Bearing Maintenance Training Manual: Types, Installation, Removal

MECHANICAL MAINTENANCE
BEARINGS
TRAINING MANUAL
COURSE EXP-MN-SM060
Revision 0

Field Operations Training
Mechanical Maintenance
Bearings
Training Manual EXP-MN-SM060-EN
Last revised: 17/10/2008 Page 2 / 110
MECHANICAL MAINTENANCE
BEARINGS
CONTENTS
1. OBJECTIVES ..................................................................................................................5
2. BASIC NOTIONS.............................................................................................................6
2.1. DEFINITION OF BEARINGS ....................................................................................6
2.2. WHAT PURPOSE DOES A BEARING SERVE? ITS ROLE.....................................7
2.3. BEARING VOCABULARY.........................................................................................8
2.3.1. Vocabulary used in a bearing assembly............................................................9
2.3.2. Ball and roller bearing vocabulary ...................................................................10
2.3.3. Thrust bearing vocabulary...............................................................................11
2.4. THE VARIOUS LOADS ACTING ON BEARINGS...................................................12
2.4.1. Loads on ball bearings ....................................................................................13
2.4.2. Loads on roller bearings..................................................................................15
3. MANUFACTURING A BALL BEARING.........................................................................16
3.1. THE MATERIALS....................................................................................................16
3.1.1. Steel................................................................................................................16
3.1.2. Ceramics.........................................................................................................16
3.1.3. Other materials................................................................................................17
3.2. THE MANUFACTURING METHODS......................................................................17
3.2.1. Manufacture of inner and outer bushings........................................................18
3.2.1.1. Machining...................................................................................................18
3.2.1.2. Heat treatment ...........................................................................................19
3.2.1.3. Grinding......................................................................................................19
3.2.1.4. Superfinishing ............................................................................................20
3.2.2. Manufacturing the balls ...................................................................................20
3.2.2.1. Punching....................................................................................................21
3.2.2.2. Rough machining of the balls.....................................................................21
3.2.2.3. Heat treatment ...........................................................................................22
3.2.2.4. Grinding on milling grinder .........................................................................22
3.2.2.5. Honing........................................................................................................22
3.2.2.6. Washing.....................................................................................................23
3.2.2.7. Final inspection..........................................................................................23
3.2.3. Manufacturing of tapered rollers......................................................................23
3.2.3.1. Die forging (punching)................................................................................24
3.2.3.2. Deburring in barrels....................................................................................24
3.2.3.3. Heat treatment ...........................................................................................24
3.2.3.4. Diameter grinding.......................................................................................24
3.2.3.5. Face grinding .............................................................................................25
3.2.3.6. Convex grinding.........................................................................................25
3.2.3.7. Washing.....................................................................................................25
3.2.3.8. Final inspection..........................................................................................25
3.2.4. Manufacturing of cages...................................................................................26
3.2.5. Final assembly (ball bearings).........................................................................26
4. THE DIFFERENT TYPES OF BEARINGS (the most widely used)................................28

Field Operations Training
Mechanical Maintenance
Bearings
Training Manual EXP-MN-SM060-EN
Last revised: 17/10/2008 Page 3 / 110
4.1. BALL BEARINGS....................................................................................................28
4.1.1. Rigid radial contact bearings...........................................................................30
4.1.2. Angular contact ball bearings..........................................................................31
4.1.3. Swivel bearing son balls..................................................................................32
4.2. ROLLER BEARINGS ..............................................................................................33
4.2.1. Cylindrical roller bearings................................................................................33
4.2.2. Tapered roller bearings ...................................................................................34
4.2.3. Bearings on spherical roller swivel ..................................................................35
4.3. NEEDLE BEARINGS ..............................................................................................35
4.3.1. Cages with one or two rows of needles...........................................................36
4.3.2. Needle socket..................................................................................................36
4.3.3. Needle bearings..............................................................................................37
4.4. RECAP OF THE TYPES OF BEARINGS................................................................38
5. THRUST BEARINGS.....................................................................................................40
5.1. BALL THRUST BEARINGS ....................................................................................40
5.2. ROLLER THRUST BEARINGS...............................................................................40
6. BEARING BLOCKS.......................................................................................................42
6.1. TWO-PART BEARING BLOCK...............................................................................42
6.2. SELF-ALIGNING BEARING BLOCKS ....................................................................43
6.3. INTEGRATED BEARINGS......................................................................................45
7. BEARING INSTALLATION............................................................................................46
7.1. PRINCIPLE OF BEARING ASSEMBLY..................................................................46
7.1.1. "Rotating shaft" installation..............................................................................46
7.1.2. Rotating housing installation (fixed shaft)........................................................47
7.1.3. Angular contact bearings.................................................................................47
7.1.3.1. "X" installation............................................................................................47
7.1.3.2. "O" installation............................................................................................49
7.1.4. Bearing fitting ..................................................................................................50
7.2. HANDLING BEARINGS..........................................................................................52
7.3. INSTALLING BEARINGS........................................................................................53
7.3.1. Cold tight-fit (bushing on shaft)........................................................................55
7.3.2. Hot tight-fit.......................................................................................................56
7.3.2.1. Induction heating........................................................................................56
7.3.2.2. Oil bath heating..........................................................................................57
7.3.2.3. Heating on a hotplate.................................................................................58
7.3.3. Combined hot / cold method............................................................................58
7.3.3.1. Inner bushing with tight fit...........................................................................58
7.3.3.2. Outer bushing with tight fit..........................................................................59
7.3.3.3. Two bushings with tight fit..........................................................................60
7.3.4. Some installation applications.........................................................................61
7.4. REMOVAL...............................................................................................................62
7.4.1. Bearing tight-fitted on the shaft........................................................................64
7.4.2. Bearing tight-fitted in the housing....................................................................64
7.4.3. Bearing tight-fitted on its shaft and in its housing............................................64
7.4.4. Some examples of removal.............................................................................65
7.5. IMMOBILISING BEARINGS....................................................................................66
7.5.1. Examples of axial immobilisation of outer bushings........................................69
7.5.2. Examples of axial immobilisation of inner bushings ........................................70

