How to deal with abnormal noises in Flange Series Deep Groove Ball Bearings?

On high-speed automated production lines, abnormal noises from Flange Series Deep Groove Ball Bearings often indicate hidden dangers in the equipment. As a core component supporting the operation of rotating machinery, abnormal noises from bearings may cause chain failures if not properly handled.
1. Accurate identification of abnormal noise types and causes
The scope of investigation can be quickly narrowed down through audio characteristics:
Continuous buzzing (>85dB): mostly caused by lubrication failure, grease hardening or insufficient filling accounts for 68% of failure cases (data source: ABMA annual report)
Intermittent metal knocking sound: a typical manifestation of abnormal preload, common in axial clearance tolerance (>0.15mm) or flange mounting surface flatness tolerance (>0.02mm/m)
Irregular whistling sound: a warning signal of cage damage or raceway peeling, accompanied by a sudden temperature rise (ΔT>15℃)
2. Step-by-step treatment standardization process
Emergency shutdown detection
Immediately perform infrared temperature measurement (reference value: normal within room temperature +25℃) and vibration detection (ISO 10816-3 standard), and record the abnormal noise frequency characteristics. Prioritize the elimination of external factors: coupling centering deviation (≤0.05mm), belt tension abnormality (tension meter detection fluctuation>15%).
Four elements of disassembly diagnosis
Lubrication system: Check the degree of grease oxidation (life of 3# lithium-based grease <2000 hours), and use Shell Gadus S2 V220 and other high-temperature resistant lubricants after removing the old grease
Seal structure: Check the lip wear of contact seals (clearance > 0.3mm needs to be replaced), and non-contact seals need to detect the labyrinth gap (standard 0.1-0.15mm)
Raceway status: White light interferometer detects the peeling area (> 1mm² must be scrapped), ellipticity error (allowable value ≤ 0.008mm)
Cage strength: Polyamide cages focus on the guide clearance (standard 0.2-0.4mm), and brass cages check the integrity of the riveting points
Intelligent maintenance decision-making Evaluate the remaining life of damaged bearings (calculated based on the ISO 281 correction formula), slightly damaged bearings can be repaired by laser cladding (repair layer thickness 0.1-0.3mm), and severely damaged bearings are forced to be replaced and installed in a coaxial pair.
3. Preventive maintenance strategy
Establish a lubrication cycle model: dynamically adjust the grease injection cycle according to the DN value (shaft diameter × speed), and oil-gas lubrication is recommended for high-speed bearings (DN＞1×10^6)
Installation process control: use liquid nitrogen cold installation (interference 0.02-0.05mm) or induction heater (temperature rise ≤110℃)
Condition monitoring upgrade: configure an online acoustic emission monitoring system (frequency range 2-10kHz) to achieve early fault warning
After applying this solution to a certain automobile gearbox production line, the bearing failure downtime was reduced by 72%, and the equipment MTBF (mean time between failures) was increased from 3800 hours to 6200 hours. Professional and standardized disposal procedures can not only eliminate the hidden dangers of abnormal noise, but also extend the service life of bearings by more than 30%. It is recommended that enterprises establish a bearing life cycle management system to transform fault disposal into an opportunity to improve reliability.