Module 7 (Maintenance Practices) Sub Module 7.11 (Bearings) PDF

PIA TRAINING CENTRE (PTC)
Module 7 - MAINTENANCE PRACTICES
Category A/B1
Sub Module 7.11 - Bearings
MODULE 7
Sub Module 7.11
BEARINGS
ISO 9001:2008 Certified

PTC/CM/B1.1 Basic/M7/03
7.11
For Training Purpose Only

Rev. 00
Mar 2014

Category A/B1

Contents
BEARINGS----------------------------------------------------------------------------- 1
TESTING ------------------------------------------------------------------------------- 1
CLEANING ---------------------------------------------------------------------------- 1
INSPECTION OF BEARINGS ------------------------------------------------------- 2
LUBRICATION ------------------------------------------------------------------------ 3
DEFECTS IN BEARINGS AND THEIR CAUSES ---------------------------------- 9

7.11 - i

Rev. 00
Mar 2014
Category A/B1
BEARINGS
When correctly installed and efficiently lubricated, bearings
require little but thorough, attention during service, to ensure a
long working life. The majority of bearings used in aircraft
engineering are of the sealed or shielded type. These bearing
are designed to prevent the ingress of foreign matter, which will
damage or contaminate the bearing contact surfaces.
TESTING
Testing a bearing is usually restricted to rotational checks and
excessive backlash or free play. Slow rotation of the rolling
elements and raceway will highlight any roughness due to
damage, corrosion or wear. A serviceable bearing should have
a smooth actuation. Free play should be tested in both a radial
and axial direction and is normally done by using a DTI. Some
wear is usually permitted and will depend on the grade of fit, but
any wear that leaves excessive backlash in the system is
unsatisfactory.
The rate of this wear depends on the speed the bearing is
rotated at, with high speed bearings failing quicker than those
which rotate slowly or through distances of less than one
complete revolution. A bearing that has any indication of a fault
should be discarded immediately.

7.11 - 1
Due to their construction internal inspection of shielded bearings

will be restricted. Taper bearings can be dismantled and a
thorough inspection of the rolling elements and raceway
surfaces can be completed.
CLEANING
Before a bearing can be checked it must be cleaned thoroughly
to remove any dirt and the old lubricating fluid. The manual will
dictate the cleaning process including use of any solvent, but a
typical method is as follows.
Remove any excess grease with clothes and dry compressed
air, whilst ensuring that the rolling elements remain stationary or
only rotate slowly.
Soak the bearing in an approved solvent, such white spirit, to
remove the remaining grease. The solvent may be applied as a
forced jet if necessary.
Dry the bearing by using clean warm and dry compressed air,
again avoiding fast rotation of any rolling elements.
Lightly lubricate all bearing surfaces with oil to prevent the onset
of corrosion.

Rev. 00
Mar 2014
Category A/B1
INSPECTION OF BEARINGS
Excessive loads
Once clean the bearing should be inspected for signs of failure,

some of the more common being:
Excessive loading of a bearing is usually the same as normal

fatigue, but the rolling elements wear path is usually heavier.
There is also increased evidence of overheating with a
widespread and deeper fatigue or spalled area. This often
causes premature bearing failure. (Refer Fig. 1)
Normal Fatigue
Excessive Loading
Installation and Misalignment
Loose Fitting or Spinning
Brinelling
Overheating and Lubrication Deficiency
Contamination and Corrosion
Normal fatigue
Normal fatigue failure is often shown as a fracture of the running
surface, with subsequent removal of small particles of metal and
is commonly called spalling. (Refer Fig. 1)
It occurs on both rolling elements and raceways, and is always
accompanied by an increase in vibration. Moderately spalled
areas show the bearing has reached the end of its normal
service life.
Spalled
Area
Ball
Path
Fig. 1
Spalled Areas

