WEAR PARTICLE ANALYSIS OF AN ANTIFRICTION BEARING · The analytical Ferrography is a two station instrument which can separately or simultaneously make side by side ferrograms. Wear

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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 9, Issue 3, March 2018, pp. 684–699, Article ID: IJMET_09_03_069

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=3

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

WEAR PARTICLE ANALYSIS OF AN

ANTIFRICTION BEARING

S Soumyaranjan Baliarsingh

ITER, Siksha „O ‟Anusandhan University

Bhubaneswar, Odisha, India

ABSTRACT

Most maintenance practitioners have become familiar with machine condition

monitoring through the use of portable non destroying measurement systems such as

vibration, oil analysis, thermography. These portable systems are typically utilized as

part of predictive maintenance program that is expensive and time consuming. With

recent advances in the field of lubricant condition monitoring utilize the concept of

real time condition monitoring with the help of expert systems that is highlighted

through a case study. The present work describes the development of an expert system

that can be used to determine the condition of lubricating oil in circulation in a

centralized lubrication system attributed for lubricating antifriction bearings. It

begins with basic concepts of oil analysis, lubrication, with analysis of bearings and

finally the development of an expert system pertinent to wear particle analysis.

The lubricant contaminant monitoring through advanced diagnostic techniques for

critical equipment is a very powerful maintenance tool in any production plant. It

predicts the condition of the oil as well as the machine in advance failure mode. The

information may be figured out from particle morphology such as composition, size

distribution aspect, shape and concentration. Lubricating oil samples were collected

on a schedule basis from identified critical centralized system of lubrication to

lubricate ball bearings. These samples were analyzed in advance diagnostic tools for

the determination of shape, size, morphology and texture of the wear particle

associated with the lubricant in circulation.

Key words: Condition monitoring, portable systems, Predictive maintenance, Real

time, Oil analysis, Particle morphology.

Cite this Article: S Soumyaranjan Baliarsingh, Wear Particle Analysis of an

Antifriction Bearing, International Journal of Mechanical Engineering and

Technology 9(3), 2018, pp. 684–699.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=3

1. INTRODUCTION

The accelerated moment of science and technology has reflected on the originative design and

development of bearings with high precisions and peak achievements ever in contrary

working environment. The bearing is a support system, which provides relative positioning

and rotational freedom while transmitting a load between two machine members. For high

Wear Particle Analysis of an Antifriction Bearing


rotational speed in some applications the rotational freedom with practically zero wear may

exit. This is achieved by creation of fluid pressure in the clearance space between the rolling

elements. Most of the bearings in use are lubricated by liquid or some gases, though solid

lubricants viz. Graphite, molybdenum disulphide etc. are also used when the bearings are

operated at high temperatures e.g. in extrusion process in hot working. Other demanding

applications of bearings now a day can be found in the space technology, electronics,

cryogenics, nuclear engineering and computer.

All productive machines during the normal operation process developed microscopic wear

particles; those are hammered out by the deformity or removal of surface material from

bearings, gears, cylinders, pistons, and other machined parts. The failure of hydraulic system

by the cause of presence of contaminates, which interferes with the ability of the hydraulic

fluid to perform its desired function. These contaminants can be solid particles of dirt wear

debris; Liquid contaminates just as water if synthetic or mineral oil is used.

These interferences ultimately result in wear of components surfaces which lead to

material loss, increase in leakage, reduced performance and finally breakdown. The

contaminants combine with the hydraulic oil to step up deterioration processes. This leads to

the need of replacement of the new oil and dispose of the old and eventually increases the

cost.

The condition based maintenance system is in operation in all the major steel plants and it

has evidenced far more effective than either disruption or time based repair. The expenditure

on maintenance varies from plant to plant but in every plant, it forms a significant percentage

of the total production cost. Emphasis is laid now on reducing the cost of maintenance in all

the plants. The goal of any condition based maintenance system is to provide timely warning

of equipment malfunctions such that corrective action can be taken to avoid unexpected down

time, prevent costly secondary damage and in some cases, protect the safety of the people

working with the equipment. The concept of condition monitoring through contaminant

monitoring is being practiced in all shops of Durgapur Steel Plant. As the condition

monitoring agenda accumulates momentum, a continuation into diagnostics analysis is well

timed. When a problem is picked out, the whole effort should be made to detect the reason.

