An in-situ synthesized model for detection of defective roller in rolling bearings

In this study a theoretical model is presented for the investigation of the damage severity on the rollers in rolling bearings using theory of dimensional analysis. The functional form of the developed model is first tested by carrying out the laboratory experiments. Effect of various parameters such as spall size, radial load, rotor unbalance, axial load, inner race speed, grease grade, radial clearance, number of rollers etc. on the vibration acceleration amplitude of the bearings is investigated. For the purpose of analysis, the bearing is artificially damaged with spalls of different sizes. Vibration acceleration amplitude is used as an output parameter for the characterization of the levels of damages on the defective roller. A strong correlation is observed between the selected parameters and the vibration acceleration values. Experimentally it is observed that the peak vibration acceleration at the characteristic defect frequency increases considerably with increase in the spall sizes. It is shown that the developed model can be used as a preliminary damage diagnostic tool for the preventive maintenance of the roller bearings