如何進行軸承故障分析
什么是軸承故障分析？
What is a Bearing Failure Analysis?
軸承故障分析是收集和分析軸承數(shù)據(jù)以確定軸承故障原因的過程。
Bearing Failure Analysis is the process of collecting and analyzing bearing data to determine the cause of a bearing failure.
需要軸承故障分析時
When a Bearing Failure Analysis is needed
軸承故障分析是客戶要求對報告的軸承故障進行軸承分析時使用的重要工具。在開發(fā)新的或改進的軸承產(chǎn)品和應(yīng)用中，這也是必不可少的。
Bearing Failure Analysis is a vital tool used when bearing(s) are submitted by a customer who requests a bearing analysis of a reported bearing failure. It is also essential in the development of new or improved bearing products and applications.
執(zhí)行軸承故障分析
Performing the Bearing Failure Analysis
收集故障數(shù)據(jù)：
Collecting failure data:
- 獲取與軸承故障相關(guān)的所有故障組件，如：軸承，軸承座，配合表面和其他相關(guān)材料（例如潤滑劑或流體，磨損碎屑，密封件和應(yīng)用組件）。
- 確認實際操作條件數(shù)據(jù)，例如負載，速度，溫度，扭矩，潤滑劑，流量；在材料應(yīng)用數(shù)據(jù)表中找到的參數(shù)。
- 獲取測試/故障數(shù)據(jù)，例如測量尺寸和性能參數(shù)的輸出，測試或服務(wù)時間，客戶報告故障的原因。
- 獲得應(yīng)用中使用材料的規(guī)格（軸和外殼的材料規(guī)格，潤滑劑和流體的規(guī)格），甚至是客戶的設(shè)計FEMA。
- Obtain all the failed components related to the bearing failure (bearing, housing, mating surface) and other related materials such as lubricants or fluids, wear debris, seals and application components.
- Confirm actual operating conditions data such as load, speed, temperature, torque, lubricant, flow rate; parameters that are found on a Materials Application Data Sheet.
- Obtain test/failure data such as printouts of measured dimensional and performance parameters, time of test or service, customer’s reason(s) for reporting a failure.
- Obtain specifications for materials used in the application (shaft and housing material specifications, lubricant and fluid specifications) and even the customer’s design FEMA.
分析數(shù)據(jù)：
Analyzing the data:
? 使用和/或不使用顯微鏡目測檢查失效的組件。照片應(yīng)根據(jù)需要拍攝。重點應(yīng)放在但不限于以下故障問題：嚴重磨損；異常磨損情況；變色；碎片；變形；分層；預(yù)期的滑動表面以外的軸承損壞。
? 對運行數(shù)據(jù)進行技術(shù)審查，以確認軸承材料和總體設(shè)計是否適合實際運行條件。 該步驟將包括但不限于將實際工作參數(shù)（單位載荷（p），速度（U），pU，溫度）與軸承材料性能進行比較； 確定軸承材料對可能存在的流體或氣體的化學(xué)耐受性； 使用實際運行參數(shù)估算干摩擦軸承壽命； 或者，如果是潤滑應(yīng)用，則估計潤滑方式（邊界，混合膜，全流體動力膜）。
該技術(shù)審查應(yīng)確認軸承應(yīng)符合軸承性能的操作要求。 否則，則可能意味著軸承材料的選擇是導(dǎo)致故障的原因，有待進一步檢查失效的軸承和組件。
僅這兩個基本步驟可能會得到對軸承故障的滿意反饋，或者可能表明需要進一步戰(zhàn)略 - 使用多種無損和破壞性方法來進行尺寸測量和/或材料分析，例如：
- 使用坐標測量機（CMM）
- 測量表面紋理
- 音蝕測試
- 差示掃描量熱法（DSC）觀察熔融和結(jié)晶以及玻璃化轉(zhuǎn)變溫度 Tg
- 熱重分析（TGA）以評估材料的熱穩(wěn)定性
- 能量色散X射線光譜法（EDS，EDX或XEDS），以確定樣品中存在哪些化學(xué)元素并估算其相對豐度
- 材料硬度測試
- 拉伸/壓縮測試
- 三瓦磨損測試
- 耐腐蝕性測試
? Visual examination of the failed components with and/or without a microscope. Photographs should be taken as needed. Focus should be on, but not limited to, the following failure issues: severe wear; abnormal wear pattern; discoloration; debris; deformation; delamination; damage to bearing other than the intended sliding surface.
? Technical review of operational data to confirm suitability of the bearing material and overall design to the actual operating conditions. This step will include, but not limited to, comparing of actual operating parameters (specific load (p), speed (U), pU, temperature) with bearing material properties capabilities; determination of bearing material’s chemical resistance to fluids or gases that may be present; estimate dry bearing life using actual operating parameters; or, if the application was lubricated, estimate lubrication regime (boundary, mixed-film, full hydrodynamic film).
This technical review should confirm that the bearing should have met the operational requirements for bearing performance. If not, this may mean the bearing material selection was the reason for failure pending further examination of the failed bearing and components.
These two basic steps alone may lead to a satisfactory response to the bearing failure or may indicate a need to develop a strategy for advanced steps of dimensional measurements and/or material analysis using a wide array of non-destructive and destructive methods like:
- Using a coordinate-measuring-machine (CMM);
- Measuring surface texture
- Sonic erosion tests
- Differential Scanning Calorimetry (DSC) ?to observe fusion and crystallization events as well as?glass transition?temperatures?Tg
- ThermoGravimetric Analysis (TGA) to evaluate the?thermal stability?of a material
- Energy-Dispersive X-ray Spectroscopy (EDS, EDX, or XEDS) to determine which chemical elements are present in a sample and to estimate their relative abundance
- Material hardness tests
- Tensile/compressive tests
- Three-shoe wear tests
- Corrosion resistance tests
出具報告：
Issuing the report:
無論是僅使用基本分析，還是使用高級分析補充基本分析，故障分析的最后一步就是出具報告。 根據(jù)分析的范圍，報告可能非常簡單或廣泛。
基本故障分析報告包含背景信息（包括技術(shù)評審），外觀檢查（可能包括基本尺寸測量）和結(jié)論（可能包括建議）就足夠了，尤其是如果這是針對給定客戶應(yīng)用程序的例行故障分析。 如果需要更多細節(jié)來滿足客戶，可以添加技術(shù)分析。
如果基本分析不足以滿足故障分析的需求，那么將需要準備一個策略，該策略首先將使用非破壞性測試/測量技術(shù)，并在必要時使用破壞性測試來完成故障分析。 根據(jù)對進階分析的需要，該報告可能包括那些其他分析的報告，以進一步支持該報告的結(jié)論和建議。
Whether we use only basic analysis or supplement basic analysis with advanced analysis, the final step in the failure analysis is issuing a report. Depending upon the scope of the analysis, the report may be very simple or extensive.
A basic failure analysis report may be sufficient with only the Background Information (which includes the technical review), Visual Examination (which may include basic dimensional measurements) and Conclusions (which may include recommendations). This is may be all that is required, particularly if this was a routine failure analysis for a given customer’s application. Technical analysis can be added if more detail is needed to satisfy the customer.
If the basic analysis is not sufficient to satisfy the needs for failure analysis, then you will need to prepare a strategy that first will use non-destructive test/measurement techniques and, if needed, destructive testing to complete the failure analysis. Depending upon the need for advanced analysis the report may include the reports of those additional analyses to further support the report’s conclusions and recommendations.
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