Finding out is absolutely necessary. Once a problem is detected, recognized and then the

equipment removed from service for repairs, it is insisting for all taking parts to be made

aware of the actual conditions distinguished and the rehabilitative action taken accordingly.

Condition monitoring with the help of oil analysis (spectrograph, particle count, ferrography)

is useful indicative tool by using which the level of contaminants (wear debris) can be

determined periodically and curative measures can be taken in advance and can avoid major

breakdown. Planning maintenance schedule in a systematic and methodical way helps in

minimizing breakdown and improves productivity in the plant.

A good amount of work has already been done to study the stability analysis of an

antifriction bearing running on hydrostatic lubrication. These bearings are normally lubricated

with low kinematic viscous oil. But, now-a-days hydrodynamic bearings are generally used

where the relative velocities are high enough. As a result of continuous increase in the size

and speeds of the rotating machinery or due to use of fluids having low kinematic viscosity,

the oil film flow in the bearings frequently becomes turbulent. Again, keeping in mind the

extremely small radial clearance required in ordinary rolling element bearings. The clearance

between the rolling element and the races are kept at three microns to facilitate the ease of

alignment. Flexibly supported bearing came into vogue for sequencing in the mills. As more

often, then not, such bearings fail under dynamic loading conditions because of oil whirl. A



non-linear study of dynamics of such bearings is important to know whether the system fails

because of instability.

Because of continuous and sustain operation the components in a rolling element bearings

are subject to failure on attaining its life factor. It is seen that the failures of these bearings are

attributed to the wear ion the rolling elements and the track on which the balls spin. A study

undertaken by a bearing manufacturer revealed that the main reason of failure of antifriction

bearings is improper lubrication. Bearings are subjected to either starvation or a state of

flooding causing the onset of wear of the components leading to its premature failure.

2. EXPERIMENTAL

Oil which has been used in any moving mechanical components for certain duration suggests

the exact condition of that fabrication. Wear metallic trace particles enters into the oil or

lubricant which is in physical contact with engine or mechanical constituents. These particles

are so small that they remain in dormancy. Many outcomes of the combustion process also get

included in the circulating oil. Thus the oil becomes a measure of condition of the machine.

By identifying and calculating these impurities, we get a hint of the wear rate and of any

excessive contamination and advice methods to reduce these.

The main purpose of oil analysis is to predict possible impending failure without

disassembling the machine components. One can take a look inside an engine, transmission or

hydraulic systems without making it apart to detect problems and suggest repair work to avoid

recess during a critical time of use.

2.1. Physical Characterization of Lubricant

Viscosity It is by far the most notable property for endowing the thickness, pressure, and

temperature of a fluid film in hydrodynamic lubrication and a significant factor in predicating

the working conditions and fatigue life of roller bearing. ASTM method D445 is used to

measure the viscosity by using arm viscometer.

Cloud-point test the cloud-point of oil is that temperature, at which dissolved solids are no

longer soluble, accelerates the second phase which results in fluid a cloudy appearance. Tests

were conducted using the ASTM D2500 standard.

Color code Oil color analysis can be used as an indicator of oil health as well as a reliable

field indicator confirming that the correct oil is being used. ASTM D1500 color code, the

lubricant color has to be determined.

Spredability test The area of the spread of the lubricant indicates the flow ability of the

lubricant. Oil with a larger spread witnessed on the glass substrate is better as it retains a

greater area of spread on the surfaces of oil wetted components like bearings and gearboxes.

2.2. Condition Monitoring Techniques

Ferrography Ferrography is a technology which is based on the analysis of wear particles. It

has been used successfully in the monitoring of gearboxes and transmissions, air craft, high

speed diesel engines, gas turbines, and hydraulic systems.

(a)DR Ferrography

It gives a blueprint about the contaminants level of the wear particles in the lubricants.

