Maintenance and Reliability Improvement of Roller Bearings Operating at High Temperature: Thermal Stress Analysis Approach

Authors

  • D Kabeya Nahum Institute of Innovation, Science and Sustainability, Federation University, Churchill, Australia Author
  • Gopinath Chattopadhyay Institute of Innovation, Science and Sustainability, Federation University, Churchill, Australia Author

Keywords:

Pinion Bearing, Lubrication Regime, Maintenance Data, Thermal Modelling, Reliability Improvement

Abstract

 

In this paper the authors present the  outcome of an experimental maintenance and reliability  investigation conducted to prevent operation failure of  pinion bearings caused by excessive temperature with a  case study of a 1360kW ball mill driveline system in  mineral processing application. Aiming to improve the  overall plant performance, the lubrication regime of pinion  bearings as key component within the ball mill driveline  system was studied to determine possible causes of  temperature increase at 80 to over 100C with a 25 - 30C  gap over the maximum operating temperature. An analytical  review of maintenance data is conducted to mitigate future  operational risks by implementing a new lubrication regime  and shutdown frequency for overall statutory inspection.  Accelerated life test based inverse power law has been  applied to identify the root causes of excessive bearings  temperature to establish immediate short-term solution  paths towards a guaranteed less required maintenance asset  improvement practice, less operational cost, and plant  availability enhancement. Furthermore, long-term solutions  have been proposed based on modelling by thermal network  approach of pinion bearings for thermomechanical stress  prevention. A single parameter based accelerated test on  pinion bearings was applied to establish operational fault  tolerant factors to be considered for asset capability  improvement, which remains an open question for future  studies. These actions have shown significant improvement  with temperature decrease between 15 and 25C below the  maximum required temperature. 

Downloads

Download data is not yet available.

References

M. Djilali Boukhelef, "Etude élasto-hydrodynamique du comportement en mode dynamique des paliers a très hautes vitesses," PhD thesis, Université des Sciences et de la Technologie d’Oran, Algeria, 2012.

J. Frene, D. Nicolas, B. Degueurce, D. Berthe, and M. Godet, "Lubrification hydrodynamique paliers et butées," Eyrolle, Paris, 1990.

S. Boubendir, S. Larbi, and R. Bennacer, "Elastic Deformation Effects on the Thermohydrodynamic Aspect of Porous Journal Bearings," Defect and Diffusion Forum, vol. 353, pp. 275-279, Trans Tech Publications, Switzerland, 2014.

J. Frene et al., "Lubrification hydrodynamique : paliers et butées," Collection de la Direction des Etudes et recherches d’Electricité de France, No. 72, Editions Eyrolles, 1990.

S. T. Tseng and E. Saibel, "Surface roughness effect on slider lubrication," ASLE Transactions, vol. 10, pp. 334-338, 1967. [6] G. K. Nikas, "Recent Developments in Wear Prevention, Friction and Lubrication," pp. 227-262, ISBN: 978-81-308- 0377-7, in Transient phenomena in elastohydrodynamic lubrication, Ed. R. P. Glovnea, 2010.

R. Larson, "PhD Thesis," Luleå University of Technology, ISSN 0348-8373, 1996.

M. Maamar et al., "Comportement des paliers hydrodynamiques en présence de défauts de forme et de rugosité."

D. Lauer, "Tribology: the Key to Proper Lubrication Selection." Retrieved from: machinerylubrication.com. [10] B. A. Wills and J. A. Finch, Will’s mineral processing technology: An introduction to the practical aspects of ore treatment and mineral recovery, 8th ed., Elsevier, Canada, 2016.

M. Amarnath, "Failure Analysis of a Grease Lubricated Cylindrical Roller Bearing," in 2nd International Conference on Innovations in Automation and Mechatronics Engineering, Procedia Technology, vol. 14, pp. 59–66, 2014.

F. Farcas and M. D. Gafitanu, "Some influence parameters on greases lubricated rolling contacts service life," Wear, vol. 225-229, part 2, pp. 1004-1010, 1999.

Y. C. Tasan et al., "Changes in the microgeometry of a rolling contact," Tribology International, vol. 40, no. 4, pp. 672–679, 2007.

