Determination of rolling element bearing condition via acoustic emission

Acoustic emission is an emerging technique for condition monitoring of rolling element bearings and potentially offers advantages for detection of incipient damage at an early stage of failure. Before such a technique can be applied with confidence for health monitoring, it is vital to understand the variation of acoustic emission generation with operating conditions in a healthy bearing. This paper investigates the effects of increased speed and load on the generation of acoustic emission within cylindrical roller bearings, and it was found that the root mean square signal level increased significantly with increasing speed whereas increasing load had a far weaker effect. The AERMS value for each experiment was compared with the trend of the Lambda value. The bearing was operating under full film lubrication regime, so it was determined that increases in AERMS were not caused by asperity contact. By consideration of trends in frequency energy amplitude, it was determined that excitation of the bearings resonant frequencies were responsible for an increase of energy in the frequency range of 20–60 kHz. The excitation energy at 330 kHz (the acoustic emission sensor’s resonant frequency) increased with load, indicating a link between high-frequency emission and stress at the contact zone. Following characterisation of the bearing under normal operating conditions, an accelerated life test was conducted in order to induce fatigue failure. The frequency response demonstrated that throughout a period of constant wear, the energy amplitude at the bearings resonant frequency increased with time. As the bearing failure became more significant, the energy of the high-frequency components above 100 kHz was spread over a broader frequency range as multiple transient bursts of energy were released simultaneously by fatigue failure of the raceways. This paper demonstrates the potential of acoustic emission to provide an insight into the bearing’s behaviour under normal operation and provide early indication of bearing failure.