Bearing Degradation in a Pickling Line Gearbox: Lubricant Degradation and Wear Debris AnalysisPages 135-141
R. Pooja Abstract:
Lubricant integrity plays a critical role in maintaining the reliability and service life of industrial bearings. This study reports a bearing failure event in a pickling line gearbox and assesses the underlying mechanisms through lubricant condition assessment and wear debris analysis. Viscosity testing indicated a reduction from 320 cSt to 208 cSt at 40 °C, while moisture content measured 500 ppm, revealing thermal degradation and water ingress. Analytical ferrography identified severe sliding and oxidative wear, characterized by large ferrous plate-like particles with blue gold interference colors. Additional red oxide debris and external contaminants suggested inadequate sealing and abrasive ingress. SEM–EDS analysis confirmed that the debris originated from iron-based low-alloy steel and contained measurable oxygen, indicating oxidation-driven surface fatigue. Collectively, these findings point to boundary lubrication caused by viscosity loss, oxidation, and contamination as the primary contributors to premature bearing failure. The work underscores the need for proactive oil health monitoring and contamination control to enhance gearbox reliability in industrial environments.
Keywords: Bearing failure,
Pickling line gearbox,
Wear Particles,
Ferrography,
Wear mechanisms,
Viscosity degradation
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