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# A Crucial Aspect of Bearing Maintenance
Even though bearings are among the toughest and most resilient components around, they can still succumb to wear-related problems.
If left unaddressed, worn-out bearings can lead to far bigger issues. Their failure often halts entire mechanical systems, necessitating repairs before operations can resume. To avoid such costly downtime, it's vital to understand the different sources of wear in rolling element bearings.
One significant factor is the operating speed of the mechanical system housing the bearings. High-speed applications are common in roller bearing setups, and maintaining them correctly helps protect against excessive wear that could cause system failure.
## The Risks of High Speeds
Excessive speed can impact bearing lifespan in several ways, with heat and friction being two of the most critical factors. High-speed operation accelerates wear in bearing systems that aren’t designed for it or are inadequately lubricated. Here are a few detrimental effects that can arise under these conditions:
### Churning
At high speeds, bearings can generate extremely high temperatures by churning through oil or grease. Lubrication is necessary to reduce the natural friction between two high-speed operating bearings. However, higher levels of bearing movement can cause a reduction in lubricant viscosity, a phenomenon known as churning. Continued bearing activity during churning leads to agitation, which can eventually cause the lubricant to fail and the bearings to overheat.
### Breakage
When operating at higher speeds, bearings accumulate greater inertial forces. If lubrication is insufficient or if there are sudden stops and starts, the forces between the retainer and the rolling bearings can grow significantly. Left unchecked, these inertial forces may cause retainers and bearing cages to break, resulting in system-wide failures.
### Slippage
Another issue arising from inadequate lubrication and higher speeds is slippage between the raceways and rolling elements. This typically happens when the lubricant coating is absent from bearing contact areas. When contact occurs at high speeds without lubricant, wear can happen rapidly. Tightly loaded bearings face the highest risk of slippage under such conditions.
## Solutions to Extend Service Life
While the above highlights the various challenges posed by high-speed operations, the solutions are relatively straightforward. Maximizing bearing longevity involves ensuring proper lubrication and making load adjustments when necessary.
### Lubrication: The Key to Longest Bearing Lifespan
Proper care ensures that bearings remain one of the most dependable components in any system. Issues like churning, breakage, and slippage can all be mitigated with proper lubrication.
It’s crucial to strike the right balance when lubricating bearing systems. Too much lubricant risks churning, while too little fails to adequately separate bearing parts. Adequate lubrication reduces bearing wear in high-speed settings, safeguarding against costly and potentially hazardous breakdowns.
Additionally, remember that lubrication has a finite service life. Subjected to mechanical stress and aging, lubricants lose viscosity and lubricity, leading to conditions like churning. Relubrication proves beneficial in such cases, minimizing wear during challenging industrial conditions.
### Adjusting Load and Bearing Size
Even with proper lubrication, wear from high-speed operation can still occur if the bearings aren't matched to the load requirements of the application. This can be resolved by either altering the system’s overall load—though this isn’t always feasible—or by using suitable bearings.
For instance, in cases of slippage, damage can happen when the load on the bearings is too light. Increasing the load under these circumstances reduces the likelihood of slippage. Alternatively, this problem can be mitigated by installing smaller bearings. These adjustments are highly effective in addressing issues arising from high-speed applications.
## Emerson: High-Quality Bearings Across the Board
Emerson Bearing boasts over five decades of experience delivering customers the most appropriate roller and ball bearings tailored to their exact specifications. Emerson’s quality products offer unmatched reliability and longevity—when maintained properly, they can outlast the machinery in which they’re installed.
To learn more about preventing failure due to high speeds and other issues, download our Emerson Bearing Failure Analysis Guide today.