B. J. Jugale and M. V. Kharade, "A Review Paper on Failure Analysis of Cylindrical Roller Bearing," IJSRD - International Journal for Scientific Research & Development, vol. 3, issue 08, 2015, ISSN (online): 2321-0613.

A. Klausen et al., "Accelerated Bearing Life-time Test Rig Development for Low-Speed Data Acquisition, Modeling, Identification and Control," vol. 38, no. 3, pp. 143–156, 2017.

F. Ahmadzadeh and J. Lundberg, "Remaining useful life estimation: review," Int. J. Syst. Assur. Eng. Mang., vol. 5, no. 4, pp. 461–474, 2014, doi: 10.1007/s13198-013-0195-0.

W. B. Nelson, Accelerated Testing: Statistical Models, Test Plans, and Data Analysis, Wiley-Interscience, USA, 1990. [18] P. D. T. O’connor and A. Kleyner, Practical Reliability Engineering, 5th ed., Wiley, UK, 2012.

A. Moukhli, "Optimiation de la maintenance de roues de turbines hydroelectriques soumises a une degradation par cavitation," Master Thesis in Industrial Engineering, University of Montreal, Canada, 2011.

E. Deloux, "Politiques de maintenance conditionnelle pour un systeme a degradation continue soumis a un environnement stressant," PhD Thesis, University of Nantes, France, 2008.

K. S. Park, "Optimal Continuous-Wear Limit Replacement under Periodic Inspections," IEEE Transactions on Reliability, vol. 37, no. 1, pp. 97-102, 1988.

S. D. Durham and W. J. Padgett, "A cumulative damage model for system failure with application to carbon fibers and composites," Technometrics, vol. 13, pp. 34-44, 1997.

R. Belhadef et al., "Evaluation et exploitation de modèle de fiabilité et de maintenabilité d’un système industriel à base d’un système expert," in ISORAP 2013, May 08-10, 2013, Marrakesh, Morocco.

H. Garg and M. Ram, Reliability Management and Engineering: Challenges and Future Trends, 2020. [25] E. Bastidas-Arteaga and A. Soubra, Reliability Analysis Methods, 2014.

L. Wilkinson, "Revising the Pareto Chart," The American Statistician, vol. 60, no. 4, pp. 332–334, 2006, doi:10.1198/000313006x152243.

N. R. Tague, "Seven Basic Quality Tools," in The Quality Toolbox, Milwaukee, Wisconsin: American Society for Quality, 2004, p. 15.

J-P. Clech, G. Henshall, and J. Miremadi, "Closed-Form, Strain-Energy Based Acceleration Factors for Thermal Cycling of Lead-Free Assemblies," in Proceedings of SMTA International Conference (SMTAI 2009), Oct. 4-8, 2009, San Diego, Canada.

J. Kalbfleisch and R. Prentice, The Statistical Analysis of Failure Time Data, 2nd ed., Wiley, 2002.

W. Nelson, Accelerated Testing: Statistical Models, Test Plans and Data Analysis, Wiley, 1989.

T. Jafar, "On the Thermally Induced Failure of Rolling Element Bearings," Louisiana State University and Agricultural and Mechanical College. Retrieved from: https://digitalcommons.lsu.edu/gradschool_dissertations,

M. Amiri et al., "On the Relationship Between Wear and Thermal Response in Sliding Systems," Tribol Lett., vol. 38, pp. 147-154, 2010.

K. Nakajima, "Thermal contact resistance between balls and rings of a bearing under axial, radial, and combined loads," Journal of Thermophysics and Heat Transfer, vol. 9, pp. 88- 95, 1995.

M. M. Yovanovich, "Thermal constriction resistance of contacts on a half-space: Integral formulation," AIAA, pp. 75-708, 1975.

Downloads

Published

2024-03-07

Issue

Vol. 11 No. 1 (2024): International Journal of Innovative Research in Engineering and Management (Feb) (2024)

Section

Articles

How to Cite

Maintenance and Reliability Improvement of Roller Bearings Operating at High Temperature: Thermal Stress Analysis Approach. (2024). International Journal of Innovative Research in Engineering & Management, 11(1), 20–30. Retrieved from https://www.acspublisher.com/journals/index.php/ijirem/article/view/13552