Acoustic response of high-speed deep groove ball bearing by modifying the internal geometry

In this paper, a mathematical model to predict acoustic responses of high-speed bearing has been developed and demonstrated in an application of Induction motors. Effect on the acoustic behaviour of bearing has studied by modifying the internal geometry, such as the number of rotating elements, curvature ratio, rotating speed with the oval shape of the track raceway due to pre-operational damage. The mathematical model predicts the contact stress, elliptical contact area, noise level dB and Frequencies of waviness pattern. High-speed bearing is tested at four different speeds to monitor acoustic behaviour. This drive end bearing undergoes different rotational speeds; however, the author has simulated the results at a majorly driven constant speed. The author has incorporated application-level testing at the customized test rig. The mathematical model has simulated using coupled governing equations with the help of the Ranga-Kutta method. The simulation and experimental results presented in this paper in the form of a waterfall diagram, FFT spectrum and colour pressure plots. Acoustic characteristics during measurements of the rolling bearing have shown systematically to correlate the mathematical model with an experimental result. Results indicate the remarkable influence of raceway nonconformities of bearing on the noise level. The novelty of research study is to estimate the amplitude of noise level due to waviness generated on rings of bearing after pre-operation damage which is the realistic scenario that occurred after a complaint recorded by the motor manufacturer. The authors believe that this technique enables the bearing designer to choose the appropriate diametric ratio of the ball and track curvature for elliptical contact stress as well as acoustic level. This method is developed specifically for an application of drive-end position ball bearing. Practical use of this method is to determine the Noise level of an electric motor (up to 60 kW capacities) due to improper handling and inappropriate installation of bearing which cause inherent waviness on components.