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INDUSTRIAL GEARBOXES

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As one of the world’s leading manufacturers of rolling bearings, linear technology
components and steering systems, we can be found on almost every continent – with
production facilities, sales offices and technology centres – because our customers
appreciate short decision-making channels, prompt deliveries and local service.

Europe

Asia
The Americas

Oceania
Africa

The NSK company

NSK commenced operations as the first Japanese network. Here we concentrate not only on the
manufacturer of rolling bearings back in 1916. Ever development of new technologies, but also on
since, we have been continuously expanding and the continuous optimisation of quality – at every
improving not only our product portfolio but also our process stage.
range of services for various industrial sectors. In this
context, we develop technologies in the fields of Among other things, our research activities include
rolling bearings, linear systems, components for the product design, simulation applications using a variety
automotive industry and mechatronic systems. Our of analytical systems and the development of different
research and production facilities in Europe, Americas steels and lubricants for rolling bearings.
and Asia are linked together in a global technology

2
Partnership based on trust –
and trust based on quality

Total Quality by NSK: The synergies of our global network of NSK Technology Centres.
Just one example of how we meet our requirements for high quality.

NSK is one of the leading companies with a long tradition in of quality based on the integrated technology platform of
patent applications for machine parts. In our worldwide tribology, material technology, analysis and mechatronics.
research centres, we not only concentrate on the development More about NSK at www.nskeurope.com or call us on
of new technologies, but also on the continual improvement + 44 (0) 1 636 605 123

INDUSTRIAL GEARBOXES 3
NSK Technology

Designed to Move – Day by Day

4
NSK stands for motion in all areas of application, all over the world. From industrial
plants to household appliances. In a global technology network of more than 62 plants,
more than 31.500 staff members ensure that approximately three million new bearings
with the NSK trademark are produced daily. The incredibly large range of NSK bearings
is employed in all sorts of application areas and this guarantees that our clients will find
the perfect solution for their requirements.

We are there when you need us Our incentive is continuous change

Products and solutions by NSK do not only provide optimum NSK products are not only known for their high reliability,
support for gears, but their inherent control over dynamic high heat and seizure resistance and long bearing life, but
performance delivers on client requirements. The areas of they are also known to be highly economical and environ-
application range from computer disk drives, tunnel boring mentally sound. However, in a world that is continuously
machines, wind generator plants, washing machines, plants changing, a company which promotes highest standards
for semiconductor production and rolling mills. NSK stands for needs to aim high. NSK is permanently developing new
perfect bearing performance no matter how contaminated rolling bearings that even exceed these high quality stan-
the environment or how severe the operating conditions. dards. Large sums of money are invested in basic research,
NSK rolling bearings are employed in the steel industry and material technology and lubrication technology. We are first
in machine tools. They ensure reliable operation of wind when it comes to developing solutions for tomorrow.
turbines and operate just as effectively in pumps for industry
and household as in compressors. The NSK product range
comprises of miniature bearings with a bore diameter of
1 mm up to rolling bearings with a diameter of 5 metres.
No matter the size, NSK is committed to developing ever
improved solutions.

INDUSTRIAL GEARBOXES 5
Focus on performance of outstanding nature

The textbook says: Gearboxes are systems for converting and translating motion.
The designer says: bearings for industrial gearboxes are a means of supporting the
torque and speeds of the drive end to the required turning moments and speeds of
the engine – according to the individual and specific operating processes. And what
does the engineer say from experience? Above all, bearings for modern industrial
drive systems face the most demanding and most versatile requirements. Features,
including sufficient availability, long life, economy and best combination features of
weight and performance, are only a few examples out of many.

Just as versatile as their functions

To achieve the desired torque and speed, a certain degree For example, environmental conditions (such as contamination,
of fatigue strength and life needs to be guaranteed for all water and shock loads) affect bearing performance, as do
components. In addition, sufficient cooling and noise levels need specific operation modes, such as stop-start mode or stand-by
to be achieved for maximum performance. These features have operation. The inherent operating requirements for precision
always been fundamental for gear operation. Considering the gears, such as employed in press printing machines, vary from
various areas of application, the number of gear types is those employed in wind generator plants, which require a high
increasing, as are the demands for smooth gear operation. degree of maintenance free operation.

When selecting a suitable bearing type the 3 4

special operating conditions at the respective

2
bearing location is taken into consideration.

1
1 Full complement cylindrical roller bearing
for low speed and high radial loads

2 Spherical roller bearings for ultra-high loads

and components in oblique arrangement

3 Cylindrical roller bearings for high speed and

3
high loads, functioning as a floating bearing

4 Four-point bearing, acting as the locating

bearing for the high speed stage, while the
1 1
cylindrical roller bearing takes the radial load

6
Hypoid bevel gears Worm gear Planet gear
The larger-sized pinion which is part of this hypoid A particular advantage is translating motion in a single Utilising planetary wheels with internal gears,
bevel gear integrating an offset pinion shaft, stage. In most cases the axis of worm and worm gear epicyclic gearboxes have significant advantages
facilitates lower peripheral force while the turning intersect below 90°, provided there is sufficiently high over other gearbox types. Volume and weight are
moment (torque) remains constant. The offset axis clearance between the axes. During operation vibration reduced. Due to low rolling speed and low sliding
provides for higher strength of pinion support in both is absorbed to a high degree and noise generation speed within the tooth system, noise generation
directions. Low noise generation is a further advantage. during operation is low. However, the high friction can also be reduced. An increased degree of efficiency
However, a disadvantage is increased friction due to reduces the degree of efficiency. This gear is usually can be achieved due to the fact that part of the
additional sliding motion. employed in combination with a globoid gear with energy is translated to the coupling performance –
cylindrical worm made from steel, because these these advantages often compensate for increased
can be subjected to tempering and grinding. maintenance.

