :

To explain suffix example of deep groove ball bearing (DGBB) has been considered. These bearings
possess deep grooves on both the rings(Fig. 6.28). These widely used bearings can support high
radial forces as well as some axial forces.

Fig. 6.28: Bearing dimensions.

 Fig. 6.29: Deep groove ball bearings, single row.

Fig. 6.29 illustrates single row deep groove ball bearing with no suffix(61804), with suffix for
shield(61804-27) and with suffix for seal(61804-2RS1). There are some advantages and
disadvantages of each configuration.

• Shield : Profiles sheet steel discs pressed into the grooves of outer ring and forming gap-type
seals with the inner-ring shoulders.

Advantages :
1. Low friction.
2. Recommended for high speed.

Disadvantages :
1. Possibility of water ingress in most environment.
2. To some extent grease may leak-out and dust may enter in dusty enviornment.

• Seals : It often made of elastic rubber. Bearings sealed on both sides are grease filled and in
normal working conditions, the grease filling lasts the entire service life of the bearings.

Advantages :
1. Very good grease retainability.
2. Does not allow dust to enter.

Disadvantages :
1. High pressure.
2. Limit on rotational speed due to temperature.

Other than deep groove ball bearings, angular contact ball bearing and cylindrical bearings are
widely used.

Angular Contact Ball Bearing (ACBB) :

Raceways are so arranged that forces are transmitted from one raceway to other under certain
contact angle-angle between line of action of the force & radial plane. Due to CA, ACBB are better
suited to sustain high axial loads than DGBB.

Cylindrical roller bearings :

 Fig. 6.30: Various configuration of cylindrical roller bearings[2].

Cylindrical roller bearings(Fig. 6.30) can accommodate heavy radial loads and can operate at high
speeds. The full complement bearings (without cage) can support particularly heavy radial loads,
but because of the special kinematic conditions in these bearings, they cannot be operated at such
high speeds as the caged bearings.

Classifications of rolling element bearings based on load.

Since most types of radial bearings can carry some thrust, there is no sharp distinction between
them; however, bearings having a contact angle α = 450 or smaller (α < 45 degrees) are
considered radial bearings and their ratings are given as radial load. Some of these bearings are
shown in Fig. 6.31.

Bearings with a contact angle α greater than 450 (α > 450) are considered thrust bearings and are
rated axial bearings. Some of these bearings are shown in Fig. 6.32.

Fig. 6.31: Radial rolling bearings.

 Fig. 6.32: Thrust rolling bearings.

• Axial load capacity increases with increase in α.

• Radial load capacity decreases with increase in α.

Selection of Rolling Element Bearing :

Each type of bearing displays characteristic properties as listed in Table 6.3. For example, deep
groove ball bearings can accommodate moderate radial loads as well as axial loads. They have
low friction and can be produced with high precision in relatively samll sizes. Therefore, they are
preferred for small and medium-sized electric motors. Spherical roller bearings can carry very
heavy loads and are self-aligning. These properties make them popular in heavy engineering,
where loads are heavy and deformations and misalignments are produced by the loads. The
information given here should serve to indicate which are the most important of the following
points to be considered when selecting bearing type and thus facilitate an appropriate choice.

• Cylindrical & Needle roller – pure radial load.

• Thrust (cylindrical roller, ball), four point angular contact ball bearings – pure axial load.

• Taper roller, spherical roller, angular contact ball bearings – combined Load.

• Cylindrical roller, angular contact ball bearing– high speed.

• Deep groove, angular contact, and cylindrical roller bearing – high running accuracy.
 Table 6.3: Characteristic properties of rolling bearings.

The table 6.3 provides a relatively superficial classification of bearing types and facilitates an
appropriate choice. It should also be remembered that the total cost of a bearing arrangement
and inventory considerations also influence the final choice. Other important criteria to be observed
when designing a bearing arrangement including load carrying capacity and life, friction,
permissible speeds, bearing internal clearance or preload, lubrication and sealing are dealt with in
depth in separate sections.

