False brinelling is a bearing damage caused by fretting, with or without corrosion, [1] that causes imprints that look similar to brinelling, but are caused by a different mechanism. False brinelling may occur in bearings which act under small oscillations [2] or vibrations. [3]
The basic cause of false brinelling is that the design of the bearing does not have a method for redistribution of lubricant without large rotational movement of all bearing surfaces in the raceway. [4] Lubricant is pushed out of a loaded region during small oscillatory movements and vibration where the bearings surfaces repeatedly do not move very far. [5] Without lubricant, wear is increased when the small oscillatory movements occur again. It is possible for the resulting wear debris to oxidize and form an abrasive compound which further accelerates wear.
In normal operation, a rolling-element bearing has the rollers and races separated by a thin layer of lubricant such as grease or oil. [6] [7] [8] Although these lubricants normally appear liquid (not solid), under high pressure they act as solids and keep the bearing and race from touching. [9] [10]
If the lubricant is removed, the bearings and races can touch directly. While bearings and races appear smooth to the eye, they are microscopically rough. Thus, high points of each surface can touch, but "valleys" do not. The bearing load is thus spread over much less area increasing the contact stress, [11] causing pieces of each surface to break off or to become pressure-welded then break off when the bearing rolls on.
The broken-off pieces are also called wear debris. Wear debris is bad because it is relatively large compared to the surrounding surface finish and thus creates more regions of high contact stress. Worse, the steel in ordinary bearings can oxidize (rust), [12] producing a more abrasive compound which accelerates wear.
The simulation of false brinelling is possible with the help of the finite element method. For the simulation, the relative displacements (slip) between rolling element and raceway as well as the pressure in the rolling contact are determined. For comparison between simulation and experiments, the friction work density is used, which is the product of friction coefficient, slip and local pressure. The simulation results can be used to determine critical application parameters or to explain the damage mechanisms. [13]
Physical simulation of the false brinelling mechanism has been standardized since the 1980's in the Fafnir Bearing test instrument, where two sets of thrust ball bearings are compressed with a fixed load, and the bearings are oscillated by an excentric arm under standardised conditions. This culminated in the ASTM D4170 standard. [14] [15] Although an old method, this is still the leading quality control method for greases that need to avoid the false brinelling damage.
False brinelling was first mentioned by Almen in 1937. [16] Almen found that wheel bearings were damaged before they were used by customers. Furthermore, he found that the bearings were more damaged for long-distance shipping of the cars and that the season of shipping also had an influence. The reason for the damaged bearings were micro-oscillations [17] which occurred due to the shipping. The small oscillations result in fatigue cracking, followed by release of particles that subsequently start to abrasively damage the contact area between a ball and the bearing race, resulting in a typical wear damage. Because the damage has a similar look to brinelling, it was called false brinelling. [18]
Although the car-delivery problem has been solved, there are many modern examples. A major maintenance problem are the pitch bearings in wind turbines, for which specialty greases had to be developed that result in almost no false brinelling damage. [19] [20] Similar damage may also occur in electric and electronic contacts that are subjected to vibrations during use, think of aerospace and automotive connectors and even remote control battery compartments. Although the damage in these areas may not be as severe as the false brinelling in bearings, the damage mechanisms are similar and result in the creation of particles in the contact that can severely influence the electrical connection.
Also, generators or pumps may fail or need service because of this damage, so it is common to have a nearby spare unit which is left off most of the time but brought into service when needed. Surprisingly, however, vibration from the operating unit can cause bearing failure in the unit which is switched off. When that unit is turned on, the bearings may be noisy due to damage, and may fail completely within a few days or weeks [21] [22] even though the unit and its bearings are otherwise new. Common solutions include: keeping the spare unit at a distance from the one which is on and vibrating; manually rotating shafts of the spare units on a regular (for example, weekly) basis; or regularly switching between the units so that both are in regular (for example, weekly) operation.
Until recently, bicycle headsets tended to suffer from false brinelling in the "straight ahead" steering position, due to small movements caused by flexing of the fork. Good modern headsets incorporate a plain bearing to accommodate this flexing, leaving the ball race to provide pure rotational movement. [ citation needed ]
A lubricant is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces. The property of reducing friction is known as lubricity.
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings. Thus, it is possible for some fluid bearings to have near-zero wear if operated correctly.
A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.
Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology.
Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical or chemical. The study of wear and related processes is referred to as tribology.