Spur gear Bevel gear

Parallel axis gears generally fall into two main types – There are three types of design depending on tooth
Spur gears and Helical gears. Whilst spur gears have the traced characteristics. If spur gearing is used, tooth
advantage of ease of manufacture and accuracy, engagement cangenerate noise. Although Helical
smooth operation and high load capacity are achieved bevel gears also use straight tooth profiles, they
through helical gears (albeit with the need to react the have reduced noise levels, due to improved mesh
thrust loads). Double helical gears constitute a sub-type characteristics. The third type of design employs
with increased load capacity and larger face width. spiral bevel gears and curved tooth bevel gears. This
type of design operates at the lowest noise levels.

INDUSTRIAL GEARBOXES 7
NSK rolling bearings meet
tomorrow’s requirements

The history of developing and designing gears is the history of continuously improving performance. Over the
course of time gears have become increasingly powerful – thus the requirements for bearing performance have
continuously increased. NSK rolling bearings have not only kept pace: great ideas have ensured that they have
always been one step ahead. However, capacities for high performance can only be fully utilised if the correct
rolling bearing is fitted in the right place. For this purpose numerous vital criteria and important features need to
be systematically considered and analysed. These issues concern bearing life, static bearing capacity at maximum
load, extreme load on part of the engine as well as the limiting speeds.

Load Shaft arrangements

First the input torque needs to be determined. If the torque is Another vital issue is to determine whether the gear shafts
variable, it is important to determine the intervals at which are to be arranged horizontally, vertically, or inclined. Do the
the torque varies. Also what are the estimations for tooth shafts change position during operation? Lubrication methods
loads and bearing loads? It is also necessary to determine if and sealing are highly dependent on the position of the shafts.
there are further loads that affect performance e.g. loads Are the shafts arranged on one level? This issue is important with
applied externally to either input or output shafts. regard to bearing load. Another issue: Are hollow shafts or solid
shafts employed? Are the bearings supported within the housing
Speed or other shafts? This issue affects load on the main shaft.
It is important to determine the level of speed and direction
of rotation. Do operating modes include stand-by mode? Shaft guidance
Interaction between the level of load and the level of speed The selection of the bearing type, design and arrangement
needs to be evaluated. are issues that are highly dependent on the operational
requirements which the shaft guiding function needs to fulfil.
Space for assembly It is important to determine the effects that internal clearance
Are certain assembly dimensions fixed? If dimensions can and bearing stiffness may have on tooth engagement. In
be altered the range of dimensions must be specified. If addition, it has to be determined to which degree axial
the space for assembly is not sufficient, problems may movement of the shaft is permissible or whether shaft
exist finding a solution for optimum bearing selection. guidance is to be performed free of clearance.
In this case it needs to be determined to which extent the
dimensions may be altered without causing any problems.

8
Strength of connecting parts Environmental conditions
Does deformation of the housing need to be taken into This is a complex issue. Environmental conditions, i.e. whether
consideration? Does misalignment at the bearing position the machine has to operate in a roofed building or whether it is
caused by shaft bending affect performance? Such issues exposed to dust, sand, strong insulation, high humidity or rain,
can cause distinct additional loads within the bearings and all affect lubrication and selection of the bearing type, sealing
therefore need to be fully understood. and fits. Are there any aggressive agents? What is the ambient
temperature? Is the bearing exposed to separate heating or
Friction cooling? Do other machines cause vibrations when the gear is
One issue is to determine whether specific friction performance in standstill operating mode?
is required to maintain accurate motion. Another issue is to
determine whether support is to be provided for a special gear Lubrication
that requires a low level of heat generation during operation. It needs to be determined whether there are certain conditions
stipulated for lubrication of the rolling bearings or if oil lubrication
Bearing life is required in individual cases. Is centralised oil lubrication
This issue is quite simple: What are the actual requirements feasible for all bearing locations? Does leakage of lubricant
for bearing life? This is driven by the area of application (even in very small quantities) affect operation of the plant
intended for gear operation. If proven and historically reliable or the overall production process?
calculation methods for determining bearing life are applicable,
dimensioning can be based on standard values. If such data Assembly
is not available, more complex calculations for determining It is vital to understand whether mass production is planned
bearing life need to be performed. or whether products are to be individually hand built. As a
rule rolling bearings made to bespoke designs need to be
Safe static capacity assembled with the help of special gauges. Costs for such
It is important to analyse whether certain operating routines devices are more likely to be amortised in series production.
require particular focus on safe static bearing operation, e.g. It is not only essential to determine the complexity of bearing
if the bearing is employed in excavators which have to cope design for initial assembly. If the gears are to be disassembled
with sudden, strong impacts. Significant plastic deformation at regular intervals due to maintenance, easy handling is highly
has to be minimised to prevent premature damage and to dependent on the assembling and disassembling of the bearing.
guarantee smooth operation.
Economy
Is increased complexity of bearing design justifiable in terms
of the benefit of increased bearing performance and operational
reliability? Above all, it needs to be determined whether
increased costs for the bearing are acceptable in view of
easier handling during maintenance.

INDUSTRIAL GEARBOXES 9
 Vital features affecting performance

10
All elements of a machine, for example components of a wind generator plant, have
to cope with high stress factors where arduous environmental conditions prevail.
Maximum reliability is required while maintenance is to be reduced to a minimum.
We have learned from experience that the fatigue life of a gear, and fatigue life of the
total plant is to a high degree dependent on the correct selection of bearing type.
This decision has to be taken prior to calculation and design of the bearing.

The right selection makes the difference

Of course, this preview can only deal with the most
important factors, i.e. basic bearing types, without
considering further important parameters such as size,
internal clearance, cage material and design. Our product
range gives an insight to the scale of the application
spectrum of our products: You can select from more than
35.000 different types of ball bearings and roller
bearings, which fulfil practically any requirement from
engineers from all branches of industry and for all sorts
of applications. Yet in our global company engineers
keep working on new developments to implement
customised applications promptly and efficiently.

