Why Industrial Bearings Fail: Analysis, Maintenance, and Prevention

Bearings are essential machine elements used to constrain motion and reduce friction between moving parts. They are used extensively in global industries, but can fail prematurely, causing downtime, damages, and lost productivity. This work presents a collection of case studies in various industries where bearings have failed, using root cause failure analysis to explore topics such as alignment, lubrication, manufacturing defects, mounting practices, contamination, and fatigue. Preventive solutions are offered to avoid future problems.

Format: Paperback / softback
Length: 256 pages
Publication date: 03 August 2022
Publisher: Industrial Press Inc.,U.S.

A bearing is a crucial mechanical component employed across diverse industries to restrict motion and minimize friction between moving parts. Its widespread application spans automotive, construction, power generation, mechanical, chemical, mining, infrastructure, medical, and food sectors, among others. In 2021, the global bearing market was estimated to be worth $128 billion, and it is projected to grow to nearly $227 billion by 2028.

However, it is disheartening that bearings can fail, often at the most inconvenient moments. This failure can result in significant downtime, financial losses, reduced productivity, and other detrimental consequences. While modern precision manufacturing and maintenance practices have helped mitigate premature failures, they have not fully addressed the root causes of bearing failures.

This work presents a comprehensive collection of case studies from various industries where bearings have experienced failure. Each case study includes a detailed failure description, observations, potential reasons for the failure, plausible causes and effects, and discussions on mitigation strategies and preventive solutions. The author employs a root cause failure analysis approach, exploring topics such as alignment, lubrication, manufacturing defects, mounting practices, contamination, and fatigue. By analyzing these factors, the author elucidates how one or a combination of these issues contributed to the failure and offers preventive measures to avoid future problems.

Throughout the book, a classical root cause failure analysis approach is followed, consisting of nine steps: defining the problem, gathering information and input from various sources, locating evidence, identifying mistakes, using Ishikawa/Fishbone diagrams, getting to the root cause, implementing solutions, and evaluating the effectiveness of the solutions.

By presenting these case studies and applying the RCFA approach, this work aims to provide valuable insights into bearing failures and their prevention. It serves as a resource for engineers, technicians, and professionals involved in the maintenance and operation of bearings, helping them identify potential issues and implement effective solutions to ensure the reliability and longevity of mechanical systems.

In conclusion, bearings play a vital role in numerous industries, and their failure can have significant consequences. This work presents a comprehensive collection of case studies and an analytical approach to understanding and preventing bearing failures. By applying the RCFA approach and adopting preventive measures, we can enhance the reliability and efficiency of mechanical systems and minimize the impact of bearing failures on businesses and society as a whole.

Dimension: 254 x 178 x 25 (mm)
ISBN-13: 9780831136802