(b)Analytical Ferrography

The analytical Ferrography is a two station instrument which can separately or simultaneously

make side by side ferrograms. Wear particles drooping in the oil sample are magnetically

precipitated on to a thin glass slide called as ferrogram. Ferroscope is a microscope with both

https://en.wikipedia.org/wiki/ASTM



transmitted and reflected light source used for identification of wear metal particles for their

size, shape and morphology. This identification is done through analytical Ferrography.

Photographs of the wear particles can be taken with the help of a digital camera. Photographs

are taken at magnification of 100, 500 and 1000. Ferroscope use light sources of both

transmitted and reflected light together with red, green with analyzer and polarizer filters.

This helps in distinguishing the size, composition, shape and texture of both metallic and non-

metallic wear particles.

Particle deposited in the ferrograms substrate is in the order of large to small size

particles. Particles with diameter greater than 5µm and smaller than 5µm are called as large

and small particles respectively.

Severity indicates the condition of lubricant and machine. More the severity higher is the

condition of failure. This can be calculated by equation DL2 – DS

2.

Spectrometry It is used to determine the metallic element present in the lubricant oil by the

help of high temperature electrode analysis.

Particle Size Distribution A comprehensive particle size analysis system, provide fast and

accurate particle size distribution and shape characterization.

Oil View Analyzer The machine presents information about the health of lubricant, based on

di-electric property of lubricants. The Tri-vector plot of the oil sample analyzed through oil

view analyzer indicates the condition of the lubricant in use.

3. RESULTS

Viscosity of both fresh and measured oil was measured by the help of viscometer. The

viscosity of fresh and used oil is found to be 34cSt a 38cSt respectively.

Cloud Point Test of the fresh lubricating oil was found out to be -2⁰c and used lubricating oil

is -5⁰c.

Color code Using the ASTM D1500 color code legend, the test lubricant color was found as

2.0 and 3.0 respectively for fresh oil and used oil.

Figure 1 ASTM D1500 COLOR CODE

Spredabillity test indicates he flow characteristics of the lubricant. From the experiment the

spread area of the fresh oil is 484sq. mm. and that of the used bearing oil was 204sq. mm.

Figure 2 Fresh Oil Figure 3 Used OIl



Condition Monitoring Techniques

Direct Reading Ferrography The results are found to be the DL value of fresh oil and used

is 3.7 and 18.1 respectively. Whereas the DS value found to be 2.3 and 8.1 for fresh oil and

used oil.

Severity

Total wear in fresh oil = 3.7 + 2.3 =6.0

Total wear in used oil = 18.1+801 = 26.1

Severity of oil in fresh oil = 3.7 – 2.3 = 1.4

Severity of oil in used oil = 18.1 – 8.1 = 10.0

Severity of wear index in fresh oil = 6.0 × 1.4 = 8.4

Severity of wear index in used oil = 26.2 × 10.0 = 262

Analytical Ferrograph

Wear particles eroded from the surface of the bearings does not react chemically with the

lubricant. These worn out particles stays in a separate phase and with the application of force

can be separated easily. A high power magnet is utilized to take out these particles. The

particles thus separated are through magnetism are collected in a carbon coated glass substrate

and are subsequently observed in a bichromatic microscope to get the relevant information of

the morphology of the particle.

Figure 4 The presence of iron particles is found which is depicted on red matrix under 400

magnifications with red reflective and green transmitting light source.

Figure 5 The presence of iron oxide particles and silica particles are viewed under 100 magnifications.



Figure 6 The presence of abrasive wear concentration was witnessed under 400 magnifications.

Metallic Element Analysis

ASTM D6590-00 standard the experimentation was conducted for 30 seconds. This

experiment is conducted to determine the elements present in the lubricant. There are three

types of element present in any lubricant. Some elements are present in the form of additives

which is essential for the stable functioning. Some elements are generated through wear

particles and the last category is ingresses in the system. Analysis of these elements gives a

clue from where these elements are generated giving a clue to the wear of those components.

Metal element also depicts the additive depletion if any.