Equivalent load :

Dynamic load capacity(as listed in table 6.2) is compared with applied radial load(axial load for
thrust rolling bearings) to estimate the bearing fatigue life. Often radial load is associated with
axial load and in those situations, concept of equivalent load is used.

• Generally vector sum(P = √(Fr2 + Fa2)) does not provide equivalent load. Amount of damage
done by thrust load is different than damage done by radial load, so it is important to find
equivalent radial load that cause same damage as combo of thrust & radial loads. Equivalent load
is given by

P = V X Fr + Y Fa

Where

V - Rotation factor = 1 if inner ring rotates,

V = 1.2 if outer ring rotates,

X - radial factor,

Fr - applied radial load,

Y - thrust factor,

Fa - applied thrust load.

Fig. 6.33 shows that below certain limit, the effect of axial force should not be counted. In other
words, equivalent load P can be given by
Where e is a dimensionless ratio, indicating axial load lower than a certain limit does not affect
total load as shown in following Fig. 6.33. Value of e depends on arrangement & static load capacity
(C0) of bearing as listed in table 6.4

Fig. 6.33: Effect of axial force on effective load.

 Table 6.4: X & Y factors for various bearings.

X & Y factors depend upon bearing geometry, number of balls and size of balls. These factors are
determined from tables and equivalent load is calculated based on those values. These tables
contain "C0", which is static load rating.
Static Load Rating C0 is defined as radial load causing permanent deflection greater than 0.01%
of ball dia.

In addition to C0, bearings are defined with dynamic load rating C, which is radial load (thrust load
for thrust bearings) that a group of identical bearings with stationary outer rings can theoretically
endure one million revolutions of inner ring.

Dynamic load rating is used to estimate bearing life using Lundberg Palmgren Approach.

Lundberg Palmgren Approach :

In ideal case, bearings fail by surface-fatigue(Fig. 6.34), which means bearing life can be
estimated.

Dynamic load rating (catalogue C reading) is the load which 90% (reliability = 0.9) of a group of
identical bearings will sustain for minimum of 106 cycles.
 Fig. 6.34: Bearing failure due to surface pitting.

To estimate bearing life at given bearing load(i.e, P1, P2,....), following equations are used.

....Eq.(6.1)

• Example : Radial load = 2 224 N, Speed = 1500 rpm, Desired life = 8 hours/day, 5 day/weeks
for 5 years, Shock factor = 1.5. For shaft diameter of 25 mm, find suitable rolling bearing.

In the present example, shock factor(load amplification factor) is used. This factor depends on
machine in which bearings are employed.

• Smooth operation --> Motor, Machine tools (1.2), air-conditioners (1.2)

• Normal operation --> Automotive vehicle, paper making machine, elevator, crane. 1.2 – 1.5

• Operation with vibration --> Crusher, construction equipment, farming equipment --> 1.5 – 3.0

To select rolling bearings, first step is to estimate the required C.

C = Radial load * shock factor * (total revolutions) 1/a.

• On substituting given values C ≥ 2224 * 1.5 * (10400 * 1500 * 60/10 6)1/a.

where a = 3 for ball bearings and a = 10/3 for roller bearings.

•C ≥ 32, 633 N for ball bearings.

•C ≥ 25, 978 N for roller bearings.

We can select bearing based on required "C" from catalogue.

 Fig. 6.35: Single row cylindrical roller bearings N205ECP.

Fig. 6.35 shows data of N205ECP roller bearing with basic dynamic rating of 28600 N ,which is
greater than the calculated value. So bearing runs desired life without failure. Another thing to be
noted from this figure is fatigue limit which is 3350N from catalogue. This value is smaller than
the radial load applied on the bearing, so bearing does not fail for proper lubrication.

Fig. 6.36: Deep groove ball barings, single row (6405).

We are able to find ball bearing(6405) which has dynamic load rating greater than the required
32,633 N as shown in Fig. 6.36.

But fatigue limit is lesser the applied radial load, so this bearing(6405) is going to fail by fatigue
load. So the best choice is roller bearing in terms of its dimensions and load aspects. Roller
bearing`s(N205ECP) outer diameter is 52 mm and length of bearing is 15 mm, which are lesser
than the corresponding dimension of ball bearing.

