Premature failure analysis of single row, deep groove bearings from idler rollers used on mine sites

Bearings are vital to the operation and efficiency of millions of systems as they allow components to rotate freely with minimal resistance or stress. They are particularly important on belt conveyors which are widely used on mine sites (the specifics of a belt conveyor system will be discussed in more detail later on). It is a common occurrence for idler rollers (the cylindrical pipes upon which the belt slides across) to fail prematurely, causing damage to the belt conveyor and resulting in down-time of the mining operations, consequently costing mining companies hundreds of thousands of dollars. For this reason, it is beneficial to perform a detailed failure analysis of these idler rollers, focusing on the bearings as these are the common point of premature failure. This thesis paper will contain mathematical models simulating the mechanical loads on a bearing using computer simulations in ANSYSY Workbench as well as practical work on damaged idler rollers where a failure analysis will be carried out. This experimental work will consist of a series of pictures taken using a camera as well as an optical microscope for detailed views of the internal surfaces of the bearings. A detailed analysis of the findings will be presented in the discussion.