INDUSTRIAL GEARBOXES 11
 Bearing types

Design and Classification

Rolling bearings generally consist of two rings, rolling elements and a cage, and they are classified as radial bearings or thrust
bearings depending on the direction of the mainload. In addition, depending on the type of rolling elements, they are classified
as ball bearings or roller bearings, and they are further segregated by differences in their designor specific purpose. The most
common bearing types are shown on the next pages.

Single-Row Deep Groove Ball Bearings

› Suitable for small and moderate radial loads and minor axial loads in both directions
› Extremely high speed possible
› Excellent noise performance
› Also available in pre-lubricated sealed versions

Double-Row Deep Groove Ball Bearings

› Suitable for moderate radial loads and minor axial loads in both directions
› Suitable for moderatespeed
› Sensitive to misalignment

Maximum Type Ball Bearings

› Only suitable for moderate radial loads and small axial loads in one direction
› High speed is possible
› Separable

Single-Row Angular Contact Ball Bearings

› Suitable for moderate radial loads and moderate axial loads in one direction
› High speed is possible. Certain design versions are also suitable for ultra-high speed

Angular Contact Ball Bearings, single row, paired

› Suitable for high radial load and high axial load
› Depending on arrangement axial loads are possible in one or two directions
› Suitable for high speed. Certain design versions are also suitable for ultra-high speed

Double-Row Angular contact Ball Bearings

› Suitable for moderate radial loads and low to moderate axial load in both directions
› Moderate to high speed possible
› Sensitive to misalignment

12
 Legend

Speed Range
Loads
Angular Misalignment

Self Aligning Double Row Ball Bearings

› Suitable for moderate radial loads and minor axial load in both directions
› Moderate and high speed possible
› Can take small degrees of misalignment
› Mounting with adaptor sleeve possible

Spherical Roller Bearings

› Suitable for very high radial loads › Can take small degrees of misalignment
› Axial load in both directions possible › Mounting with adaptor sleeve possible
› Moderate speed possible

Cylindrical Roller Bearings

› Suitable for high radial load
› Depending on bearing type, axial loads in one or two directions are also possible
› Suitable for high speed
› Normally separable

Tapered Roller Bearings

› Suitable for high radial load and axial load in one direction
› When arranged in pairs axial load in both directions possible
› Suitable for moderate speed
› Separable

Thrust Ball Bearings – Single Direction

› Suitable for moderate axial load in one › Suitable for lower speed
direction › Minimum axial load required
› Radial load is not permissible › Separable

Thrust Ball Bearings – Double Direction

› Moderate axial load in both directions possible
› Suitable for low speed
› Minimum axial load required
› Separable

Spherical Thrust Roller Bearings

› Suitable for very high axial load in one › Only suitable for lower speed
direction. Radial load only permissible up to › Accommodates misalignment
55 % of axial load › Oil lubrication is recommended
› Separable

INDUSTRIAL GEARBOXES 13
 Bearing types

Angular Misalignement

Self-Aligning Capability
Low Noise and Torque

Tapered Bore in Inner

Fixed End Bearing

Free End Bearing

Combined Loads
Bearing Types/Features

High Accuracy
Radial Loads

High Speeds
Axial Loads

Comments
Rigidity

Rings
Deep Groove Ball Bearings •• •• •• •••• •••• •••• ••• ∆ *

Magneto Bearings • • • ••• • A

Angular Contact Ball Bearings ••• ••• ••• •••• •••• • B

Double-Row Angular Contact Ball Bearings ••• ••• ••• •• • ∆ *

Duplex Angular Contact Ball Bearings ••• ••• ••• ••• •••• ••• • ∆ * C

Four-Point Contact Ball Bearings • ••• •• ••• ••• • ∆ * D

Self Aligning Ball Bearings •• • • ••• •••• ∆ ∆ * ∆

Cylindrical Roller Bearings ••• x x •••• •••• ••• ••• •• ∆ E

Double-Row Cylindrical Roller Bearings •••• x x ••• •••• •••• • ∆ ∆ F

Cylindrical Roller Bearings with Single Rib ••• •• •• ••• ••• •• G

Cylindrical Roller Bearings with Thrust Collars ••• •• •• ••• ••• •• ∆ H

Needle Roller Bearings ••• x x ••• ••• • ∆

Tapered Roller Bearings ••• ••• ••• •• ••• ••• •• I

Double- and Multiple-Row Tapered Roller Bearings •••• ••• •••• •• •••• • ∆ * J

Spherical Roller Bearings •••• •• ••• •• •••• ∆ ∆ * ∆

Thrust Ball Bearings x ••• x x ••• x

Thrust Ball Bearings with Aligning Seat x ••• x x •••• ∆

Double-Direction Angular Contact
Thrust Ball Bearings
x ••• x •• •••• ••• x

Cylindrical Roller Thrust Bearings x •••• x • •••• x K

Taperded Roller Thrust Bearings x •••• x • •••• x

Sperical Thrust Roller Bearings • •••• • • •••• ∆ L

14
 Characteristics of Rolling Bearings
Compared with plain bearings, rolling bearings have the
following major advantages:
› Their starting torque and friction is low and the difference
between the starting torque and running torque is small
› With the advancement of worldwide standardization, rolling
bearings are internationally available and interchangeable
› Maintenance, replacement, and inspection is easy because
the structure surrounding rolling bearings is simple
› Many rolling bearings are capable of taking both radial
and axial loads simultaneously or independently
› Rolling bearings can be used under a wide range
of temperatures
› Rolling Bearings can be preloaded to produce a negative
clearance and achieve greater rigidity

Comments Key to the symbols

A In general two bearings are mounted face-to-face • • • • Excellent
B Contact angle of 15°, 25°, 30° and 40°. In general two • • • Good
bearings are mounted in opposition • • Suitable under certain conditions
C Combination of DF and D bearings is feasible, • Poor
however not used at the free end. Desired x Not suitable
clearance needs to be adjusted ∆ Applicable
D Contact angle of 35° * Applicable, but it is necessary to allow shaft contraction/
E Including N-Type elongationat fitting surfaces of bearings
F Including NNU-Type One direction only
G Including NF-Type Two directions
H Including NUP-Type
I In general two bearings are mounted in opposition.
Desired clearance needs to be adjusted
J KH and KV-Types are also available;
however, not suitable for use at thefree end
K Including needle roller thrust bearing
L Oil lubrication recommended

INDUSTRIAL GEARBOXES 15
 Bearing position in gears

We hold much in store for you

A rotating gear shaft requires at least two bearings for optimum support and guidance
with regard to the stationary element. NSK rolling bearings do not only accommodate
the respective radial and axial loads, but they also ensure accommodation of shaft
expansion. A fundamental issue concerns the arrangement of a thrust (fixed) bearing
and floating bearing and any necessary set-up adjustments.

