Predicting the abrasive wear of ball bearings by lubricant debris

Abstract

Solid debris particles in a lubricant can become entrained into the contacts of ball bearings. The particles damage the bearing surfaces. This can lead to rolling contact fatigue failure or material loss by three body abrasion. This work concentrates on modelling the later process for brittle debris materials. A brittle particle is crushed in the inlet region and the fragments are entrained into the contact. Rolling bearing contacts (because of the high degree of conformity) are subject to contact microslip. When this slip takes place, the trapped particle scratches the bearing surfaces. Repeated scratching by many particles results in substantial material removal. Although this failure mechanism is usually not as rapid as debris initiated fatigue, it is frequently important in mineral handling or desert environment rolling bearing applications. A simple model has been developed which considers the wear as the sum of the individual actions of each particle. The number of debris particles is determined by considering the volume of oil entrained into the bearing contacts and an empirically derived `particle entry ratio'. The abrasive action of each particle is determined by the volume of material displaced during sliding and another empirical factor for the proportion of this removed as a wear particle. The predictions are compared with some experimental results. The correlation between bearing wear and the debris particle size is encouraging.