Bearing failures are one of the most common causes of unexpected machinery downtime. The good news? Most failures aren’t caused by the bearing itself. In fact, studies suggest that only a small percentage of bearings reach the end of their natural fatigue life. The majority fail because of preventable issues such as poor lubrication, contamination or incorrect installation.
Understanding the causes of bearing failure can help reduce downtime, extend equipment life and save significant maintenance costs.
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Inadequate Lubrication
One of the leading causes of bearing failure is incorrect lubrication.
This doesn’t just mean using too little grease—it can also mean using too much, using the wrong lubricant or failing to lubricate at the correct intervals.
Poor lubrication increases friction, leading to excessive heat, accelerated wear and ultimately premature bearing failure.
Warning signs include:
- Excessive operating temperatures
- Discoloured grease
- Unusual noise
- Increased vibration
Tip: Always use the lubricant recommended for the application and follow the manufacturer’s relubrication schedule.
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Contamination
Dust, dirt, water and other contaminants are among a bearing’s biggest enemies.
Even microscopic particles can damage the raceways and rolling elements, creating wear that gradually develops into vibration, noise and eventual failure.
Contamination often enters bearings through damaged seals, poor storage or during installation.
Common contaminants include:
- Dust
- Metal particles
- Moisture
- Cleaning chemicals
- Process debris
Keeping bearings clean during storage and installation can dramatically improve service life.
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Incorrect Installation
A bearing installed incorrectly is unlikely to perform correctly.
Using excessive force, striking the bearing directly with a hammer or applying pressure through the wrong ring can damage internal components before the machine has even started.
Proper installation tools and techniques are essential.
Best practice includes:
- Using the correct fitting tools.
- Applying force only to the correct bearing ring.
- Ensuring shafts and housings are within tolerance.
- Following manufacturer installation procedures.
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Misalignment
Even slight shaft or housing misalignment can place uneven loads on a bearing.
This results in increased friction, higher temperatures and uneven wear patterns that shorten bearing life.
Regular alignment checks and precision installation help prevent unnecessary failures.
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Overloading
Bearings are designed to operate within specific load limits.
Unexpected shock loads, excessive belt tension or changes to machine operation can overload bearings, leading to fatigue and premature damage.
If operating conditions have changed, it may be time to review whether the bearing specification is still suitable.
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Electrical Damage
Electric motors controlled by variable frequency drives (VFDs) can sometimes allow electrical current to pass through bearings.
This creates microscopic arcing, resulting in characteristic fluting marks and surface damage.
Insulated bearings or shaft grounding solutions may be required for these applications.
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Poor Storage
Even before installation, bearings can suffer damage if stored incorrectly.
Moisture, vibration or improper handling can cause corrosion or false brinelling while the bearing is still on the shelf.
Bearings should always be stored:
- In their original packaging.
- In a clean, dry environment.
- Away from vibration.
- At stable temperatures.
Prevention Is Better Than Replacement
Replacing a failed bearing fixes the symptom—but understanding why it failed prevents the problem from happening again.
By reviewing lubrication practices, improving installation techniques and selecting the correct bearing for the application, businesses can significantly reduce downtime and maintenance costs.
Leicester Bearings Can Help
With more than 40 years of experience supporting UK industry, Leicester Bearings doesn’t just supply bearings—we help customers identify the right solution for their application.
Whether you need assistance selecting the correct bearing, troubleshooting a recurring failure or improving your maintenance practices, our experienced team is here to help.
From bearings and power transmission products to lubricants, seals and engineering consumables, we provide the products and technical support to help keep your operation running efficiently.
Because keeping industry moving starts with keeping your bearings moving.
Need expert advice?
If you’re experiencing recurring bearing failures or simply want to ensure you’re using the right products for the job, speak to us today.
0116 254 9886
sales@leicesterbearings.co.uk
www.leicesterbearings.co.uk
