The flaking is one of the typical fatigue failure mode. Surface presented with cracks, the development of such failure starts from high shear stress in the sub-surface of the material which initiated micro cracks. Due to repeated shear stress on the micro cracks, eventually these cracks extend to the surface and present the flaking phenomenon.
Improper guideway size selection, excessive load, poor lubrication, foreign contamination and particle invasion.
Failure mode：Rust and corrosion
While the lubrication grease or oil film on the rail surface been worn out. Then the gradual oxidation chemical reaction with the exposed metal material will lead to such rust and corrosion. AS without grease or oil film protection to isolate the water moisture or coolant with chemical solutions. The rust and corrosion will lead to flaking failure mode as end result.
Poor lubrication and maintenance, coolant invasion, high-humidity environment.
Failure mode：Water or coolant invasion
When water or coolant invades the guideway , lubrication and anti-rust protection will deteriorate. This leads to rusting and eventually flaking.
Water or coolant solution invasion, high humidity environment
Due to the rotation elements’ insufficient lubrication, then friction generates over heating. The guideway will present with discolored surface condition, and reduces its hardness. Eventually, the surface will develop flaking and the surface of the guideway surface with such kind of pitting and deformation as shown.
Poor lubrication, excessive load
The guideway under excessive load condition, leading to poor circulation movement of balls or rollers. The excessive concentration of load and stress causes wear ad cracks to appear.
Excessive external impact force, poor circulation of balls and rollers.
Failure mode：Denting or Fretting Corrosion
Micro-motion (short stroke) or vibration destroy the lubrication oil film between rollers or balls and their contact points. Which leads to sliding movement and friction increased. The friction generates small debris and dent points on the contact surface. Finally leads to intervals of dents appearing as shown. Such failure is affected by rolling surface roughness and oil film thickness.
Micro-motion(short stroke), poor lubrication, excessive load