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Rev. 00
Mar 2014
Category A/B1
LUBRICATION
Reduce friction and wear
Lubricant
Direct metallic contact between the bearing rings, rolling

elements and cage, which are the basic components of a
bearing, is prevented by an oil film, which reduces the friction
and wear in the contact areas.
A lubricant (sometimes referred to as "lube") is a substance

(often a liquid) introduced between two moving surfaces to
reduce the friction between them, improving efficiency and
reducing wear They may also have the function of dissolving or
transporting foreign particles and of distributing heat. And the
science of lubrication is called tribology
History of lubrication
Romans were the first to use rag dipped in animal fat to
lubricate wagon wheels and other domestic applications.
Lubricant composition
Typically lubricants contain 90% base oil (most often petroleum
fractions, called mineral oils) and less than 10% additives.
Vegetable oils, synthetic liquids such as hydrogenated esters,
silicones, fluorocarbons and many others are sometimes used
as base oils. Additives deliver reduced friction and wear,
increased viscosity, improved viscosity index, resistance to
corrosion and oxidation, aging or contamination, etc.
Adequate lubrication is essential for all types of rolling bearings.
The purposes of the lubricant are to lubricate the areas of
rubbing contact, e.g. between the rolling elements and the cage,
to prevent premature failure. Lubrication will,

7.11 - 3
Extend of fatigue life

The rolling fatigue life of bearings depends greatly upon the
viscosity and film thickness between the rolling contact
surfaces. A heavy film thickness prolongs fatigue life, while
insufficient film thickness shortens it.
Dissipate frictional heat and cooling
Circulating lubrication may be used to carry away frictional heat
or heat transferred from the outside to prevent the bearing from
overheating and the oil from deteriorating.
Others
Adequate lubrication also helps to prevent foreign material from
entering the bearings and guards against corrosion and rusting.
For low rotational speeds, or for oscillating functions such as
are found in a number of airframe applications grease is a
suitable lubricant; at higher rotational speeds grease would
generate excessive temperatures because of churning, and oil
is more suitable. Because of the variety of uses to which rolling
bearings are put, and the varying requirements of different
locations, it is important that only those lubricants
recommended in the approved Maintenance Manual should be
used.
Rev. 00
Mar 2014
Category A/B1
A typical bearing

7.11 - 4

Rev. 00
Mar 2014

Category A/B1

Bearings fitted in engines and gearboxes are generally

lubricated by oil spray, splash, mist, drip feed, or controlled level
oil bath, and loss of lubricant is prevented by the use of oil
retaining devices such as labyrinth seals, felt or rubber washers,
and oil throwers.
Most bearings used in airframe and External applications are
shielded or sealed to prevent the entry of dirt or fluids which
could adversely affect bearing life and are usually packed with
anti-freeze grease because of the low temperatures
encountered; these bearings cannot normally be re-greased,
and must be replaced if it is evident that the lubricant has been
washed out, or otherwise lost through failure of the seals or
bearing wear.
Wheel bearings are normally tapered roller bearings, and

should be re-packed with the correct grease when refitting the
wheel. Ball and roller bearings, if properly lubricated and
installed, have a long life and require little attention. Bearing
failures may have serious results, however, and aircraft
Maintenance Manuals and approved Maintenance Schedules
include inspections and where applicable, lubrication
instructions for all types of rolling bearings.
Ball Bearing
Grease nipples are provided for some open bearings so that the
grease may be replenished at specified intervals, or when
grease is lost through the use of solvents, paint strippers,
detergents or de-icing fluid. Nipples should be wiped clean
before applying the grease gun, to prevent the entry of dirt into
the bearing. Grease forced into the bearing will displace the old
grease, and any surplus exuding from the bearing should be
wiped off with a clean lint-free cloth.
7.11 - 5