Support by means of fixed and floating bearings The selection of the bearing type employed as a thrust bearing
The position of the thrust bearing on the shaft and in the is dependent on the axial load levels and the requirements put
housing has to be set in anaxial direction, i.e. it needs to forward for precise axial guidance of the shaft. Bearing types
guide the shaft axially and it needs to accommodate the axial suitable for accommodating combined stress factors may be
loads of the gear mesh. Fit variations of bearing positions employed as a thrust bearing. These include deep groove ball
on the shaft and in the housing, as a result of production bearings, spherical roller bearings and double row angular
tolerances and operating temperatures, are compensated contact ball bearings. Single row angular contact ball bearings
and balanced by the floating bearing. These compensating mounted in pairs and tapered roller bearings may also serve
and balancing features are vital for preventing strain on as fixed bearings, as do thrust bearings that are assembled in
the bearing. The floating bearing takes the radial loads and combination with a radial bearing.
accommodates axial movement.

16
 Combination of thrust bearing and
floating bearing arrangement with a
cylindrical roller bearing and a
tapered roller bearing arranged in
asymmetric pairs, suitable for high
radial loads and high axial loads from
one direction.
Floating bearing support with two
Two cylindrical roller bearings and
cylindrical roller bearings NJ type. The two
one four-point contact bearing. The
cylindrical roller bearings accommodate radial
two cylindrical roller bearings take
load and are arranged in pairs for uniform
the radial loads while the four-point
and balanced load distribution. To ensure
contact bearing takes axial loads only.
sufficient axial clearance axial adjustment is
performed by means of spacers.
Bearing with two tapered roller
Floating bearing support with two bearings in X-Arrangement, suitable
full complement cylindrical roller for high radial and axial loads.
bearings, suitable for high radial and
moderate axial loads.
Cylindrical planet gears with different bearing arrangements

Adjusted bearing support

Average wind velocity rate
This arrangement does not provide for a particular thrust bearing. The shaft is
guided axially in one direction by each of the two bearings. However, there is the
Turbulence
risk of mutual strain impacts with this bearing type. Basically all bearing types,
which are in a position to accommodate axial loads in at least one direction, as
well as accommodating radial loads, can be used. These include deep groove ball Cross flow

bearings, spherical roller bearings, angular contact ball bearings and tapered roller
bearings. If accurate shaft guidance is required as, for example, with pinion support
integrating spiral bevel gears, adjusted bearing support is of particular advantage.

Floating bearing support

The conditions applying to floating bearing support are similar to that of adjusted
Tower interface
bearing support. However, axial adjustment of the shaft is feasible to a certain
Average vertical air flow gradient
extent. On measuring the extent of axial adjustment, negative thermal conditions
are taken into consideration in order to avoid that the bearing is exposed to axial Air Flow Profile of a Wind Generator Plant
strain impacts. The extent of axial clearance is subject to clearance tolerances. Partial wind velocity depends on rate, place
and time and results in considerable dynamic
Generally floating bearing support is selected if toothing requires released axial load impacts affecting the plant as well as
setting or if highly accurate axial shaft guidance is not of particular importance. subassemblies including the rolling bearings.

INDUSTRIAL GEARBOXES 17
 Bearing position in gears

Preview of Bearing Arrangements

Arrangement Comments Fields of application

Floating bearing support for moderate

radial loads. Outer rings are often adjusted Small electric motors and gears
by means of springs

Free end bearing for high radial loads.

Press fit for inner and outer ring feasible.
Small and medium-sized gears,
Care must be taken so the axial clearance
vibration engines
does not become too small during
Bearing arrangement – adjusted or floating

operations

Standard bearing arrangement for high

loads. Suitable for short distance between
the bearings, because the distance bet- Bevel pinion with integrated shaft in
ween the bearings increases due to back gears, wheel bearings in vehicles
to back arrangement. Adjusting internal
clearance is possible during assembly

Arrangement is selected if press fit for

inner ring is required. Easy handling of
assembly and positioning. Face to face
Small and medium-sized gears
reduces bearing support clearance.
Adjusting bearing clearance is required
on assembly

Suitable for high speed and moderate

radial and axial loads. If certain design
versions are used,preload (e.g. by means
Small gears, machine tools
of spring support) is possible. Adjustment
of bearing clearance and preload is
required on assembly
Combination of thrust bearing and floating

The bearing arrangement is often used

if the load at the bearing positions is
uniform and balanced. Lower axial loads Small electric motors, gears
to reduce noise the bearings are often
adjusted by means of springs

This is a common arrangement.

Medium-sized electric motors,
Loads on the bearings vary.
ventilators, gears
Lower axial loads

18
 Arrangement Comments Fields of application

Intended for higher radial loads and lower

axial loads. Due to the separability of
the cylindrical roller bearings, these are Gears, traction motors
suitable for assembly requiring a press fit
of the inner ring and outer ring

Intended for high radial loads at both

bearing positions with moderate axial Gears, roller conveyors, paper machines
loads. Not sensitive to misalignment

Intended for high radial and moderate

Combination of thrust bearing and floating bearing arrangement

axial loads at high speed. (To avoid radial

loading of the deepgroove ball bearing,
Gears, ventilators
which is employed as an axialbearing in
the housing above, the deep groove ball
bearing needs to be relieved)

Intended for high radial and moderate

Gears, paper machines
axial loads

Intended for high radial and axial loads.