Example : Assume radial and axial loads on a bearing to be 7500N and 4500N respectively.
Rotating shaft dia = 70 mm. Select suitable single row deep groove ball bearing. To choose ball
bearing, which shall fit on shaft of 70 mm, we shall see bearing catalogue of deep groove ball
bearings with bearing series ending with 14, as given in Table 6.5. As per given data, shield or
seal may not be required, therefore, we can remove bearings, having shields or seals from
selection Table 6.5. After this intial screening 61814, 61914, 16014, 6014, 6214 and 6314 may
be tested for static load capacity.
 Table 6.5: Deep groove ball bearings of 70 mm bore size.

Using above value, calculate the ratio then decide the X, Y factors. Then calculate the equivalent
load (P).

Table 6.6: X & Y factors for deep groove bearing.

Based on axial load (Fa), radial load (Fr), and static capacity (C0),, factors X & Y can be evaluated
using Table 6.6. In present example (Fa/Fr) = 0.6. (Fa/C0) for bearing 6014 is 4500/31000. Using
table 6.6, X = 0.56 and Y = 1.37. Based on these data equivalent load = 10365. Similarly (F a/C0)
for 6314 bearing is 4500/68000. Using these data and table 6.6, X = 0.56 & Y = 1.65. Equivalent
load P = 11625 N.

Example : Assume radial and axial loads on a bearing are 7500N and 4500N respectively, shaft
dia = 70 mm and select a deep groove ball bearing. Consider shaft rotates at 1000 rpm and
expected bearing life = 3000 hours. In present example equivalent loads calculated in previous
example may be used to find bearing life.

Life consideration :

(C)a 106 = P1a L1 = P 2a L2 = P3a L3

a = 3 for ball.

Table 6.7: Bearing data.

Bearing life in hours = (C/P)3 [1000,000/(60*speed)]

For present example, speed = 1000 rpm => Bearing life in hours = (C/P) 3 (50/3)

Using table 6.7 and above equation; bearing life of 6014 shall be 937 hours, while life of 6314
shall be 14,500 hours. This means bearing 6314 shall be selected.

Angular contact ball bearings :

In previous example we selected deep groove ball bearing for a combined load application. We
may have selected angular contact bearings. Angular contact ball bearings are often used in
adjustable bearing arrangement. Two popular arrangements are :

O arrangement.

X arrangement.

With O arrangement, the pressure cone apexes formed by the contact lines point outward, while
with X arrangement they point inward as shown in Fig. 6.37. With these two arrangements bearing
can take up axial load in both the directions. However, sometime larger load capacity is required
only in one direction, where tandem bearing are used.
 Fig. 6.37: Arrangements of angular contact bearings.

When arranged in tandem, the load lines are parallel and the radial and axial loads are equally
shared by the bearings. The bearing set can only take up axial loads acting in one direction. If
axial loads act in the opposite direction, as well as combined loads, these are taken up by a third
bearing which is adjusted against the tandem pair.

The major problem with these bearings is misalignment, which leads to increase ball loads and
cage stresses as well as a reduction in bearing life. Any misalignment of the bearing rings will also
lead to an appreciable increase in running noise. Special attention should also be paid to back-to-
back and face-to-face arrangements when the axial load acts predominantly in one direction. The
unfavourable rolling conditions for the balls of the unloaded bearing under such conditions can
lead to noise, rupture of the lubricant film and increased stressing of the cage. X and Y factors for
angular contact bearings are listed in Table 6.8. These factors can be used to estimate equivalent
load and bearing life as explained in next example.

Table 6.8: X & Y factors for angular contact bearings.

Example : A radial load of 3000N combined with thrust load of 2500N is to be carried on a 6214
ball bearing for 70 mm dia rotating shaft at 1000 rpm. Determine equivalent radial load to be used
for calculating fatigue life. Compare life of 6214 bearing with that for a 7214 (nominal contact
angle 300).

Step 1: C0 for 6214 is 45kN and 7214 is 60 kN. C for 6214 is 63.7 kN and 7214 is 71.5 kN.

