Mechanical Technology Guide

PAPA DIOUF, P.E | Dodge Sleevoil Bearing Development Engineer

Baldor Electric Company
Fort Smith, Ark.

Detect Bearing
Failure
Identify and correct two common culprits
of oil-film bearing failure.

IF YOU SEE air-moving equipment, chances are oil-film bear-

ings lie at the heart of centrifugal and axial fans. Serious damage can result to the entire unit should these bearings fail.
Therefore, its important to identify and determine the causes
of bearing failure to keep personnel and equipment safe and
prevent costly repairs.
Oil-film bearings can fail in several ways. These include
scoring, wiping, fretting, overheating, fatigue, and corrosion.
In industrial fans, the two most-common failure modes are
scoring and wiping. Both failure modes can be identified as
circular parallel grooves on the bearing-lining surface. Scoring is primarily caused by contamination while wiping develops from displacement of the babbitt.
SCORING

The severity of scoring is influenced by particles size,

bearing load, shaft-surface finish, and speed. The grooves

associated with scoring are on the order of 0.001 to 0.040in.

width and depth.
The grooves lie primarily over the load zone of the bearing.
In oil-film bearings, a converging wedge of oil between the
rotating shaft and the bearing lining surface creates hydrodynamic pressure in the lubricant film that keeps the surfaces
completely separated. The oil-film thickness separating the
parts is generally around 0.0004 to 0.004in. depending on the
bearing-operating conditions.
External or internal abrasive contaminants may find their
way into the lubricating oil and travel with the oil through the
bearing clearance, especially through the area where the minimum oil film is located. The lubricating oil recirculates continuously through the clearance during the bearing operation.
Abrasive particles larger than the minimum oil-film thickness will either be embedded into the babbitt surface or pass
through the oil-film gap causing wear or erosion. The con-

PARTS OF AN OIL-FILM BEARING

Oil-ring groove
Housing
Oil ring

Oildistribution
groove

Shaft or
journal

Load zone

Babbitt
lining (tin
or lead
based)

Thrust bearing

62

Oil sump

Steel or cast-iron
backing

07.18.13

MACHINE DESIGN

Mechanical Technology Guide

tinuous wearing and gouging of the babbitt

surface that occurs when the particles are
not embedded will lead to scoring.
Particles less than 0.0004in. are usually
smaller than the oil-film thickness and are
not always considered harmful. During a
full-film operating condition, these particles will travel between the shaft and the
bearing-lining surface and be carried away
with the oil. However, these smaller particles can generate wear during boundary
lubrication conditions.
Generally, boundary lubrication occurs
when the shaft is running at speeds less than
the minimum speed required for a full oilfilm development. This can happen, for example, during starts
and stops. Boundary lubrication permits metal-to-metal contact and this is when smaller particulates will embed into the
babbitt or abrade the babbitt material. Heavy-loaded bearings,
with unit loads larger than 250 psi, are more likely to see abrasion from smaller particles because the heavy load will reduce
the oil-film thickness. A thicker oil film lets larger particles flow
through, thus reducing the damaging effect of contaminants.
Bearings running at higher speeds will also accelerate the
abrasion process because of the increased number of times
the particles circulate through the bearing clearance. If the
contaminants are not filtered, or if the contaminated oil is not
changed, they will eventually embed into the babbitt and form
a harder lining surface, therefore, impairing the embedability
of the babbitt material. This will lead to shaft scoring, as the
larger particles try to move through the bearing clearance.
Sources of particulate contamination can be external or
internal. External contaminants come from the surrounding
environment such as fly ash, dust, or other industrial pollutants. They find their way into the lubricating oil if the housing
seals are not adequate for the operating condition; or during
bearing installation or inspection. If the source of contamination cannot be eliminated, the oil-change frequency should be

Circular, parallel grooves

on the bearing-lining
surface identify a common cause of failure
called scoring.