Field Operations Training
Mechanical Maintenance
Bearings
Training Manual EXP-MN-SM060-EN
Last revised: 17/10/2008 Page 4 / 110
7.5.2.1. In the middle of the shaft............................................................................70
7.5.2.2. On the end of the shaft...............................................................................71
7.5.3. Tightening nut and lock washer.......................................................................72
7.5.3.1. Tightening nut ............................................................................................72
7.5.3.2. Lock washer...............................................................................................72
8. LUBRICATION METHODS............................................................................................73
8.1. LUBRICATION WITH GREASE..............................................................................73
8.1.1. Grease selection criteria..................................................................................75
8.1.2. Compatibility between greases........................................................................75
8.1.3. Manual greasing method.................................................................................76
8.1.4. Automatic greasing method.............................................................................78
8.1.5. Advantages and drawbacks ............................................................................79
8.2. LUBRICATION WITH OIL.......................................................................................80
8.2.1. By oil mist........................................................................................................81
8.2.2. By oil circulation ..............................................................................................82
8.2.3. By trickling and projection................................................................................83
8.2.4. By oil bath........................................................................................................83
8.2.5. Lost oil.............................................................................................................83
8.2.6. Automatic gravity oilers ...................................................................................84
8.2.7. Advantages and drawbacks ............................................................................84
8.3. LUBRICATION WITH SOLID OIL............................................................................84
9. BEARING SERVICE LIFE .............................................................................................86
10. BEARING MAINTENANCE..........................................................................................88
10.1. MEASUREMENT OF THE VIBRATIONS..............................................................88
10.2. LUBRICATION AND MAINTENANCE...................................................................88
10.3. MONITORING AND MAINTENANCE ...................................................................91
10.3.1. Bearing damage............................................................................................91
10.3.2. Aspects of deterioration.................................................................................92
10.3.2.1. Fatigue chipping.......................................................................................92
10.3.2.2. Surface chipping ......................................................................................93
10.3.2.3. Seizing .....................................................................................................93
10.3.2.4. Deformation imprint..................................................................................93
10.3.2.5. Wear ........................................................................................................93
10.3.2.6. Craters and grooves.................................................................................94
10.3.2.7. Impacts, cracks, breakages......................................................................94
10.3.2.8. Contact corrosion.....................................................................................94
10.3.2.9. Corrosion..................................................................................................94
10.3.2.10. Damage to the cages.............................................................................95
10.3.3. Origins of damage.........................................................................................95
11. EXERCISES................................................................................................................98
12. GLOSSARY...............................................................................................................102
13. LIST OF FIGURES ....................................................................................................103
14. LIST OF TABLES ......................................................................................................107
15. ANSWERS TO THE EXERCISES.............................................................................108

Field Operations Training
Mechanical Maintenance
Bearings
Training Manual EXP-MN-SM060-EN
Last revised: 17/10/2008 Page 5 / 110
1. OBJECTIVES
By the end of this presentation, the mechanic (or future mechanic) will :
Be able to adopt the appropriate approach to the different types of bearings
Have acquired a basic understanding of the main problems encountered with
bearings.