Step 2: Fa/VFr > e.

Step 3: Radial load for 6214 bearing is 5955N & for 7214 bearing radial load is 3070. Using these
data and following equation bearing life can be calculated.

Bearing life in hours = (C/P)3(1000,000/60 speed).

Step 4: Life for 6214 will be 7192 hours and 7214, life = 124,420 hours.

This example clearly demonstrates better life of angular contact bearing compared to deep groove
ball bearing.

Equivalent load under variable loading :

Often bearings operate at various rotational speeds. For example, bearing operates at 1000 rpm,
applied load of 500 N for 100 hours then bearing operates at 1200 rpm, 250 N for 250 hours. In
such situation it is advisable to find an equivalent load, using :
 as L = L1 + L2 + L3 + ......

Example : A ball bearing is run at to four piecewise load and speed conditions, as given in table
6.9. Find its equivalent load.

Table 6.9: Data related to variable bearing load.

P = (p13 f1 + p23 f2 + p33 f3 + p43 f4)1/3,

P = (8.6636 X 109)1/3 = 2054 N.

Friction in Rolling Element Bearings

Bearing selection based on load and expected life was explained in previous subheadings.
Sometime, friction plays role in bearing selection. A rough estimation of frictional coefficients(f) is
:

• Self-aligning ball bearings, f = 0.0010

• Cylindrical roller bearing, f = 0.0011

• Thrust ball bearings, f = 0.0013

• Single-row deep-groove ball bearings, f = 0.0015

• Tapered and spherical roller bearings, f = 0.0018

• Needle bearings, f = 0.0045

Coefficient of friction is represented by symbol f. The value of f is a system property and will
change with kind of lubricant, applied load, and mounting. The values quoted are idle values. The
lowest coefficient of friction is 0.001 and highest coefficient of friction is 0.0045. From this
comparison it can be concluded that self aligning bearings are preferable choice.

Why coefficient of friction in needle roller bearings is higher than other bearings ?

• Considerably greater length than dia.

• Rollers cannot be manufactured as accurately as other cylindrical rollers.

• Rollers cannot be guided well.

• Rubbing action against each other.

 Fig. 6.38: Needle roller bearings.

Anti-friction bearings is a common terminology used by a number of authors for rolling element
bearings. This means bearings which go against friction and almost negligible friction. But we are
trying dig out all possible sources of friction in these anti-friction bearings. One common cause of
friction in all rolling element bearing is hysteresis losses. Such losses occur due to loading and
unloading of rolling element on rings.

The lowest value of coefficient of friction due to hysteresis happen in chrome steel, therefore,
chrome steel is used as one of materials for rolling elements. It is necessary to understand
ball/roller are subjected from zero load (as shown in green color in Fig. 6.39(b)) to maximum (as
shown in red color in Fig. 6.39(b)) load. Due to such load variation, elastic deformation of rolling
elements change from zero to maximum as shown in Fig. 6.39(a).

Fig. 6.39: Loading and unloading of rolling elements.

 Fig. 6.40: Hysteresis load.

Other than elastic hysteresis, relative speed (sliding between rolling elements and cage, sliding
between rolling elements and rings, lubricant shearing), seals and misalignment cause friction.

Fig. 6.41: Bearing seal.

• Total friction = Frictionload + Frictionspeed + Frictionseal

The total frictional moment of a bearing is obtained by adding the frictional moment M 0, which is
independent of the bearing load, and the load-dependent frictional moment M1. For sealed bearings
and axially loaded cylindrical roller bearings, additional components of the frictional moment must
be taken into account. Sliding friction occurs at guiding surfaces of rolling elements in the cage,
at the roller faces and the raceway lips, and between adjacent rolling elements in cage-less
bearing. Internal friction & churning action of lubricant cause friction.

Load dependent friction moment :

Under ideal conditions(P » 0.1 C, good lubrication, mean speed range ~0.3 to 0.7 permissible
speed, without seal) the frictional moment can be calculated from the following equation.

MP = f P (d/2)

where P = √(Fr2 + Fa2)

MP = Frictional moment due to external (+pre-) load, N.mm.

f = Coefficient of friction.