Two oil samples one fresh oil and the other used oil was tested in the instrument to

understand the trending pattern the oil undergoes with its prolong use.

Table 1 Elements present in the fresh oil in ppm

Table 2 Elements present in the used oilin ppm



Particle Count

Particles present in the lubricating oil were counted using an optical instrument working in the

principle of light interference method. The reporting is made in six different ranges in tabular

form.

Table 3 No of particles present in fresh oil

Range 2-5µ 5-15 µ 15-25 µ 25-50 µ 50-100 µ >100 µ

No. of

Particles

1882417 2244387 421571 110036 10227 674

Table 4 No of particle present in used oil

Range 2-5µ 5-15 µ 15-25 µ 25-50 µ 50-100

µ

>100 µ

No. of

Particles

823029 983971 84279 85006 8850 242

Oil View Analyzer

The tri-vector plots of the fresh and used oil is plotted for change of chemistry, contaminants

and wear particle concentration.

Figure 7 Comparison between fresh oil and used oil

Figure 8 Tri-Vector Plot



Microscopic Evaluation of wear particles

The color, texture and the size of the particles were measured using reflected light source. The

particles were magnified to 100 to see the morphology of the particles.

Figure 9 Average grain size 5µ

Figure 10 Average grain size 5.5µ

Figure 11 Average grain size 7.5µ

4. DISCUSSIONS

Viscosity and cloud point temperature increased in used oil than fresh oil which suggest the

addition of contaminants and debris particles from the atmosphere.

Lubricant color was found as 2.0 and 3.0 respectively for fresh oil and used oil. The color of

the oil changed from golden yellow to reddish. The change in color is due to the operation of

60 hours.

The spread area of used oil is less than that of fresh oil because, the addition of contaminants

and debris material made the oil more viscous.



Ferrography

Dr Ferrography

Figure 12 Wear concentration of large particles….. Figure 13 Wear concentration of small particles

The more severity of wear index indicates the system is unstable. This severity will

increase over a period of time. This is deleterious on the health of the bearings.

For a stable lubrication system, the generation of large particle should be restricted. In this

present analysis it was observed that the large particle is increased by 5 times where as small

particles is increased only by 3 times. So the system is trending towards instability as larger

particles will come out from the surface of the antifriction bearings over a period of time.

Analytical ferrograph

Fig 4 shows the bearing material is slowly wearing out. The morphology of the particle is

spherical. These are tiny spherical particles of less than five microns.

Fig 5 shows that ferrous particles are seen in red color and silica particles are seen in

white color. The size of silica particles as viewed is much smaller as compared to ferrous

particles. It can be inferred as ferrous particles are generated in the system where as silica

particles are ingresses to the system.

Fig 6 shows the presence of abrasive wear concentration was witnessed which is

supplementing to the earlier findings.

Metallic Element Analysis

Figure 14 Zn Particles (in ppm)

3.7

18.1

0

5

10

15

20

DL

valu

e

oil

fresh oil used oil

2.3

8.1

0

2

4

6

8

10

DS

valu

e

oil

fresh oil used oil

114.9

105

100

102

104

106

108

110

112

114

116

concentr

ation

oil

fresh oil

used oil



Fig 14 suggests that the presence of zinc in the lubricant is reduced significantly which

will result in reduced load bearing capacity of the oil. It can be inferred that a depletion of

zinc has taken place.

Figure 15 Fe Particles (in ppm)

Fig 15 gives indication of improvement in iron contain is witnessed in the used oil.An

increase of 24 times are evinced in the presence of iron. Iron is a constituent of bearing

material and is not a functionary of oil. It‟s very presence indicates an incipient wear of the

bearings.

Figure 16 Cu Particles (in ppm)

Fig 16 It can be seen in the figure 5.8 that not a trace of copper was found in fresh oil. But

its presence in used oil is significant. So a metallic wear of bearing is noticed. This will cause

the system to be unstable in course of time and will lead to the failure of the bearings.

