Analysis of wear-debris from full-scale bearing fatigue tests using the ferrograph

The ferrograph was used to determine the types and quantities of wear particles generated during full-scale bearing fatigue tests. Deep-groove ball bearings made from AISI 52100 steel were used. A MIL-L-23699 tetraester lubricant was used in a recirculating lubrication system containing a 49 mm absolute filter. Test conditions included a maximum Hertz stress of 2.4 GPa, a shaft speed of 15,000 rpm, and a lubricant supply temperature of 74 C (165 F). Four fatigue failures were detected by accelerometers in this test set. In general, the ferrograph was more sensitive (up to 23 hr) in detecting spall initiation than either accelerometers or the normal spectrographic oil analysis. Four particle types were observed: normal rubbing wear particles, spheres, nonferrous particles, and severe wear (spall) fragments.