Analysis of the reasons for KOYO bearing failure

**Analysis of the Reasons for KOYO Bearing Failure** Home > Bearing Knowledge > Analysis of the Reasons for KOYO Bearing Failure *Source: China Bearing Network | Date: September 15, 2013* During the grinding process of KOYO bearings, a significant amount of energy is consumed in the contact area between the grinding wheel and the workpiece. This leads to the generation of high temperatures within the grinding zone, which can reach up to 1000–1500°C. These extreme conditions can cause various microstructural changes in the bearing surface, including oxidation, amorphous arrangement, high-temperature tempering, secondary quenching, and even cracking. 1. **Oxide Layer Formation** The high temperature during grinding causes the formation of an oxide layer on the surface of the bearing. This thin layer, typically 20–30 nm thick, is composed of iron oxide. The thickness of this oxide layer is directly related to the grinding process and serves as an important indicator of the quality of the grinding operation. 2. **Amorphous Structure** The intense heat generated during grinding can melt the surface material, leading to a rapid cooling process. This results in a very thin layer of amorphous structure, approximately 10 nm thick. Although this layer exhibits high hardness and wear resistance, it can be easily removed during fine grinding. 3. **High-Temperature Tempering** The grinding heat can also cause a high-temperature tempering effect at a certain depth beneath the surface (10–100 nm). This layer may not reach the austenitizing temperature but still undergoes structural changes, resulting in reduced hardness. The higher the temperature, the more pronounced the softening effect. 4. **Secondary Quenching** If the grinding process raises the surface temperature above the austenitizing point (Ac1), the material may undergo secondary quenching, forming a martensitic structure. However, this layer is usually accompanied by a high-temperature tempering zone, which further affects the mechanical properties of the bearing. 5. **Grinding Cracks** Secondary quenching can lead to stress changes on the bearing surface. The quenched region experiences compressive stress, while the tempered region is under tensile stress. This stress concentration makes the bearing susceptible to cracking, especially along the original austenite grain boundaries. In severe cases, the entire surface may develop cracks. In addition to these internal factors, external signs such as unusual rolling sounds, excessive oscillation, and abnormal temperature rise are also key indicators of potential bearing failure. Monitoring these parameters can help identify early signs of damage and prevent catastrophic failure. **Checking Rolling Sounds** A sound meter can detect irregular or abnormal noises from the bearing, which may indicate minor damage such as peeling or deformation. **Measuring Oscillation** Bearing oscillation is highly sensitive to damage. Any issues such as pitting, indentation, rust, or cracks will affect the oscillation readings. Specialized equipment like frequency analyzers can measure and analyze these vibrations effectively. **Temperature Monitoring** The operating temperature of the bearing is another critical factor. Normally, the temperature rises gradually during operation and stabilizes after 1–2 hours. If the temperature increases rapidly or exceeds normal limits, it may signal a problem. Thermal sensors can continuously monitor the temperature and trigger alarms or shut down the system when necessary. **Smoothness and Wear** Smoothness plays a vital role in the performance and lifespan of rolling bearings. Poor smoothness can lead to increased friction, wear, and heat generation. Studies show that around 40% of bearing failures are related to improper smoothness. Ensuring proper lubrication and surface finish is essential for reducing wear and extending bearing life. **Related Articles** - Bearing Heat Treatment Methods in Foreign Machinery Industry - Understanding VSI’s Advanced Constant Temperature System for Bearings - SKF Bearing Accuracy Grade Selection for High-Speed Applications For more information on bearings and their maintenance, visit [China Bearing Network](http://www.chinabearing.net). Previous: Rolling Bearing Judgment Method Next: Data Function Analysis of the Inner Ring and Rolling Elements

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