increased; or an oil-circulation and filtration system added to

continuously filter and recirculate the oil into the bearing.
In circulating-oil systems, filtered, pressurized oil flows into
the bearing. The filter should be sized adequately to pass only
the particles smaller than the predicted oil-film thickness. In
addition to filtering the oil, an auxiliary high-performance,
combined labyrinth and contact sealing system can be used to
prevent the ingress of contaminants into the bearing.
Internal contaminants come from bearing-component
wear, for example, iron particles from the spherical seats of
the bearing liner and housing; babbitt wear generated during
starts and stops; and copper particles from the oil ring rubbing
against the liner. During installation, all bearing components
should be thoroughly cleaned with manufacturer-recommended solvent and then flushed with the same oil to be used
during operation. After the first two weeks of operation, technicians should drain, flush, and refill the oil to remove most
internal contaminants left in the bearing during installation.
Another common cause of scoring is the installation of a
new bearing liner on a damaged or previously scored shaft. A
new liner running against a grooved shaft will lead to scoring.
Before installing a new bearing liner, if a grooved shaft cannot
be replaced, it should be polished to remove all the high spots

Skip the prep. Forget the drill. Install in seconds!

Harness more efficiency.

Superior to adhesives, Tack Mount fasteners are the one-step solution
for securing cabling, tubing and wiring harnesses without drilling.
Molded in durable, impact resistant nylon, a built-in hardened steel Metal Tack
enables pneumatic nailing into virtually any metal surface.
And Tack Mount brackets are designed to rotate in place
for final alignment making harnessing operations a snap!

800 474 7624 Visit Gripnail.com for a video demo

TackMountAdFNL3_tm_resize.indd 1

GRIPNAIL

Tack Mount Fasteners

MADE IN USA

7/2/13 1:10 PM

Mechanical Technology Guide

Excessive wiping
occurs when there is
a loss of lubrication.

Reliability
in a Clutch
...a clutch, brake or power
transmission part for that
matter. Since 1903 Carlyle
Johnson has solved some of
historys toughest motion
control challenges its what
we love to do. Our precision
electrical, mechanical, air and
hydraulic power transmission
products consistently prove
reliable and dependable in
every application. Underwater,
on the ground and in the air,
CJM is everywhere.

This thrust
bearing shows
wiping from
overheating.

and sharp edges. A surface finish of 0.000032in. average roughness or better will
attenuate the abrasion process.
WIPING

Standard and Custom Clutch, Brake

& Power Transmission Solutions

291 Boston Turnpike Bolton, CT 06043

Phone: 860-643-1531

www.cjmco.com
66

Wiping damage involves the displacement of babbitt from the load zone to another location in the bearing. The most-common mechanism that will cause wiping is
the babbitt melting as a consequence of a direct contact between the shaft or thrust
runner (also known as the thrust collar) and the babbitt surface. This happens when
a temporary breakdown in the oil film causes boundary lubrication.
A less-common mechanism causing wiping is an excessive peak pressure developing
in the oil film causing localized plastic deformation of the babbitt. The deformed material will then be pushed into the clearance and displaced by the shaft or thrust runner.
Conditions causing physical displacement of babbitt are encountered in bearings
with insufficient clearance, misalignment, unbalanced loading, excessive vibration,
excessive loading, or oil starvation.
A bearing with insufficient clearance will run hotter because oil flow through
the bearing clearance is restricted, therefore limiting heat dissipation through
the oil. This condition can also lead to bearing overheating. This problem is more
prevalent in cold start-up where heat generated in the oil film may cause the shaft
to grow more rapidly than the liner and bearing housing.
An elliptical bore profile bearing with the same vertical clearance as a cylindrical bore profile will have a larger horizontal clearance, therefore letting more

07.18.13

MACHINE DESIGN

Mechanical Technology Guide

oil flow easily through the bearing and increasing heat dissipation through the oil. Bearings with elliptical bores run
cooler and are less sensitive to thermal effects than cylindrically bored bearings. Constantly monitoring the bearing
temperature can prevent costly downtime from overheating
and wiping.
Misalignment will overload one side of the bearing and
cause edge loading and pinching. With the oil squeezed out,
metal-to-metal contact occurs, the babbitt will overheat,
and eventually be displaced. In the case of a thrust bearing,
misalignment will cause the runner to overload one side of
the thrust bearing, leading to the same effect. Slight polishing on one side of the liner near the edge is normal as the
babbitt material is designed to accept slight misalignment by
conforming to the shaft. Severe wiping on one or both edges
of the liner indicates a need for better alignment.
Another cause of edge loading is unbalanced load. This
imposes a rotating dynamic force in the system which
results in an offset bearing pressure center. This causes a
jump-rope type lateral vibration of the rotor, which manifests into an alternating edge loading of the bearing.
Excessive vibrations may be induced from instability in
the oil film. This is characterized by a circular motion of