Figure 17 Ni Particles (in ppm)

0.2

4.8

0

1

2

3

4

5

6

concentr

ation

Oil

0

7.9

0

2

4

6

8

10

concentr

ation

Oil

0.1

0.3

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

concentr

ation

OIL

fresh oil

used oil



Fig 17 suggests a slight increase in nickel from 0.1 to 0.3 ppm is found. Nickel is part of

the chemistry of the bearing material to imbibe the anticorrosive property to the bearing. This

is a surface phenomenon and its presence in oil leads to the conclusion that the bearing is

slowly deteriorating for functional characteristics such as anticorrosive properties.

Particle Count

The fresh oil was having NAS 10 class whereas the used oil was operating at NAS 12 class.

This result indicates that the online filter captive for particle separation is not functioning.

Figure 18 No of Particles in 5-15



983971

2244387

0

500000

1000000

1500000

2000000

2500000N

o.

of P

art

icle

s

Oil

84279

421571

0

100000

200000

300000

400000

500000

No.

of P

art

icle

s

Oil

85006

110036

0

20000

40000

60000

80000

100000

120000

No.

of P

art

ixle

s

Oil



Figure 21 No of Particles in >100

It can be seen from the graphs and the table that an increase in particle concentration is

evinced in every range of particle identification. Fresh oil has a large number of particles but

the oil that was collected after prolong use of the centralized lubrication system has increased

the particle concentration many folds. Unfortunately, the instrument cannot distinguish

between the particle that was generated or ingress in to the system.

Oil View Analyzer

The result obtained through oil view analyzer instrument for fresh and used oil is given in

figure 7.

The duration of the test was for 500 seconds. No change of characteristics was witnessed

between 300 seconds.\though the fresh oil was slightly better to used oil. The properties

changed drastically after 300 seconds of operation. The fresh oil was constantly operated till

500 seconds whereas the used oil underwent a drastic change in its dielectric strength. It can

be seen that the oil film was unstable at 400 seconds. A spike was seen in the characterization;

this property was increased but subsequently fell down. The slope of curve was very stiff but

after some time flattened off. It indicates the oil film was unstable for some time but corrected

itself subsequently to become stable. The stability behavior was witnessed in less than 10

seconds and. It can be inferred that the lubricant has deteriorated to some extent but a stage

has not come to replace the oil. The test duration of 500 seconds was obtained from the cycle

time of the centralized lubrication system. This cycle time is obtained as a ratio of reservoir

capacity to pump discharge.

From the tri-vector plot it can be observed that a change in chemistry and wear is

witnessed whereas no significant change in contaminant is witnessed. This only indicates that

the particles present in the used oil are not contaminants eroded from the surface of the

bearings. This also supplements the findings of ferrography that particles are ingresses into

the lubrication system. Used oil sample was compared to the fresh oil sample and the

lubricant has not lost its physical properties and has not become unstable as the oil is still to

operate in red condition. Whatever change that has taken place is purely physical and

corrective measures can be taken like improved filtration process can be adopted to bring it

back for its physical properties restoration.

Microscopic Evaluation of wear particles

Figures 9 to 11 shows the size of the worn out particles as obtained in a metallurgical

microscope.

242

674

0

100

200

300

400

500

600

700

800

No.

of P

art

icle

s

Oil



The size of the particles varied between 5 to7.5 microns. The shape of the particles was

spherical in nature. No cutting wear particle was viewed and all the particles are regular in

shape. These wear particles are spherical in nature which is substantiating the findings of

previous researchers. Wear particles have been generated in the lubrication system itself and

are getting generated from the antifriction bearings.

Comparision

Doglas Scott Reference No

:

Figure 21 Wear particle generation in a ball bearing

Fig 5.21 is a scanning electron micro photograph taken at a magnification of 3000 for

particle generation due to wear of the raceways in an antifriction bearing. A large particle is

generated from the race way and is liberated from the raceways, in this figure the smearing

and undulations of the raceways are also seen. A small particle is in the process of generation

in the raceway. The morphology of the wear particle is spherical in size. It can be inferred that

all the particles generated from the ball bearings in our centralized lubrication system are

spherical in size as was evinced in microscopic evaluations in our studies.

