Common causes of bearing failure (and how to prevent it)
Anyone working with machinery knows how critical bearings are. They enable smooth motion, reduce friction, and make efficient power transmission possible. But when a bearing fails, the consequences can be serious: production downtime, costly repairs, and even safety risks.
The good news? In most cases, bearing failure is preventable. In this article, we will walk you through the most common causes, and share practical tips to extend your bearings’ lifespan and reliability.
Poor or incorrect lubrication
One of the leading causes of bearing failure is improper lubrication. This could mean too little lubricant, too much, using the wrong grease or oil, or contamination of the lubricant with dirt, dust, or moisture. When the lubricant film breaks down or is unsuitable for the application, the rolling elements come into direct contact with the raceways. The result? Increased friction, elevated temperatures, and accelerated wear.
How to prevent
The solution is straightforward: always use the correct type and quantity of lubricant, avoid mixing different lubricants, store them properly, and schedule regular inspections and replenishment.
Contamination and corrosion
Bearings are precision components, but they often operate in challenging environments. Dirt, sand, metal particles, or water can enter through poor seals or improper handling. Once inside, these contaminants act like abrasive grit, damaging the raceways and rolling elements. Moisture can also trigger corrosion, further reducing service life.
How to prevent
Maintaining a clean work environment, using proper sealing, and filtering lubricants are simple yet highly effective ways to keep contaminants out.
Mounting errors and misalignment
Even the best bearing will have a short life if it’s mounted incorrectly. Striking with a hammer, applying pressure to the wrong ring, or ignoring shaft and housing alignment can cause damage right from the start. Misalignment creates uneven load distribution, placing excessive stress on one side of the bearing, which leads to premature wear and potential cracking.
How to prevent
Always use the proper mounting tools, follow the manufacturer’s guidelines, and ensure accurate shaft and housing alignment before start-up.
Overloading
Bearings are designed for specific load capacities. When loads exceed those limits, whether due to constant overload or sudden impact, the material will fatigue and deform more quickly. Both steady overload and shock loading are damaging.
How to prevent
The key is careful bearing selection: choose a model with adequate static and dynamic load ratings, and introduce damping where possible to absorb unexpected shocks.
Heat issues
Excessive heat is a silent killer for bearings. It often stems from insufficient lubrication, high rotational speeds, poor heat dissipation, or even stray electrical currents passing through the bearing. High temperatures can degrade lubricant and reduce the hardness of the steel.
How to prevent
Proper cooling systems, temperature monitoring, and heat-resistant lubricants can prevent these issues and keep bearings running smoothly.
Brinelling and false brinelling
If you’ve ever seen small indentations on a bearing raceway, that’s brinelling: permanent deformation caused by heavy static or impact loads. False brinelling looks similar but occurs when vibration or oscillation happens while the bearing is stationary. In these cases, lubricant is gradually displaced, causing localized wear.
How to prevent
Protect bearings from vibration during transport or downtime, and use specialty lubricants for oscillating applications to reduce the risk.
Fatigue and White Etching Cracks (WEC)
Over time, cyclic loading can cause microscopic subsurface damage known as rolling contact fatigue. In some cases, white etching cracks develop: fine cracks beneath the surface, often caused by a combination of mechanical stress, temperature, and sometimes electrical erosion. Eventually, these lead to surface spalling and failure.
How to prevent
Preventing this type of damage requires precise monitoring, adequate lubrication, protection against stray currents, and the use of high-quality bearing materials.
IBS Rotterdam: Your partner in bearing solutions
Preventing bearing failure isn’t just about knowing the causes, it’s about having the right products, the right practices, and the right partner. At IBS Rotterdam, we understand that every bearing and every application is unique. That’s why we offer a total solution: from analyzing your application and recommending the right bearing and lubrication, to supplying quality products, providing proper mounting, and training your maintenance team.
Read about how IBS can help your company processes by giving advice. If you have specific questions or want your situation assessed, you are always welcome to visit us in Rotterdam or contact us via a form, our emailadress or phone number. Our specialists are happy to help you minimise downtime and avoid unnecessary costs.
Conclusion
In most cases, bearing failure is not a matter of bad luck, it’s a result of identifiable causes. Poor lubrication, contamination, mounting errors, overloading, overheating, and mechanical damage are among the most common. By taking preventive measures (and by working with a specialist like IBS Rotterdam) you can extend the life of your bearings significantly.
The result? A reliable machine fleet, smooth production, and controlled maintenance costs. Contact us today!