Rev. 00
Mar 2014

Category A/B1

Types of lubrication
Four distinct forms of lubrication may be identified:
Hydrodynamic (Film)
Boundary
Hydrostatic
Solid-film
Hydrodynamic lubrication means that the load carrying

surfaces of the bearing are separated by a relatively thick film of
lubricant, so as to prevent metal-to-metal contact.
Hydrodynamic lubrication does not depend upon the
introduction of the lubricant under pressure, though that may
occur; but it does require the existence of an adequate supply at
all times. Hydrodynamic lubrication is also called full-film or
fluid, lubrication.
The thinner the oil, then generally the greater the ease with
which shearing can take place. In this type of lubrication
viscosity is the important property, because it is the friction
between the oil layers, which reduces the mechanical friction.
In this type of lubrication a measurable quantity of oil is retained

between the mating surfaces. In this form of lubrication the oil
comprises three distinct layers, with the two outer layers of oil
clinging to their respective surfaces. The central layer consists
of molecules of oil, which are continuously being torn apart from
each other or sheared as the mating parts move.

7.11 - 6

Rev. 00
Mar 2014
Category A/B1
Boundary lubrication; In this situation the oil film between

mating parts are only a few molecules thick. Viscosity is not
important factor; the important factor is Oiliness. This is
ability of oil to cling together (cohesiveness) and stick to
surfaces (adhesiveness).
the
the
the
the
Hydrostatic lubrication is obtained by introducing the

lubricant, which is air into the load bearing area at a pressure
high enough to separate the surfaces with a relatively thick film
of lubricant.
So unlike hydrodynamic lubrication, this kind of lubrication does
not require motion of one surface relative to another.
Effect on coefficient of friction

7.11 - 7

Rev. 00
Mar 2014

Category A/B1

Solid film lubrication is the use of suitable grease for

lubrication purposes. When parts are operated at extreme
temperatures, a lubricant such as graphite or molybdenum
disulfide must be used because the ordinary mineral greases
are not satisfactory.

7.11 - 8

Rev. 00
Mar 2014
Category A/B1
DEFECTS IN BEARINGS AND THEIR CAUSES
Peeling
In general, if rolling bearings are used correctly, they will survive

to their predicted fatigue life. Bearings, however, often fail
prematurely due to avoidable mistakes. The causes of, this
premature failure include improper mounting, mishandling, poor
lubrication, entry of foreign matter or abnormal heat generation.
For example, one cause of premature failure is rib scoring which
is due to insufficient lubrication, use of improper lubricant, faulty
lubrication system, entry of foreign matter, bearing mounting
error, excessive deflection of the shaft or some combination of
these. Examples of bearing damage and their causes are
presented in the following sections. Please consult these
sections when trying to determine the cause of bearing damage.
Damage condition
Flaking
Dull or cloudy spots appear on surface along with light wear.

From such dull spots, tiny cracks are generated downward to a
depth of 5-10 m. Small particles fall off and minor flaking
occurs widely.
Causes
Unsuitable lubricant
Entry of debris into lubrication
Rough surface due to poor lubrication
Surface roughness of mating rolling parts.
Damage condition
Scoring
Flaking occurs when small pieces of bearing material are split
off from the smooth surface of the raceway or rolling elements
due to rolling fatigue, thereby creating regions having rough and
coarse texture.
Causes
Excessive load; Poor mounting (misalignment); Moment load;
Entry of foreign debris, water penetration; Poor lubrication,
improper lubricant; Unsuitable bearing clearance; Improper
precision for shaft or housing, unevenness in housing rigidity,
large shaft bending; Progression from rust, corrosion pits,
smearing, dents (brinelling).
7.11 - 9
Damage condition
Scoring is surface damage due to accumulated small seizures
caused by sliding under improper lubrication or severe
operating conditions. Linear damage appears circumferentially
on the raceway and roller surfaces. Cyclical shaped damage on
the roller ends and scoring on the rib surface contacting roller
ends also occur.

