Analysis of the Reasons for KOYO Bearing Failure

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KOYO bearings are widely used in industrial applications due to their high performance and reliability. However, like any mechanical component, they can fail under certain conditions. Understanding the causes of failure is essential for improving maintenance practices and extending bearing life. One of the primary causes of KOYO bearing failure is the heat generated during the grinding process. The contact area between the grinding wheel and the workpiece generates a significant amount of energy, resulting in high temperatures—often reaching up to 1000–1500°C in the grinding zone. This intense heat can lead to various forms of damage, including oxidation, amorphous structures, tempering, quenching, and even cracking. 1. **Oxide Layer Formation**: The high temperature causes oxygen from the air to react with the steel surface, forming a thin layer of iron oxide (about 20–30 nm thick). The thickness of this oxide layer is closely related to the grinding quality and can serve as an indicator of the grinding process's effectiveness. 2. **Amorphous Structure**: When the temperature is high enough, the material may partially melt. As it cools rapidly, a very thin layer of amorphous structure is formed, which has high hardness but is easily removed during fine grinding. 3. **High-Temperature Tempering**: The heat from grinding can cause a layer beneath the surface to undergo high-temperature tempering. This reduces the hardness of the material, especially at greater depths (10–100 nm), depending on the temperature reached. 4. **Secondary Quenching**: If the surface temperature exceeds the austenitizing temperature (Ac1), the material may transform into martensite upon cooling. However, secondary quenching often results in a high-temperature tempering layer beneath it, leading to further changes in microstructure and properties. 5. **Cracking Due to Stress**: Secondary quenching can create stress variations on the bearing surface. The quenched area experiences compressive stress, while the tempered area experiences tensile stress, making it more prone to cracks. These cracks tend to propagate along the original austenite grain boundaries. In addition to thermal effects, other factors such as improper lubrication, misalignment, and contamination can also contribute to bearing failure. Monitoring the bearing’s sound, vibration, and temperature is crucial for early detection of potential issues. - **Sound Analysis**: Even minor damage, such as flaking or wear, can produce abnormal sounds. Using a sound meter to check the rolling noise helps identify early signs of failure. - **Vibration Measurement**: Bearings are highly sensitive to damage. Issues like pitting, indentation, rust, or cracks can be detected through vibration analysis using specialized equipment like frequency analyzers. - **Temperature Monitoring**: Normal bearing operation involves a gradual temperature rise, stabilizing after 1–2 hours. A sudden increase in temperature may indicate a problem. Thermal sensors can provide real-time monitoring, triggering alarms or shutdowns when necessary. - **Lubrication and Smoothness**: Proper lubrication is critical for reducing friction, wear, and heat generation. Studies show that about 40% of bearing failures are linked to poor smoothness. Ensuring optimal lubrication and surface finish significantly improves bearing performance and lifespan. By understanding these failure mechanisms and implementing regular maintenance and monitoring, the service life of KOYO bearings can be extended, ensuring reliable performance in industrial applications.

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**Related Articles** - Bearing Heat Treatment Methods in Foreign Machinery Industry - How VSI's Constant Temperature System Ensures Reliable Bearing Operation - SKF Bearing Accuracy Grade Selection for High-Speed Applications This article is sourced from China Bearing Network. Link: http://www.chinabearing.net Previous: Rolling Bearing Judgment Method Next: Data Function Analysis of the Raceway and Rolling Elements

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