Face to face of the tapered roller bearing
Pinion shafts in gears
allows misalignment to a slightly higher
extent compared to back to back

Intended for moderate axial loads. The

angular contact ball bearings need to be
used in universal combination (BG) or Fields of application with high
paired design. Often acylindrical roller requirements on axial guidance
bearing is used instead of the radial
bearing

Bearing employed when misalignment and

high axial loads in one direction are present.
The combination of spherical roller bearings
and thrust spherical roller bearings is also
often used. The spherical centre of the self- Thrust bearing blocks, post cranes
aligning seat must coincide with that of the
self-aligning ball bearing. Axial minimum
load is to be observed. Also suitable for
vertical assembly (post cranes)

INDUSTRIAL GEARBOXES 19
 Calculation Methods

The key to the perfect solution

Having selected the bearing type, the next step is to determine the required bearingsize and
bearing design to come to a solution that considers all aspects for high capacity and efficient
design. One criterion is of paramount significance: estimating bearing life. For a long time
experts have been aware of the fact that many features are to be considered for providing a
reliable estimation. NSK’s latest developments include optimised methods and calculation
procedures that increase accuracy for estimating bearing life.

A host of features to be considered

Numerous influencing features are to be considered when
determining bearing life. In the individual area of application,
the type and bearing load capacity as well as speed are just
as important as the design surrounding the bearing, i.e. the
properties of the shaft and the housing, their material and
tolerances. Outer sealing, lubrication method, operating
temperature and ambient temperature: all these forces which
affect the gear system need to be taken into consideration,
calculated and assessed. Further influencing factors are, for
example, load evolving from coupling, cardan shafts and belt
drives, and loads evolving from the shaft and gears, and many
more, all of which are just as important as the environmental
conditions prevailing on the site. Briefly put: We are dealing
with complex calculations. NSK has developed numerous
methods and procedures for assessing and analysing these
complex calculation issues.

20
Conventional calculation methods Standard conventional methods
Conventional standardised calculation methods for determining
p p
C
L10h= 10 C
6
bearing life are also referred to as the catalogue method. L10= or
P . n 60 P
These are stipulated in ISO 281. The parameters involved
are: bearing load, speed, load rating and bearing type. The C Dynamic load rating
bearing life figures that result are: L10 or L10h. The extended P Dynamic equivalent load
p Exponent (3 for ball bearings, 10/3 for roller bearings)
standardised calculations according to ISO 281, go further
n Speed
and take the limiting loads for fatigue life of the bearing, the
lubrication parameter, and the degree of lubrication purity
into account and thus provide a more accurate outline of the Modified calculation for bearing life

bearing operating condition and performance. The bearing p

life figures that result are: L10a or L10ah. Both are generally Lna= a1 . aDIN . C
P
approved methods, but as seen before, there is always
or
potential for improvement.
p
106 C
Lna= a1 . aDIN .
n.60 P
a1 Coefficient for anticipated bearing life
a DIN Coefficient for operating conditions

The ABLE-Forecaster The ABLE-Forecaster

The ABLE-Forecaster (Advanced Bearing Life Equation) is
the latest software which NSK has developed for increased
Bearing load

Conventional theory
accuracy in estimating bearing life. The standardised Extended theory for
calculations according to ISO 281 have been extended: calculating bearing life
Limiting loads for fatigue life
the main difference (and progress) is the fact that this
method is based on information resulting from actual
applications and tests performed over a period of several
decades. In addition, this avanced calculation method,
which NSK has developed, considers a great variety of
Bearing life
features, including environmental conditions, limiting
loads for fatigue life, lubrication parameters as well as
LNSK=a1 · aNSK · L10h
contamination factors and material.

a1 Coefficient for anticipated bearing life

a NSK Coefficient for operating conditions

INDUSTRIAL GEARBOXES 21
 Calculation Methods

STIFF

A further invention: STIFF

STIFF is a program developed by NSK that considers
important parameters such as deformation of the shaft
and housing, misalignment, displacement of the bearing
itself (and adjacent bearings) as well as internal operating
cycles. The conventional methods merely analyse the
rolling bearing itself, regardless of other features affecting
bearing life. STIFF works from the principle of a bearing-
shaft-housing-system. The software is outstanding due
to its calculation scope and provides results that allow
several analyses within a short period of time. Additionally
it eliminates many time intensive tests of special rolling
bearings and adjustments with regard to the individual
application conditions.

Radial force Calculation procedures on estimating

Axial force
bearing life – STIFF-Program

Estimating strength
Analysis of component deformations
Parameter:
› Load on components and component deformation
Shaft (mm) – Shaft deformation › Loads on bearings and resultant bearing deformations
Deflection (mm)

Estimating factors affecting performance

Analysis of internal friction conditions
› Kinematic aspects of the rolling elements
› Tilt and skew motion of the rolling element
Cylindrical roller bearing Tapered roller bearing Tapered roller bearing
›
Contact pressure [GPa]

Contact pressure [GPa]

Thickness of lubrication film supplied

Contact pressure [GPa]

(left hand-side) (right hand-side)

› Heat generation and dynamic torque

More accurate estimates of bearing life

Analysis of internal stress factors of the rolling element
Lenght of rolling element Lenght of rolling element Lenght of rolling element
(mm) (mm) (mm)
› Contact pressure and internal load distribution

Cross-section on stress of rolling with maximum load Estimating reliability and operational safety
Wear parameter
› PV-Value (resulting from contact potential and peripheral
velocity; this value gives evidence of potential states of
friction and wear)

Load distributions and load sections

22
Even more tools – developed on the basis of experience
and skills
Another example of calculation methods employed by
NSK is FEM Analysis. Finite Element analysis examines
the distribution of stress factors within the bearing and
its components and thus provides optimum support for
non-standard applications. Frequency analysis, on the
otherhand, examines noise generation of the rolling bearing
within the application of which performance and operating
characteristics of the bearing system can be understood.
Adding to these bespoke calculation capabilities are a host
of bearing calculation programmes for speeding up more
routine analyses.