Rev. 00
Mar 2014
Category A/B1
Causes
Fracture
Poor lubrication
Damage condition
Particles are caught in the surface
Inclination of inner and outer rings
Fracture refers to small pieces, which were broken off due to

excessive load or shock load acting locally on a roller corner or
rib of a raceway ring.
Shaft bending
Causes
Poor precision of the shaft and housing
Smearing
Impact during mounting
Excessive load
Poor handling such as dropping
Damage condition
Smearing is surface damage, which occurs from a collection of
small seizures between bearing components caused by oil film
rupture and sliding.
Surface roughening occurs along with melting.
High speed and light load
Sudden acceleration/deceleration
Improper lubricant
Entry of water

7.11 - 10
Cracks
Damage condition
Cracks in the raceway ring and rolling elements. Continued use
under this condition leads to larger cracks or fractures.
Possible causes
Excessive interference
Excessive load, shock load
Progression of flaking
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Mar 2014
Category A/B1
Heat generation and fretting caused by contact between

mounting parts and raceway ring
Heat generation due to creep
Poor taper angle of tapered shaft
Poor cylindricality of shaft
Interference with bearing chamfer due to a large shaft

corner radius
Causes
Poor mounting (Bearing misalignment)
Poor handling
Large moment load
Shock and large vibration
Excessive rotation speed, sudden acceleration and

deceleration
Poor lubrication
Temperature rise
Cage damage
Damage condition
Cage damage includes:
Cage deformation, fracture and wear
Denting
Fracture of cage pillars
Damage condition possible causes
Deformation of side face
Wear of pocket surface
Wear of guide surface
When debris such as small metallic particles is caught in the

rolling contact zone, denting occurs on the raceway surface or
rolling element surface. Denting can occur at the rolling element
pitch interval if there is a shock during the mounting (brinell
dents).

7.11 - 11

Rev. 00
Mar 2014
Category A/B1
Causes
Causes
Debris such as metallic particles are caught in

surface
the
Entry of debris
Progression from rust and electrical arcing
Excessive load
Poor lubrication
Shock during transport or mounting
Sliding due to irregular motion of rolling elements
Fretting
Pitting
Damage condition
Pitting has a dull luster and appears on the rolling element
surface or raceway surface.
Causes
Debris becomes caught in the lubricant
Exposure to moisture in Poor lubrication
Damage condition
Wear occurs due to repeated sliding between the two surfaces.
Fretting occurs at fitting surface and also at contact area
between raceway ring and rolling elements.
Fretting corrosion is another term used to describe the reddish
brown or black worn particles.
Causes
Wear
Poor lubrication
Vibration with a small amplitude
Insufficient interference
Damage condition
Wear is surface deterioration due to sliding friction at the
surface of the raceway, rolling elements, roller end faces, rib
face, cage pockets, etc.
7.11 - 12

Rev. 00
Mar 2014
Category A/B1
False brinelling
Causes
Damage condition
Insufficient interference or loose fit
Among the different types of fretting, false brinelling is the

occurrence of hollow spots that resemble brinell dents and are
due to wear caused by vibration and swaying at the contact
points between the rolling elements and raceway.
Insufficient sleeve tightening
Seizure
Causes
Damage condition
Oscillation and vibration of a stationary bearing during

such times as transporting
Oscillating motion with a small amplitude
When sudden overheating occurs during rotation, the bearing

becomes discolored. Then, the raceway rings, rolling elements,
and cage will soften, melt and deform
as damage accumulates.
Poor lubrication
Causes
Creep
Poor lubrication
Damage condition
Excessive load (Excessive preload)
Creep is the phenomenon in bearings where relative slippage

occurs between fitting surfaces and thereby creates a clearance
between them surface. Creep causes a shiny appearance,
occasionally with scoring or wear.
Excessive rotational speed
Excessively small internal clearance
Entry of water and debris
Poor precision of shaft and housing Excessive shaft

bending

7.11 - 13

Rev. 00
Mar 2014

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