chesterton causes of bearing failure improper lubrication - 43% –how much, how often, what type,...

CHESTERTON

CAUSES OF BEARING FAILURE

Improper Lubrication - 43%– How Much, How Often, What Type, What Thickness,– What Properties are Important

Improper Mounting - 27%– Alignment, Work Area, General Practices, Inventory

Control and Storage of Bearings

Other Lubrication Causes - 21%– Separation in Storage– Temperature Limit Exceeded– Moisture Contamination– Other Contamination

Fatigue - 9% Ultimate L10 Life Expectancy

64% of Bearing Failures are Lubrication Related IS Not The Whole Story

In the Industry We Serve, Most Bearings Fail Due To Some Form of CORROSION

CHESTERTON

INDUSTRIES SERVED

CHESTERTON

EFFECT OF MOISTURE ON BEARING LIFE

MOBIL OIL REPRINT

Base Oil DescriptionWater Content of

Wet Oil, %

Fatigue Life Reduction,

PercentTest Equipment Author Reference

Mineral Oil -Dried 0.002 480.014 54 4-Ball Scott, 19603.00 786.00 83

Squalene Oil 1.000 32-43 4-Ball Schatzberg & Felsen, 1969

Mineral Oil-DriedNot Stated,

Moist environment

80 4-Ball Ciruna & Szieleit, 1972

Esters 0.050 29-73 #204 Bearings Fein, 1969

Mineral Oil-Based Hydraulic Oil

1.00 45Angular Contact

BearingsFelsen,1972

CHESTERTON

WATER WASHOUT RESISTANCEASTM D1264 (DIN 51807)

% Weight Loss of Grease Measured Typical Grease (Lithium) - 5% Water Resistant Grease <2% Exceptional < 0.5%

Water, 80oC (175oF)

Grease Packed Bearings

90

80

70

60

50

40

30

20

10

0.002 3.0 6.0

% WATER IN OIL

% R

ED

UC

TIO

N IN

FA

TIG

UE

LIF

E

48

7883

Mobil Oil evaluation on bearing fatigue life– 0.002% water reduces fatigue life 48%– 6.0% water reduces fatigue life 83%– 0.002% water is 1 drop of water in a quart of oil

WATER CONTAMINATION REDUCES BEARING LIFE SIGNIFICANTLY

CHESTERTON

^30K^ Contacts Here

FRETTED SHAFTS & SLEEVES

When shaft scoring occurs. A newly installed Lip Seal riding in same location on shaft will leak.

Water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced

CHESTERTON

^30K^ Contacts Here

Fretted Shafts & Sleeves

When shaft scoring occurs. A newly installed Lip Seal riding in same location on shaft will leak. A SpediSleve Seal is often used.

While an improvement, the seal eventually fails, water penetrates the bearing immediately…in all cases corrosion is RAPID and Bearing Life is reduced

CHESTERTON

^30K^ Contacts Here

Numerous Self-Fretting Bearing Seals Available

Some are just metallic shields as OEM

CHESTERTON

CIC 7810-192Exhibit III

CIC 7810-192Exhibit III

% F

AIL

UR

E

100

80

60

40

20

1000 2000 3000 4000

TIME HOURS TO FAILURE

NATIONAL

CR

CR (Mean Life 1844 hours)

NATIONAL (Mean Life 645 hours)

CIC 7810-192Exhibit IV

CIC 7810-192Exhibit IV

NATIONALHours to Failure

MEDIAN RANK( % Failure)

CR WAVESEALHours to Failure

®.

182

188

275

300

556

648

772

902

1264

1366

6.7

16.32

25.94

35.57

45.19

54.81

64.43

74.06

83.68

93.30

144

576

1343

1736

1763

1973

1979

2946

2982

3003

REPRINT FROM A CR INDUSTRIES REPORT

Percent Failure vs. Hours to Leakage

Conventional Bearing Lip SealsTesting Data

(57 Days) (125 Days)

CHESTERTON

CORROSION PROTECTIONSalt Fog Performance - ASTM B117

0 200 400 600 800 1000 1200

# 615 HTG

AluminumComplex

LithiumComplex

Hours to Failure

12 microns

37 microns

Film Thickness

CHESTERTON

BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES)

Shaft Diameter

<2.5cm 2.5cm- 5.1cm- 7.1 cm- 10.2cm 5.1cm 7.1cm 10.2cm

<1” 1” to 2” 2” to 3” 3” to 4” Over 4”

OperatingTemperatures

LubricantRecommended

Oil ViscositySec. @ 38oC Greases(100oF) NLGI No.

Up to Up to Up to Up to Up to1,000rpm 500rpm 300rpm 200rpm 100rpm

1,000 to 500 to 300 to 200 to 100 to3,000rpm 1,500rpm 1,000rpm 750rpm 500rpm

3,000 to 1,500 to 1,000 to 750 to 500 to10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm

Over Over Over Over Over10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm

Below 0oC (32oF)0oC (32oF) to 38oC (100oF)38oC (100oF) to 93oC (200oF)Over 93oC (200oF)




150 to 185 0 to 1250 to 350 1400 to 1,000 21,500 to 2,500 2 to 3

150 to 185 0 to 1250 to 350 1400 to 600 2700 to 1,000 2

90 to 120 0 to 1150 to 185 0 to 1250 to 350 1500 to 1,000 2

33 to 85 0 to 150 to 110 0 to 175 to 250 1350 to 550 2

CHESTERTON

BALL AND ROLLER BEARING LUBRICATION (OIL AND GREASES)

Shaft Diameter

<2.5cm 2.5cm- 5.1cm- 7.1 cm- 10.2cm 5.1cm 7.1cm 10.2cm

OperatingTemperatures

LubricantRecommended

Oil Viscosity GreasesSec. @ 38oC NLGI No.