P = Resultant load, N.

d = Bore dia, mm.

Generally, f is a function of load. Data given in table are applicable for P = 0.1 C.
 Table 6.10: Friction coefficient.

Lubricant & Speed Dependent Friction Moment :

where;

ν = Operating viscosity of oil, mm2/s.

N = Rotational speed, rpm.

ML = Moment, N.mm.

dm = mean diameter, mm.

Table 6.11: Lubricant factor f . L

Seal Dependent Friction Moment :

In this component of friction moment, there is fixed and variable parts of friction. Where the
bearing is only sealed at one side, Ms/2 should be used instead of Ms. Where bearings are fitted
with rubbing seals, the frictional losses arising from the seal may exceed those arising from the
bearing itself.

Table 6.12: Friction factors for seals.

• Total friction moment M = MP + ML + MS

Example : Estimate friction moment of 6214-2RS1 bearing running at 6,000 rpm under 5000 N
radial load when jet lubricated by synthetic ester jet engine oil having a viscosity of 6 mm 2/s (cSt)
at operating temperature.

Ans : 468.5 N.mm.

Bearing Temperature :

• Dependence on total friction moment, speed, extraneous heat source and heat dissipation
capability.
• Ideally, operating temprature needs to be atmospheric temp. because bearing friction is small.

• Excluding extraneous heat, steady state temperature of a bearing can be calculated by balancing
heat flow generated by bearing and heat flow dissipated into environment.

=> Heat dissipation rate QR = Rate of generation QL.

Heat flow dissipated to environment is calculated from the difference between the bearing
temperature and ambient temperature, size of heat transfer surfaces and heat flow density, which
depends on cooling conditions.

Example : Estimate bearing operating temperature of 6214-2RS1 bearing running at 6,000 rpm
under 5000 N radial load when jet lubricated by synthetic ester jet engine oil having a viscosity of
6 mm2/s (cSt) at operating temperature. Assume ambient temp = 30 0C and natural cooling of
bearing, OD = 125, B = 24.

Substituting values
In idle conditions, bearing temperature is well within limits, but due to installation faults, bearing
temperature increases significantly.

Bearing Clearance

In idle condition, friction loss and temperature rise are well within permissible range. But bearing
performance strongly depends on the bearing mounting, which affects the clearance between
elements of rolling bearing.

Fig. 6.42: Diametral clearence.

Clearence, before bearing mounting, is shown in Fig. 6.42 and tabulated in table 6.13. Bearing
clearences are often classified as normal(standard) clearence, C2 clearence, C3 clearence and
C4 clearence. C2 clearence, lesser than normal clearence, is recommended for very precise position
of shaft, such as spindle bearings. C3 and C4 clearences greater than standard clearences and are
recommended for high temperature applications. Generally reduction in bearing clearence occurs
after mounting.
 Table 6.13: Beraing clearences.

• Bearings are mounted on shaft and in housing with transition to interference fit.

• If interference fits exceed the internal radial clearance, the rolling elements become preloaded.

Fig. 6.43: Reduction in bearing clearence.

Operating/Running clearance in rolling bearings depends on the manufacturing processes(IT
grade) and bearing (light/medium) fit.

Manufacturing Processes :

Fig. 6.44: Tolerance range for various manufacturing processes.

IT Grade refers to the International Tolerance Grade of an industrial process. This grade identifies
what tolerances a given process can produce for a given dimension as listed in table 6.14.
Table 6.14: IT grades and corresponding tolerances for various dimensions.

Bearing Fits :

Recommended bearing fits are :

• Light duty speed :

- H6 k5 fine.
- H7 k6 normal.
- H8 k7 coarse.

• Medium duty speed :

- H6 m5 fine.
- H7 m6 normal.
- H8 m7 coarse.

It is important to note that tolerances belong to one component but fit is referred to assembly of
components. For example H6k5 refers to role tolerance(bearing bore) and shaft tolerances. Here
6 & 5 are referred to IT6 and IT5 respectively. Letters associated to these numbers are in Fig.
6.44 & Fig. 6.45.
 Fig. 6.44: Hole and shaft tolerance(μm).

