Although high quality ball and roller bearings are generally durable components – especially when purchased through a reputable supplier and produced by a world leading brand, such as Dunlop – these components can and do develop faults through regular use.
Recognising the first signs or symptoms of a failing bearing can allow inspection, maintenance or replacement before the fault causes further mechanical damage or unplanned downtime.
In this article, we discuss the main early warning signs to look out for that could indicate an emerging fault with your bearings.
One of the tell-tale symptoms of a failing bearing is excessive or unusual noise during operation. In particular, a growling, squealing, or humming noise could indicate insufficient lubrication, poor alignment, or the early stages of a mechanical fault.
A good bearing will be designed to minimise vibrations during operation, with a smooth transfer of motion and kinetic energy. Vibrations, therefore, can be a sign of a problem with your bearings. For example, if the ball bearing is not properly aligned or is damaged or worn, it will start to vibrate unusually during operation, even at its specified speed and load.
Heat during operation is generated through a build up of friction – an issue that ball bearings are specifically designed to avoid. Above usual levels of heat are, therefore, a common sign of friction building up between the bearing surfaces and should be addressed quickly before it causes overheating and damage. Excess heat can have a detrimental effect on other components in your system if it is not addressed promptly.
Leakage around a bearing housing, seal or lubrication point can indicate seal damage, excessive lubricant, incorrect lubricant viscosity or developing wear. Loss of lubricant can increase friction and temperature, while a damaged seal may also allow contaminants to enter the bearing. A lubricant leak could progress into additional symptoms, such as excessive heat, vibration, and noise, and the issue should be addressed as quickly as possible.
For further guidance, read Why Lubrication Is Critical for Bearing Performance.
Bearings are designed to allow smooth rotation under load. If movement becomes rough, sluggish, or uneven, this can indicate internal wear, contamination, or damage to the rolling elements.
If you notice a change in the smoothness or range of movement in your machinery, it is advisable to inspect the bearings and surrounding components to identify any potential issues before further damage occurs.
Contamination from dust, dirt, or moisture can damage the internal surfaces of a bearing. Even small particles can cause abrasion and lead to premature wear or failure. Bearings operating in harsh environments should be protected with proper seals and regular lubrication.
Shaft misalignment places uneven stress on bearings and can lead to vibration, noise, and early failure. Ensuring proper alignment during installation and maintenance helps reduce unnecessary loads on the bearing.
Bearings are designed to operate within specific load limits. If these limits are exceeded, the bearing surfaces can deform or wear prematurely. This may occur when machinery is overloaded or when an incorrect bearing specification is used.
If a bearing shows signs of excessive noise, vibration, overheating, or contamination, it should be inspected and replaced where necessary. Continuing to operate machinery with a damaged bearing can lead to further mechanical damage and costly downtime.
Planned inspection and correct handling can help prevent repeat failures. See Proper Bearing Maintenance: A 7-Step Guide.
If inspection indicates that a bearing needs replacing, record the bearing reference, shaft and housing dimensions, load, speed and operating conditions where possible.
View the BTL-UK Bearings Catalogue or contact BTL-UK for help identifying a suitable replacement.
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