Up to Up to Up to Up to Up to1,000rpm 500rpm 300rpm 200rpm 100rpm

1,000 to 500 to 300 to 200 to 100 to3,000rpm 1,500rpm 1,000rpm 750rpm 500rpm

3,000 to 1,500 to 1,000 to 750 to 500 to10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm

Over Over Over Over Over10,000rpm 5,000rpm 3,000rpm 2,000rpm 1,000rpm

Below 0oC0oC to 38oC38oC to 93oC

Over 93oC

Below 0oC0oC to 38oC

38oC to 93oCOver 93oC





150 to 185 0 to 1 250 to 350 1 400 to 1,000 2 1,500 to 2,500 2 to 3

150 to 185 0 to 1 250 to 350 1 400 to 600 2 700 to 1,000 2

90 to 120 0 to 1 150 to 185 0 to 1 250 to 350 1 500 to 1,000 2

33 to 85 0 to 1 50 to 110 0 to 1 75 to 250 1 350 to 550 2

CHESTERTON

615 HIGH TEMPERATURE GREASE Very High Dropping Point, 300

oC ( 570

oF)

Temperature Range - 40oC to 204

oC (- 40

oF to 400

oF)

Excellent Shear Resistance

Excellent Shock Load and Wear Properties

Very High Timken O.K. Load 29 kg (65 lbs.)

Good Compatibility with Popular Greases

Very High Water Washout Resistance, Below 1.6% Loss

Extreme Water Tolerance (Add 30% Water and Still Get 20 kg (45 lbs.) Timken)

Excellent Corrosion Resistance

Highest Rating Possible for Automotive Bearing and Chassis Lubrication, NLGI GC-LB

CHESTERTON

615 HTG #1 “Best in Class” Extreme Pressure Properties and

Antiwear Characteristics

Exceptional Corrosion Protection

Excellent Oxidation Resistance, Long Grease Life

Excellent Resistance to Water Washout and Contamination

Easily Pumpable, Good in Central Lubrication Systems

Shear Stability and Grease Performance Maintained Over Wide Temperature Range

Measurably Longer Bearing Life

Temperature Range - 40oC to 204

oC (- 40

oF to 400

oF)

CHESTERTON

615 HTG #1

General Rule of Thumb on Where to Use 615 # 1 Vs. the Standard 615:

Where Operating Speeds are Higher

Where Average Operating Temperatures are Lower

When Customer Wants to Use in Automatic Lubrication System

See Pocket Guide for Reference on Specific Operating Conditions

CHESTERTON

TEMPERATURE EFFECT ON GREASE LIFETIME

“ Most Mineral-Oil-Based Greases (of Adequate Dropping Point)

Will Operate Successfully to About 121oC (250

oF).

A Smaller Number Can Handle 150oC (300

oF). A Few Mineral-

Oil-Based Greases Can Operate to About 177oC (350

oF).”

Relubrication Intervals - Rolling Element Bearings, 8 hours per Day

82oC (180

oF) - 6 Months

104oC (220

oF) - 3 Months

149oC (300

oF) - 1 Month

193oC (380

oF) - 1 Week

238oC (460

oF) - 1 Day

Source: NLGI, Lubricating Grease Guide

CHESTERTON

LUBRI-CUP®

Demand Feed System - Patented Metering System, Slowly Feeds Grease Only as Needed

Prevents Over or Under Filling of Bearings

– Eliminates Cause of Over 40% of Bearing Failures

Low Feed Pressure Prevents Bearing Seal Failure

Time Interval for Relubrication Increased by 6x

Reduces Labor Cost to Regrease by Over 80%

Can Be Mounted at Any Angle Transparent Grease Reservoir -

Easy to See Grease Level Easy to Refill in Place

CHESTERTON

REFILLING THE LUBRI-CUP®

Refilling Lubri-Cup® with 615

CHESTERTON

BEARING LIFE EXTENSION with LUBRICUP and 615 GREASE

CHESTERTON

615 HTG – Vibration AnalysisDryer Fan, Horizontal Bearing, Paper Mill

10.000

7.500

5.000

2.5000

20/10/99 14/11/99 09/12/99 03/01/00 28/01/00

Vib

rati

on, K

hz 615 HTG APPLIED

MPM Multiparamater Receiver, Wilcoxon Model 782A Sensor

[email protected]

[email protected]

CHESTERTON

615 Additive Plating Technology

615 smoothes out surface roughness, reduces wear and vibration. Extends bearing life.

CHESTERTON

615 Additive Plating Technology

CHESTERTON

615 HTG – Technology Overview

Chesterton's 615 is formulated using a surplus of Lubricity, EP and Anti-Wear additives, blended into a highly refined G III base oil, and thickened with a metallic organo-sulfonate complex. The resulting grease is "Best in Class" with respect to EP, Lubricity, Corrosion & Water Resistance.

Unlike conventional Aluminum, Calcium, & Lithium soap and complexed thickeners, Chesterton 615 is immune to hydrolysis or water breakdown. The grease remains functional even in heavy water contaminated bearings and equipment.

Chesterton's 615, with QBT (Quiet Bearing Technology) uses state of the art tribological technology to reduce vibration and ultra-sonic bearing noise. Proprietary polar and non-polar additives and thickener chemically fuse to the metal surfaces filling in asperities to form a "wear shield" on the metal surfaces.

This fusion of lubricating additives and thickeners to the molecular surface of the metal, protects the bearings from

WEAR, PRESSURE and WATER CORROSION.

chesterton causes of bearing failure improper lubrication - 43% –how much, how often, what type,...

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