Fig. 6.45 indicates smaller size of shaft (-ve sign) and larger size of bearing bore (+ve sign)
provides clearance fit, while larger shaft size (+ve sign) and smaller (-ve sign) make interference
fit.

Fig. 6.45: Bearing fit.

Preload :

Due to negative clearance between rolling elements and bearing rings, bearing gets preloaded.
Preloading of bearings is required to prevent/ suppress shaft runout/vibration/noise. Preloading
improves the running accuracy and increases the bearing stiffness. But preloading increases the
friction loss and so running temperature.With increase in temperature, viscosity of grease/oil
decreases, which further increases the metallic friction. Therefore, preloaded bearings must be
designed with care.

Misalignment: Performance of rolling bearing is very sensitive towards misalignment. High

preloading on one side of the bearing happens due to misalignment.

• 0.10 misalignment results 52 μm preloading for 30 mm length.

• 0.010 misalignment results 5 μm preloading.

To understand the effect of preloading on bearing load, we can use concept of elastic
deformation(Fig. 6.46) and following formula.

Elastic Deformation suggested by Timoshenko & Goodier: :

Fig. 6.46: Elastic deformation during bearing mounting.

Example : Estimate bearing operating temperature of 6214-2RS1 bearing running at 6,000 rpm
under 5000 N radial load when jet lubricated by synthetic ester jet engine oil having a viscosity of
6 mm2/s (cSt) at operating temperature. Assume ambient temp = 30 0C, ball dia=12 mm,
Deflection due to improper mounting = 5 μm, and forced cooling of bearing.

Intial load on bearing due to preloading can be estimated using

E for bearing steel is 207 GPa and ν = 0.28. As per given data r = 6 mm & δ 1 = 0.005 mm. This
means Fintial = 42.337 kN. If we consider only applied force MP = μP(bore dia./2) => MP = 262.5
N.mm. On considering deflection MP = 2485 N.mm. This means significant increase in friction
moment occurs by 5 μm elastic deformation of rolling elements.
Ms = 105 N.mm.

Total moment = 2691 N.mm.

As we calculated in previous examples

=> t = 30 + 2.3.

This temperature rise (2.30C) occurs under forced cooling envioronment. If we assume normal
environment

The increase in temperature by 5.80C is acceptable, which means bearings are designed with some
capacity to handle some misalignment & interference fit.

Bearing Lubrication

To reduce friction, lubrication is needed. In addition lubrication is required to avoid rapid wear and
early failure. Lubricant minimizes metal to metal contact between surfaces in rolling contact and
sliding motion, thereby minimize friction and wear commonly used lubricants are :

• Greases :

- Used for most of rolling elements.

- Life long lubrication < 1.5 * 10 6 mm/min.

• Oils :

- An aid to heat dissipation.

• Solid Lubricants :

- Compensation for surface roughness.

- Life long lubrication, if < 1500 mm/min.

Grease has the advantage over oil that it is more easily retained in the bearing arrangement,
particularly where shafts are inclined or vertical, and it also contributes to sealing the arrangement
against contaminants, moisture and water. An excess of lubricant will cause the operating
temperature to rise rapidly, particularly when the bearings are running at high speeds. As a general
rule, the free space in the housing should be partly filled (30 to 50 %) with grease. Where bearings
are to operate at very low speeds and must be well protected against corrosion, it is advisable to
completely fill both bearings and housings with grease. Greases thickened with polyuria can soften
and harden reversibly depending on the shear rate in the application, i.e. they are relatively stiff
at low speeds and soft or semi-fluid above a given speed. For normal speeds and loads, use
medium soft grease, since it readily covers all the working parts and does not ridge up on the
sides of tracks. For small bearings functioning at high speeds under light loads, use a soft grease.

• NLGI grades nos. 1, 2, 3, or 4 are recommended for lubrication. Some of NLGI grades is given
in Table 6.15.

• NLGI 2 would normally be the first choice.

Table 6.15: NLGI grades.