Optimised cage design: On the basis of the FEM-Analysis, component

parts with stresslevels beyond allowable levels can be examined. Such
areas can be re-designed enabling stress levels within the bearing to
be reduced and thus improve bearing performance.

Planet gears are thin-walled machine parts exposed to high stress.

On evaluating planet gear deformation, internal geometry aspects of
the bearings were analysed and adjusted for uniform and balanced
distribution of load. Thus improved bearing life was achieved.

INDUSTRIAL GEARBOXES 23
 Material for Roller Bearings

NSK – Absolutely tough

NSK is first when it comes to developing rolling bearings which can cope with high
stress factors and severe operating conditions. NSK rolling bearings stand for high
reliability, long life and high resistance to wear and seizure.

High investments, in particular for basic materials technology material that sets new benchmarks, in particular when it
research, ensure that our demanding goals are achieved. comes to operating conditions in contaminated environment
Investing in new methods has paid dividends as many recent or if high stress factors are encountered. The new materials
achievements reveal: NSK has developed a ground-breaking can be employed for a wide range of bearing types.

Methods for achieving longer bearing life

Goal:
longer bearing life

Sub-surface cracks Flaking on rolling surfaces

Material Heat treatment Sealing

High purity Special Heat Treatment Control of retained austenite

VIM-VAR Z-Steel UR-Process TF Bearings Sealed bearings

for automotive
gearboxes
EP-Steel HI-TF Bearings

Sealed tapered
Super-TF
roller bearings
Bearings

24
Cause and effect Main fields of application
All rolling bearings have a limited fatigue life, which shows Super-TF technology can be applied in a wide range of bearing
when fine cracks develop beneath the surface resulting in types, for example, cylindrical roller bearings, tapered roller
flaking on the contact areas of the rolling element and rolling bearings, spherical roller bearings, deep groove ball bearings
surface. The life is highly dependent on the degree of purity of as well as angular contact ball bearings.
the steel used for the rolling bearings. Failure before the end of
the calculated bearing life; however, is more frequently caused
by flaking formation directly at the contact surfaces, which is
due to stress at the rolling surfaces. Contamination of the
lubrication caused by metallic particles, sand particles, or
improper handling during assembly or maintenance is often
the reason for premature failure of the rolling bearing. To
combat these causes of failure NSK has developed a new
material: Super-TF for rolling bearings operating under high
stress conditions. A new material that undergoes a new heat
Distribution and size of carbide and carbonitride particles in
treatment method. Super-TF material (left) compared to distributionand size in a
standard material (magnified by 4.000).
Simply tough: Super-TF
The development process was aimed at improving the
Failure (sµm)

properties of the previous TF-material. For this purpose NSK

developed a material composition and heat treatment process SUJ2X26
that ensures even distribution of the carbide particles within Super-TF™ with special heat treatment

the bearing steel while at the same time minimising the size
of the particles. In addition, NSK has employed a new method
to bond even finer particles of carbides and nitrides in steel –
a method that has been patented in Japan and overseas.
Rolling bearings made from Super-TF Material not only have a
longer bearing life under contaminated lubrication conditions –
about ten times above that of standard material – but their
resistance against flaking, wear and thermal stress factors is
also superior to the previous TF-material. An impressing
price-performance ratio for the client. Life cycle hours

Longer bearing life due to Super-TF material

INDUSTRIAL GEARBOXES 25
 Lubrication

So everything runs smoothly

About 40 % of damage that rolling bearings suffer prior to the Separating the contact surfaces
end of estimated bearing life is caused by improper lubrication. To ensure that the contact surfaces are permanently
Damage becomes obvious in the form of wear, insufficient and separated, a straight forward method for specifying the
uneven lubrication, flaking, seizure, fatigue damage or conditions of the lubrication necessary. Based on the theory
overheating of the bearings. All are caused by deficient of elasto-hydrodynamic lubrication, the ratio of actual to
lubrication – too much lubrication is also one of the causes – required oil viscosity during operation needs to exceed a
and all could be avoided if more attention were paid to the factor 1. According to ISO 281 nominal bearing life expressly
individual application demands for lubrication. Optimum refers to this minimum value. The required viscosity is
separation of the contact surfaces by a lubrication film is not driven by the operating speed and the rolling element pitch
the only function of a lubricant in rolling bearings. Reducing circle diameter.
friction, preventing contamination, protection against corrosion
and aiding heat transfer, are all important features. Oil or grease
Commonly rolling bearings are usually lubricated with the
same oil as is employed for the gears. A key advantage of oil
lubrication is the numerous possibilities to ensure permanent
lubrication of all contact points. In this context, selective supply
and discharge of oil constitutes another advantage. In addition,
oil is an effective medium to transfer heat from the contact
points and replacing the lubricant is usually straight forward.
Calculation of required oil quantity Grease lubrication on the other hand, contributes to application
sealing and can offer maintenance free lubrication.
0.19 • 10-5
Q10= T2 - T1
d • µ • n • F(N)
Lubrication for the purpose of heat reduction
Q Oil supply (litre/min) Rolling bearings which operate at high speed run the risk of
T1 Oil temperature at inlet (in °C)
excessive heat generation due to the friction of the bearing
T2 Oil temperature at outnlet (in °C)
d Bearing bore diameter (in mm) and churning of the lubricant. This may result in unacceptable
µ Dynamic friction coefficient (see table below) temperature rise of the gearbox components. Heat transfer is
n Speed (rpm)
thus essential for preventing overheating of the bearing. Various
F Radial load on bearing (in N)
methods are available for this purpose, but one procedure
has proven to be particularly effective with respect to large
Friction coefficient
machines employing large rolling bearings, e.g. pressing
Bearing type for different machines, paper machines, steel processing machines: heat
bearing types µ
transfer is effected by means of higher lubricant volume
Spherical roller bearing 0.0028 supplied under pressure. The actual operating conditions
Thrust spherical roller bearing 0.0028
of the gear serve as a basis for calculating the lubrication
Tapered roller bearing 0.0022
Angular contact ball bearing 0.0015 quantity required for sufficient heat transfer.
Radial deep groove ball bearing 0.0013
Cylindrical roller bearing 0.0010

