Whether it’s in heavy machinery, automobiles, or domestic appliances, bearings handle massive loads, reduce friction, and ensure smooth operation. But when a bearing fails, it can bring entire operations to a grinding halt. At ZNL Bearings, we understand how crucial reliable bearings are to your systems. That’s why we’ve put together this comprehensive guide to help you identify common bearing issues—and more importantly, how to fix them before they escalate.
1. Lubrication Failure
Problem:
Lubrication-related issues remain one of the leading causes of bearing failure. Whether it’s the wrong lubricant, contamination, or insufficient re-lubrication, the result is increased friction, overheating, and ultimately, bearing damage.
Signs:
- Unusual noise or vibration
- Excessive heat during operation
- Visual signs of lubricant contamination or drying out
Fix:
- Always use the recommended type and amount of lubricant for the application.
- Follow a scheduled lubrication routine.
- Ensure that the lubricant is clean and contaminant-free.
- In workspaces with frequent exposure to dust or moisture, opt for sealed bearing options.
Pro Tip from ZNL: For longer service life, opt for our pre-lubricated sealed bearings, especially in harsh industrial environments.
2. Misalignment
Problem:
Misaligned shafts or housings can lead to uneven load distribution across the bearing, causing excessive stress on one side.
Signs:
- Uneven wear marks on the bearing
- Increased vibration and noise
- Reduced bearing lifespan
Fix:
- Ensure accurate shaft and housing alignment during installation. To achieve precision, use tools like laser aligners or dial indicators, which help maintain proper positioning within acceptable limits.
ZNL Tip: Our self-aligning ball bearings and spherical roller bearings are engineered to compensate for shaft misalignments and minimize wear, ensuring smooth and reliable performance.
3. Contamination
Problem:
Foreign particles such as dust, moisture, and metal shavings can infiltrate bearings, leading to surface damage on the raceways and rolling components over time.
Signs:
- Pitted or scratched surfaces
- Bearing noise increases
- Sudden failure despite regular maintenance
Fix:
- Ensure the work environment and tools are clean and dry.
- Use protective seals or shields to prevent contamination.
- To prevent contamination, always handle and store bearings with care. Keep them in clean, dry conditions and use protective packaging until installation.
Maintenance Reminder: Always inspect bearings before installation. Even tiny particles can cause major issues.
4. Overloading
Problem:
Bearings have load limits. When they’re exposed to higher-than-rated loads—either due to improper selection or sudden operational shocks—they can fail prematurely.
Signs:
- Deformation of raceways or rolling elements
- Early fatigue or cracking
- Excessive temperature rise
Fix:
- Choose the correct bearing type and size for the load and speed requirements.
- Use load-reducing components such as dampers or shock absorbers if applicable.
- Consult with ZNL experts for selecting high-load capacity bearings.
Did You Know? ZNL’s spherical roller bearings are designed to handle heavy radial and axial loads, making them ideal for tough operating conditions.
5. Improper Mounting
Problem:
Incorrect installation methods—such as forcing the bearing onto a shaft or using improper tools—can lead to structural damage inside the bearing.
Signs:
- Bearing noise or vibration from the start
- Poor alignment and premature failure
- Visual damage like cracked rings or dents
Fix:
- Always rely on the correct tools for mounting bearings, such as induction heaters, fitting kits, or hydraulic nuts, to ensure safe and precise installation.
- Never apply force directly to the rolling elements.
- Follow the manufacturer’s guidelines for installation.
Helpful Tip: When you’re having trouble removing a bearing, try applying heat with an induction heater to gently expand the inner ring. This technique makes removal smoother and reduces the risk of damaging surrounding components.
6. Electrical Damage (EDM Pitting)
Problem:
When unwanted electrical currents pass through a bearing, they can create microscopic sparks, resulting in small pits or grooves on the rolling elements and raceways—gradually leading to bearing damage and failure.
Signs:
- Craters or fluting marks on the bearing surface
- Increased noise
- Shortened bearing life in electric motors
Fix:
- Use electrically insulated bearings in motors.
- Ensure proper grounding of equipment.
- Avoid stray currents through the shaft.
Insulated bearings, specially developed for applications prone to electrical leakage and stray currents.
7. Fatigue (Spalling)
Problem:
Fatigue occurs when a bearing is used beyond its expected life or in extreme conditions. Over time, material flakes away from the surface, creating rough and pitted areas.
Signs:
- Spalling on raceways or rolling elements
- Vibration and noise increase
- Gradual loss of performance
Fix:
- Monitor bearing temperature, vibration, and lubrication regularly.
- Replace bearings as part of preventive maintenance before they reach their fatigue limit.
- Avoid overloading and excessive operating speeds.
Conclusion
Bearings are engineered for high performance—but only when treated right. With proper selection, installation, and maintenance, bearing issues can be minimized, if not completely avoided.
At ZNL Bearings, we combine global manufacturing standards with deep industry experience to deliver reliable, high-quality bearings built for performance. Whether it’s deep groove ball bearings, spherical roller bearings, or custom-engineered solutions — we’ve got the perfect fit for every need.
Facing frequent bearing failures? Don’t just replace—fix the root cause. Need expert advice tailored to your needs? The team at ZNL Bearings is here to help with customized solutions and dependable technical support designed to keep your operations running efficiently.
Stay smooth. Stay moving. Stay ZNL.