• For better sealing and vertical shaft arrangements. Grease no. 3 or 4 is recommended.

• Shock load or vibration tends to cause grease to slump into moving components. A Harder
grease reduces problem.

• Centralized grease supply uses a softer grade.

Selection of lubricating oil :

• Bearing life may be extended by selecting an oil whose viscosity ν at the operating temperature
is somewhat higher than ν1. The values of ν1 can be obtained using Fig. 6.47.

• If the viscosity ratio, k = ν/ν1, is less than 1, an oil containing EP additives is recommended.
 Fig. 6.47: Required kinematic viscosity at operating temperature.

The viscosity of an oil is temperature dependent, becoming lower as the temperature rises. The
viscosity/temperature relationship of an oil is characterized by the viscosity index VI. For rolling
bearing lubrication, oils having a high viscosity index (little change with temperature) of at least
85 are recommended. Certain bearing types, e.g. spherical roller bearings, taper roller bearings,
and spherical roller thrust bearings, normally have a higher operating temperature than other
bearing types, e.g. deep groove ball bearings and cylindrical roller bearings, under comparable
operating conditions, therefore, high VI oil must be selected.

Example :

A bearing having a bore diameter d = 340 mm and outside diameter D = 420 mm is required to
operate at a speed n = 5000 r/min.

Since dm = 0.5 (d + D), dm = 380 mm. From Fig. 6.47, the minimum kinematic viscosity ν1 required
to give adequate lubrication at the operating temperature is 13 mm2/s. From Fig. 6.48, assuming
that the operating temperature of the bearing is 700C, an oil having a viscosity ν at the reference
temperature of 400C of at least 39 mm2/s will be required.
 Fig. 6.48: Temperature cum viscosity.

Elastohydrodynamic lubrication of rolling contact :

In order to understand the role of a lubricant in rolling bearings, it is necessary to explore the
elastohydrodynamic lubrication. Under elastic deformation, effective film thickness increases as
shown in Fig. 6.49. A detailed analysis of EHL is out of scope, therefore widely used curve fit
equations will be discussed.

Fig. 6.49: Elastohydrodynamic lubrication in rolling bearings[3].

It is interesting to note (Fig. 6.50) that sesitivity of film thickness toward increase in load is very
low.
 Fig. 6.50: Effect of load on film thickness.

As lubricant is drawn into the leading edge of the film by the roller surface, the viscosity of the oil
increases rapidly and the lubricant film pressure rises to match the elastic Hertz contact pressure.
After passing the center of contact area, pressure of the lubricant film falls until it reaches the
outlet zone. Here the decreasing contact pressure relieves the compression of the roller surface,
the gap narrows to h0, and a distinctive pressure spike is reached at film exit as shown in Fig.
6.51. As speed decreases or load increases, this pressure spike moves further towards the exit
and eventually disappears for very heavily loaded contacts.

Min. film thickness (h0) is often empirically represented in terms of material, speed and load
parameters.

Line Contact :

Curve fit equation for min film thickness in cylindrical bearings is given by;

Fig. 6.51: : Non-dimensional distance from

center of contact.

Point Contact:

Curve fit equation for min film thickness in spherical/ball bearings is given by;
Example : 6210 bearing has balls of 12 mm diameter and maximum load on each ball is 1500 N.
Young’s modulus of balls is 202 GPa Poisson`s ratio is 0.28 and pressure viscosity coefficient is
1.8 * 10-8 m2/N. Dynamic viscosity is 11.3 mPa.s. Radius of inner ring in direction of rolling is 28
mm and its groove radius is 6.5 mm. Speed = 900 and estimate minimum film thickness.
To sustain EHL, roughness of rolling surfaces must be lesser than 0.125 μm.

References : :

1. Edwards K S & McKee R B, Fundamentals of Mechanical Component Design, McGraw-Hill Inc.,

1991.

2. http://www.skf.com/group/products/bearings-units-housings/index.htmlaccessed on 20th
February 2013.

3. http://www.maxxtorque.com/dieselcommunity/winter-2008/intro-to-lubrication?start=2
accesses on 20th February 2013.