26
Damage caused by lubrication problems

Damage symptom Cause Reason

In places of component contact a lubrication film is not formed. Lubrication film is insufficient to
Insufficient lubrication
totally separate components
Application film too thin due to insufficient viscosity of oil or grease base oil. When grease is employed, the structure
Noise Inappropriate lubrication
of the thickener may have an unfavourable effect (grease component particles cause noise generation)

Contamination Foreign particles disrupt lubrication film causing noise generation

In places of component contact, a lubrication film is not formed. Lubrication film is insufficient to
Insufficient lubrication
totally separate components
Cage wear
Inappropriate lubrication Insufficient viscosity of oil or grease base oil; lubricant does not contain additives for protection against wear

In places of component contact lubrication film is not formed. Lubrication film is insufficient to totally separate components.
Insufficient lubrication
Fretting corrosion from oscillating relative movement
Wear of rolling elements, Insufficient viscosity of oil or grease base oil. Lubricant does not contain additives for protection against wear or EP-Additive
Inappropriate lubrication
rolling surfaces, rib surfaces (for high load)

Contamination Particulate or liquid contaminants with corrosive or abrasive effects

Insufficient lubrication In places of component contact a insufficient lubrication film to support high contact stresses. For protection against wear

Fatigue spalling Inappropriate lubrication Insufficient viscosity of oil or grease base oil. Lubricant pressure-viscosity characteristics insufficient

Contamination Ingress of hard particles resulting in indentations and thus high surface stress. Corrosion damaging contact surfaces

In places of component contact a lubrication film is not formed. Lubrication film is insufficient to
Insufficient lubrication
totally separate components
High temperature rise of
Inappropriate lubrication High friction and temperature rise due to sporadic component contact
bearing, seizure (overheating)

Contamination High lubrication friction with average and high speed, in particular on sudden lubrication supply

Degraded lubricant Insufficient lubrication Operating temperature exceeds temperature permissible for lubricant (causing breakdown and residue)
(discoloured, solidified, reduced
lubrication performance) Inappropriate lubrication Re-lubrication intervals or lubricant change period too long

Monitoring through lubrication

Monitored Parameters Method Detectable or avoidable damage type

Lubrication Analysis (water content, contamination, content, pH, saponification number) Fatigue wear, wear, corrosion, inappropriate lubrication

Lubrication system Oil pressure, oil condition, oil flow and oil temperature Bearing runs hot, wear

INDUSTRIAL GEARBOXES 27
 Proper dimensioning

If the inner ring of a rolling bearing element is fitted to the always required for rings where the load does not move with
shaft, without using other fixing methods, there is often the respect to it. Depending on the field of application a clearance
risk of slippage between the inner ring and the shaft. This fit may be employed for either the inner or outer ring. For
slippage, commonly referred to as creep, may cause particles example, if the bearing needs to move in the axial direction
to separate from the surfaces resulting in wear, which in turn, for the purpose of assembly, disassembly or to accommodate
causes considerable damage to the shaft. Particles from thermal expansion. In this case lubrication or other suitable
metallic abrasion can enter into the inside of the bearing and procedures need to be considered to avoid damage at the
damage the rolling surfaces. In addition, metallic abrasion can contact points caused by creeping.
cause excessive temperature rise and vibration. It is important
to prevent creep by providing a sufficient and permanent
location for the safe attachment of the ring – either on the
shaft or in the housing. However, an interference fit is not

Fits of Radial Bearings with Housings

Tolerances for Axial Displacement

Load Conditions Examples Remarks
Housing Bores of Outer Ring

Heavy Loads on Bearing Automotive Wheel Hubs

in Thin-Walled Housing (Roller Bearings) P7
of Heavy Shock Loads Crane Travelling Wheels

Rotating Automotive Wheel Hubs

Solid
Outer Ring Normal or Heavy Loads (Ball Bearings) N7 Impossible _
Housings
Load Vibrating Screens

Conveyor Rollers Rope

Light or Variable Loads M7
Sheaves Tension Pulleys

Heavy Shock Loads Traction Motors M7 Impossible _

Direction
If axial displacement
of Load
Normal or Heavy Loads K7 Impossible of the outer ring is
Indeter-
Pumps Crankshaft Main not required
minate
Bearings Medium and Large
Solid Motors Axial displacement
or Split Normal or Light Loads JS7 (J7) Possible of outer ring is
Housings necessary

General Bearing
Loads of All Kinds Applications, Railway H7
Rotating Axleboxes
Inner Ring Easily possible _
Load
Normal or Light Loads Plummer Blocks H8

28
Procedures for perfect fit selection Equation Method 1

To calculate the proper fit for the bearing, it is important to

d
consider the bearing load. At the load application point the ∆dF = 0.08 F • 10 -3 (N)
B
inner ring of the bearing undergoes radial compression while
∆d F Required Interference fit
opposite to this point the ring expands. This effectively reduces d Bore diameter (mm)
the component interference. The method shown in Equation B Width of inner ring (mm)
F Radial load (N)
method 1 may be employed for calculating fit reduction.
In practice, the actual interference level selected should
always exceed the result from Equation 1. Calculation on the Equation Method 2

basis of Equation 1 is sufficient for comparatively low loads,

F1
expected in most areas of application. If higher loads are ∆dF ≥ 0.02 • 10 -3 (N)
B
expected, however, Equation method 2 should serve as
∆d F Required Interference fit
basis for calculation. B Width of inner ring (mm)
F Radial load (N)