APPENDIX A

Experimental setup of Centralized Lubrication System

Oil Reservoir

Piping network

Pump

Filter



Flow control valves

Bypass Line

Plummer blocks

Bearings

Electric motor

Speed regulator

Belt and pulley for loading the bearings

A reservoir of the size 300 X 300 X 300 mm was fabricated with galvanized iron (GI)

sheet of 0.8 mm thickness for storing the lubricating oil.

ISO VG 32 grade bearing oil was identified for conducting experiments. This oil has

relatively low viscosity and an excellent fluidity so that it can easily be pumped for

lubrication process into the bearings.

A 0.5 hp centrifugal pump with high discharge was selected to transfer the oil to the

bearings.

The filter has a housing which has paper as filter element. This filter element is made of

layers of high pressure sustainable paper and is interchangeable for the filtration process.

In order to get the accuracy of discharge of lubricant, flow control valves are used to

control the flow of oil into the bearings. A bypass line is created for surplus oil to return to the

reservoir.

Plummer blocks are cast steel structure and are having provision of oil entry inlet.

Lubricant coming out of the bearings and

Plummer blocks are collected in a tray located beneath the bearings.

Shield ball bearing having bearing no 6205Z is identified to perform the test. Detail

specification of the bearing is given below. Reference - RKB bearing catalogue no.

BC2010A.

To rotate the bearings, an electric motor was used having specification having Watts

=120W, Volts = 220V, Current = 0.6A, Frequency =50/60 Hz.

An accelerator is connected to control the speed of revolution of the motor.

A return line is provided in the circuit to collect the lubricant after it comes out from the

bearings. Oil is collected in individual trays after its use and is returned to the reservoir for

recirculation.

5. CONCLUSIONS

Viscosity of the used oil was increased as compared to the fresh oil. This indicates the

decrease of operating temperature of the oil. This will lead to failure of the lubricant. On-line

filter was not functioning as it is not separating the particles associated with the lubricant.

properly. Used oil is having more NAS number than that of Fresh oil value. This implies to

replace the filtering material element present inside the filter housing. Wear in the bearing

was noticed as the presence of metal components like Fe, Al, Cu, Mg, Na, Ni in used oil in

the spectrographic analysis. Tri-vector plot of oil view analyzer indicates oil and lubrication



system is running in marginal wear zone. It can be seen from tri-vector graph that maximum

region is obtained in purple zone. This means the lubricant is yet to come in severe condition

zone. Further it can be concluded from the tri-vector analysis that

a. Wear is prevalent in the system.

b. With the use, properties of the lubricant has changed from the fresh oil, because of the

addition of wear particles from bearings and surroundings.

c. Particle eroded from the bearing is normal zone.

The contaminants are in controlled range indicates the bearings are functioning properly.

The figure also indicates the degradation has started after 300seconds.At 400 seconds it tried

to be stable but instability has started in the lubrication system is observed. The system

became stable subsequently after 420 seconds. Oil view analyzing test suggest that no

significant presence of ferrous particle in the oil. Water was condensed from atmosphere and

the water present in oil was found to be 0.0254%. This will result in change in chemistry of

the lubricants. The load bearing capacity of oil will decrease subsequently. Once the water

level in oil increases, this will lead to further instability in the system as the filter elements are

paper based. Ferrography analysis was conducted to get the details of wear particles present

in the used oil. DL DS value got changed in the used oil as compared to the fresh oil. This is

due to the contaminants i.e. wear particles added from the bearings during the

experimentation. The particle generated in the system was obtained as spherical. This is the

confirmation to the findings obtained through Scanning Electron Microscope. The particles

were not conglomerate. The size of the particle as measured through bichromatic and optical

microscope was obtained as 7 microns in size. Particle count gives us the result as NAS value

of fresh oil and used oil is 10 and 99. It indicates the contaminates with respect to particle

size. The silica particles are not getting generated in the system but are getting ingresses to

the system.

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Documents

WEAR PARTICLE ANALYSIS OF AN ANTIFRICTION BEARING · The analytical Ferrography is a two station instrument which can separately or simultaneously make side by side ferrograms. Wear