POWER TRANSMISSION-PART CONVEYING

PYRATHANE
BELTS
With Lifetime Warranty Against Manufacturing Defects

A displaced babbitt caused by excessive misalignment.

the shaft center in the bearing clearance in the direction

of the shaft rotation. This type of vibration can generate
impact loading and boundary lubrication leading to wiping. Bearing vibration should be monitored and trended
for system reliability.
Wiping may also be caused by excessive loading, especially
during starts and stops. Radial-bearing loads of 400psi or
higher are more likely to cause wiping during starts and
stops. A hydrostatic-lubrication system is required at these
loads to prevent boundary lubrication problems. Pressur-

COLORS AVAILABLE

Samples available at little or no cost

CUSTOM MADE IN INCH, METRIC & O-RING SIZES

Round, Flat and Connectable Polyurethane Belts
Very Clean in Operation Eliminates Tensioning Devices
Exceptional Abrasion Resistance

Line Shaft Conveyor Belts - Original Equipment & Connectable

DIAMETAPE BELT
MEASURING TOOL
Allows for accurate, non
destructive measurements on
o-ring and belt inside
diameter (ID) or inside
circumference (IC).
Available in Standard and
Metric Sizes.

www.pyramidbelts.com
AN ISO 9001
CERTIFIED COMPANY

68

(P) 641.792.2405 E-mail: [email protected]

522 North Ninth Avenue East, Newton, IA 50208

Connectable (PC) Belts available in diameters ranging from .093 through .562.
07.18.13

MACHINE DESIGN

Wiping will manifest itself as bearing temperatures

increase. This is due to the loss of bearing clearance
caused by the displaced material previously discussed.
If the cause is not identified and the problem resolved,
the wiping process will continue until excessive friction
causes seizure or catastrophic failure. A sudden spike in
bearing temperature should always be investigated and
corrective actions taken.
Edited by Lindsey Frick,
[email protected], @MaterialShout
Edge loading appears when wiping is caused by an unbalanced load.

RESOURCES:
Baldor Electric Co., www.baldor.com

ized oil flows through channels and pockets into the bearing clearance to lift and support the shaft before the system
starts or stops. Once the shaft reaches the speed necessary to
develop a full hydrodynamic-oil film, then the hydrostaticoil system shuts downs.
Another cause of wiping is oil starvation, which happens
when the oil delivered to the shaft is insufficient to generate
a full oil film. An oil-ring-lubricated bearing in low ambient
temperatures may not deliver sufficient oil during start-up,
which leads to boundary lubrication and wiping.

D. F. Wilcock and E. R. Booser,Bearing Design and Application, McGrawHill, New York, (1957)
T. H. McCloskey,Troubleshooting Bearing and Lube Oil System Problems,
Proceedings of the Twenty-Fourth Turbomachinery Symposium, Gas Turbine Laboratories, Texas A&M University, Texas, (1995)
J. M. Conway-Jones and A. J. Leopard,Plain Bearing Damage, Proceedings of the Fourth Turbomachinery Symposium, Gas Turbine Laboratories,
Texas A&M University, Texas, (1976)

Poly-V pulleys endcap Hutchinson ad_Layout 1 10/19/2012 2:54 PM Page 1

ConveyXonic

r a-Belt
u
D

Dura-Belt provides one-stop shopping for

Hutchinson ConveyXonicTM Poly-V belts
and a broad line of glass reinforced nylon drive
and idler pulleys, plus poly-V roller endcaps.
Available with either H and/or J size ribs.
ABEC-1 bearings are molded into pulleys, so
they cannot slip or fall out. Bore adapters fit

Dura-Belt

Poly-V is a registered trademark of the Goodyear Tire & Rubber Company.

GO TO MACHINEDESIGN.COM

most shaft sizes. Fast delivery. No tooling

charges. Economically priced. Dura-Belt also
offers a complete line of round, Vee & flat idler
and drive pulleys, plus long-life polyurethane
drive belts, warranted not to break at the weld
joint. ConveyXonic is probably the worlds
strongest, longest lasting, most abrasive
resistant, stretchy, multi-rib rubber belt.
800-770-2358 614-777-0295 Fax: 614-777-9448

[email protected]

www.durabelt.com
69