Tolerances for Axial Displacement

Load Conditions Examples Remarks
Housing Bores of Outer Ring

Solid High Temperature Rise

or Split of Inner Ring Through Paper Dryers G7 Easily Possible –
Housings Shaft

Rotating
Grinding Spindle Rear Ball
Inner JS6 (J6)
Bearings
Ring Load
Possible –

High Speed Centrifugal

Compressor Free Bearings
Accurate Running
Desirable under
Normal or Light Loads
Grinding Spindle Front
Direction Ball Bearings
For heavy loads,
Solid of Load interference fit tigh-
K6 Impossible
Housing Indeter- ter than K is used.
minate High Speed Centrifugal When high accuracy
Compressor Fixed Bearings is required, very
strict tolerances
sould be used for
Accurate Running and Cylindrical Roller Bearings fitting
High Rigidity Desirable for Machine Tool Main M6 or N6 Impossible
Rotating under Variable Loads Spindle
Outer
Ring Load
Minimum noise is
Electrical Home Appliances H6 Easily Possible –
required

INDUSTRIAL GEARBOXES 29
 Fits of Radial Bearings with Shafts

Load conditions Examples

Radial Bearings with cylindrical bores

Easy axial displacement of inner

Wheels on stationary axles
ring on shaft desirable

Rotating Outer Ring Load

Easy axial displacement of inner
Tension pulleys, rope sheaves
ring on shaft unnecessary

Electrical home appliances, pumps,

Light loads or variable Loads
blowers, transport vehicles, precision machinery,
(≤ 0.06 Cr (1))
machine tools

General bearing applications,

Rotating Inner Load Normal loads
medium and large motors,
turbines, pumps,
(0.06 to 0.13 Cr (1))
or Direction of Load Indeterminate engine main bearings, gears,
woodworking machine

Railway axleboxes, industrial

Heavy loads or shock loads vehicles, traction motors,
(> 0.13 Cr (1)) construction, equipment,
crushers

Axial Loads Only

Radial Bearings with tapered bores and sleeves

General bearing applicaions, railway axleboxes

All Types of Loading

Transmission shafts, woodworking spindles

Notes: (1) Cr represents the basic load rating of the bearing.

This table is applicable only to solid steel shafts.

30
 Shaft Diameter (mm)
Tolerance
Remarks
Ball bearings
Cylindrical roller bearings,
Spherical roller bearings of shaft
tapered roller bearings

g6
Use g5 and h5 where accuracy
is required. In case of large
All Shaft Diameters
bearings, f6 can be used to
allow easy axial movement
h6

≤ 18 – – js5
18~100 ≤ 40 – js6 (j6)
–
100~200 40~140 – k6
– 140~200 – m6
≤ 18 – – js5~6 (j5~6)
18~100 ≤ 40 ≤40 k5~6
100~140 40~100 40~65 m5~6 k6 and m6 can be used for
140~200 100~140 65~100 m6 single-row tapered roller bearings
and
200~280 140~200 100~140 n6 single-row angular contact ball
– 200~400 140~280 p6 bearings instead of k5 and m5
– – 280~500 r6
– – > 500 r7
– 50~140 50~100 n6
– 140~200 100~140 p6 More than CN bearing internal
– > 200 140~200 r6 clearance is necessary
– – 200~500 r7

All Shaft Diameters js6 (J6) –

h9/IT5 IT5 and IT7 mean that the

deviation of the shaft from its
true geometric from, e.g.
All Shaft Diameters roundnes and cylindricity should be
within the tolerances of IT5 and IT7
h10/IT7 respectively

INDUSTRIAL GEARBOXES 31
 NSK Sales Offices – Europe, Middle East and Africa

UK
NSK UK Ltd.
Northern Road, Newark
Nottinghamshire NG24 2JF
Tel. +44 (0) 1636 605123
Fax +44 (0) 1636 643276
[email protected]

France & Benelux Middle East South Africa

NSK France S.A.S. NSK Bearings Gulf Trading Co. NSK South Africa (Pty) Ltd.
Quartier de l’Europe JAFZA View 19, Floor 24 Office 2/3 25 Galaxy Avenue
2, rue Georges Guynemer Jebel Ali Downtown, Linbro Business Park
78283 Guyancourt Cedex PO Box 262163 Sandton 2146
Tel. +33 (0) 1 30573939 Dubai, UAE Tel. +27 (011) 458 3600
Fax +33 (0) 1 30570001 Tel. +971 (0) 4 804 8205 Fax +27 (011) 458 3608
[email protected] Fax +971 (0) 4 884 7227 [email protected]
[email protected]

Germany, Austria, Poland & CEE Spain

Switzerland, Nordic NSK Polska Sp. z o.o. NSK Spain, S.A.
NSK Deutschland GmbH Warsaw Branch C/ Tarragona, 161 Cuerpo Bajo
Harkortstraße 15 Ul. Migdałowa 4/73 2a Planta, 08014 Barcelona
40880 Ratingen 02-796 Warszawa Tel. +34 93 2892763
Tel. +49 (0) 2102 4810 Tel. +48 22 645 15 25 Fax +34 93 4335776
Fax +49 (0) 2102 4812290 Fax +48 22 645 15 29 [email protected]
[email protected] [email protected]

Italy Russia Turkey

NSK Italia S.p.A. NSK Polska Sp. z o.o. NSK Rulmanları Orta Doğu Tic. Ltd. Şti
Via Garibaldi, 215 Russian Branch 19 Mayıs Mah. Atatürk Cad.
20024 Garbagnate Office I 703, Bldg 29, Ulya Engin İş Merkezi No: 68/3 Kat. 6 
Milanese (MI) 18th Line of Vasilievskiy Ostrov, P.K.: 34736 - Kozyatağı - İstanbul 
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[email protected] Fax +7 812 3325072 [email protected] 
[email protected]

Please also visit our website: www.nskeurope.com

Global NSK: www.nsk.com

Every care has been taken to ensure the information in this publication is accurate but no liability can be accepted for
any errors or omissions. © Copyright NSK 2009. The contents of this publication are the copyright of the publishers.
Ref: IG/D/E/09.16

32