Tribology is the science and engineering of understanding friction, lubrication and wear phenomena for interacting surfaces in relative motion. It is highly interdisciplinary, drawing on many academic fields, including physics, chemistry, materials science, mathematics, biology and engineering. The fundamental objects of study in tribology are tribosystems, which are physical systems of contacting surfaces. Subfields of tribology include biotribology, nanotribology and space tribology. It is also related to other areas such as the coupling of corrosion and tribology in tribocorrosion and the contact mechanics of how surfaces in contact deform. Approximately 20% of the total energy expenditure of the world is due to the impact of friction and wear in the transportation, manufacturing, power generation, and residential sectors.
A plain bearing, or more commonly sliding contact bearing and slide bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore, the part of the shaft in contact with the bearing slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.
In mechanical engineering, a rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing rolling elements between two concentric, grooved rings called races. The relative motion of the races causes the rolling elements to roll with very little rolling resistance and with little sliding.
Fretting refers to wear and sometimes corrosion damage of loaded surfaces in contact while they encounter small oscillatory movements tangential to the surface. Fretting is caused by adhesion of contact surface asperities, which are subsequently broken again by the small movement. This breaking causes wear debris to be formed.
The Stribeck curve is a fundamental concept in the field of tribology. It shows that friction in fluid-lubricated contacts is a non-linear function of the contact load, the lubricant viscosity and the lubricant entrainment speed. The discovery and underlying research is usually attributed to Richard Stribeck and Mayo D. Hersey, who studied friction in journal bearings for railway wagon applications during the first half of the 20th century; however, other researchers have arrived at similar conclusions before. The mechanisms along the Stribeck curve have been in parts also understood today on the atomistic level.
Dry lubricants or solid lubricants are materials that, despite being in the solid phase, are able to reduce friction between two surfaces sliding against each other without the need for a liquid oil medium.
Brinelling is the permanent indentation of a hard surface. It is named after the Brinell scale of hardness, in which a small ball is pushed against a hard surface at a preset level of force, and the depth and diameter of the mark indicates the Brinell hardness of the surface. Brinelling is permanent plastic deformation of a surface, and usually occurs while two surfaces in contact are stationary and the material yield strength has been exceeded.
Space tribology is a discipline in the field of tribology which deals with tribological systems for spacecraft applications. Research in the field aims to design reliable tribological systems that can withstand the harsh environment of space.
Spiral groove bearings are self-acting, or hydrodynamic bearings used to reduce friction and wear without the use of pressurized lubricants. They have this ability due to special patterns of grooves. Spiral groove bearings are self-acting because their own rotation builds up the pressure needed to separate the bearing surfaces. For this reason, they are also contactless bearings.
The pitch bearing, also named blade bearing, is a component of modern wind turbines which connect the rotor hub and the rotor blade. The bearing allows the required oscillation to control the loads and power of the wind turbine. The pitch system brings the blade to the desired position by adapting the aerodynamic angle of attack. The pitch system is also used for emergency breaks of the turbine system.
DN factor, also called DN Value, is a number that is used to determine the correct base oil viscosity for the lubrication of various types of bearings.
Extreme tribology refers to tribological situations under extreme operating conditions which can be related to high loads and/or temperatures, or severe environments. Also, they may be related to high transitory contact conditions, or to situations with near-impossible monitoring and maintenance opportunities. In general, extreme conditions can typically be categorized as involving abnormally high or excessive exposure to e.g. cold, heat, pressure, vacuum, voltage, corrosive chemicals, vibration, or dust. The extreme conditions should include any device or system requiring a lubricant operating under any of the following conditions:
White etching cracks (WEC), or white structure flaking or brittle flaking, is a type of rolling contact fatigue (RCF) damage that can occur in bearing steels under certain conditions, such as hydrogen embrittlement, high stress, inadequate lubrication, and high temperature. WEC is characterised by the presence of white areas of microstructural alteration in the material, which can lead to the formation of small cracks that can grow and propagate over time, eventually leading to premature failure of the bearing. WEC has been observed in a variety of applications, including wind turbine gearboxes, automotive engines, and other heavy machinery. The exact mechanism of WEC formation is still a subject of research, but it is believed to be related to a combination of microstructural changes, such as phase transformations and grain boundary degradation, and cyclic loading.
Rolling Contact Fatigue (RCF) is a phenomenon that occurs in mechanical components relating to rolling/sliding contact, such as railways, gears, and bearings. It is the result of the process of fatigue due to rolling/sliding contact. The RCF process begins with cyclic loading of the material, which results in fatigue damage that can be observed in crack-like flaws, like white etching cracks. These flaws can grow into larger cracks under further loading, potentially leading to fractures.