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Objective of lubrication
Lubricate
Cool
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Objective of lubrication
Corrosion protection
Maintain cleanliness
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Elements to be lubricated
Bearings
Gears
Cylinders
Hydraulic system
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Type of lubricants
Oil
Mineral
Synthetic
Grease
Mineral
Synthetic
- Thickener type
Lithium, Lithium complex, sodium, aluminum, aluminum
complex, calcium, calcium complex
Solid lubricant
Graphite
Molybdenum disulfide
Cupper
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Lubrication Condition
Boundary Lubrication
The lubrication effect mainly depends on
the lubricating properties of the boundary
layer
Mixed lubrication
Both the load carrying oil film and the
boundary layer play a major role
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Lubrication Regimens
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Solid lubricant
Solids such as graphite and
Base Material
S
Mo
Base Material
Base Material
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Frictional Moment
The frictional moment M of a
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10%
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Association (AGMA)
industrial gear oils
Society of Automotive
Engineers (SAE)
engine (crankcase) oils
automotive gear oils
Saybolt Universal Seconds
(SUS)
mineral base oils
A comparison of these other
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temperature decreases
a lubricant having the correct
viscosity at the operating
temperature may be too viscous for
cold start
Viscosity decreases as the
temperature increases
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Temperature (C)
100
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high VI = 80 - 120
low VI = 0 - 40
Industrial lubricants:
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Temperature (C)
VI is typically 95 100
100
Addition of VI improvers or the
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A flat curve is
indicating a high VI.
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Viscosity
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Synthetic Oils
The most significant advantages
of synthetic oils are:
Thermal and oxidation stability
Favorable viscosity /
temperature behavior
Toxicity
Higher price
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Viscosity
Viscosity is the most important property of a lubricating
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Viscosity Guide
Maximum Viscosities cSt
22,000
Optimum Viscosities cSt
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Hydraulic Systems
30
Plain Bearings
40
75
At Operating Temperature
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Hydraulic Systems
13
Plain Bearings
21
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Additives
Viscosity Index Improver
Oxidation inhibitors
Rust inhibitors
Metal deactivators
Antiwear additives
Extreme pressure
additives
Friction modifiers
Detergents
Dispersants
Pour point depressants
Anti-foam agents
Tackifiers
Emulsifiers
Biocides
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How it works
The additives act like popcorn. At low temp. they are tight
balls which do not significantly increase the oil resistance. At
high temp. these tight-balls explode into long chain polymers,
which increase the oils resistance to flow (viscosity) and thereby
preventing the oil from thinning out too rapidly.
Examples
Polymethacrylates (PMA)
Olefin Copolymers (OCP)
Styrene-Isoprene (SI)
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Pour Point
The Pour Point is defined as the lowest temperature at which an oil will flow
Most oils lubricate down to approximately 10C above their pour point
The table below shows some typical pour points of mineral and synthetic oils.
Lubricating oils
Pour Point ( C)
Mineral oils
- 40 - 10
Ester oils
- 70 - 20
Polyglycol oils
- 50 - 20
Polyphenylether oils
- 12 - 21
Silicone oils
- 80 - 30
Perfluoroalkylether
- 70 - 30
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How it works
Example
Polymethylmethacrylates
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Oxidation
Oxidation is a chemical reaction between oxygen and the
sludge
gums
varnish
acid
Oxidation increases the viscosity of the oil
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Days
416
208
104
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Rule of Thumb
Every 10C rise in temperature above 70C halves the life
expectancy of the oil.
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Anti-Oxidant
IVE
T
I
D
AD
What it does
How it works
Reacts more readily with oxygen (air) than the oil does
The additive is consumed and requires replenishment by top-up
or oil changes
Examples
Amines
Phenols (e.g. BHT)
Naturally Occurring Anti-oxidants (e.g. Vitamin E)
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Demulsibility
Demulsibility is defined as the ability of an oil to separate from
water
Demulsibility is a desirable property in many types of lubricants
Demulsibility test time required for a specified oil-water emulsion
Oil
40 ml
Water
40 ml
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Demulsibility
Additives that are added to the
Hydraulics
Turbines
Gears
Circulating oils
Sometimes demulsibility
additives are added to oils
(e.g. Industrial Gear Oils)
Generally, highly refined
straight mineral oils have
inherently good demulsibility.
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Demulsifier
IVE
T
I
D
AD
What it does
Prevents or inhibits the formation of emulsions
Accelerates the speed at which the oil separates from
water
How it works
Promotes combination of small water droplets into
larger droplets, which coalesce more easily
Examples
Cationics
Polymers
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Foam
Almost every lubricant foams to some extent due to the agitation and
aeration that occurs during operation. Air entrainment due to the agitation
encourages foam formation.
The presence of some detergent and dispersant additives tend to promote
foam formation. Foaming increases oxidation and reduces the flow of oil to
the bearings. In addition, foaming may cause abnormal loss of oil through
orifices. Anti-foam agents are used to reduce the foaming tendencies of the
lubricant. Foam inhibitors may be added to a lubricant in service if a
foaming problem is detected. The lubricant and equipment manufacturer
should be consulted before adding foam inhibitors. ASTM D892 is a
laboratory test used to determine the foaming characteristics of the
lubricant. It can monitor the foaming tendency and stability.
The tendency of oils to foam can lead to inadequate lubrication, thus
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Foam
Foam is an accumulation of air bubbles on the surface of an oil. It
bearing surface
Foaming can wreak havoc on a hydraulic system
Air gets into oil from:
Churning gears
Leaky suction lines
Low fluid levels
Improper system design
Interaction with materials e.g. seals, rubber, paint etc.
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Foam Inhibitor
IVE
T
I
D
AD
What it does
How it works
Examples
Silicones
Methacrylates (Foam Inhibitor and Air Release Agent)
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Air Entrainment
How well does the oil release entrained air?
Entrained air
- Looks like a milkshake
- Must rise to the surface to disperse
- Lighter oil releases entrained air faster
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How it works
Examples
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What it does
Protects iron, steel and other metallic surfaces from attack
by air, water, acids, etc.
How it works
Reacts chemically with metal surfaces forming an inert film.
This film is a barrier to air, water, and acid attack
Examples:
Derivatives of fatty acids
Amines
Imidazolines
Triazoles
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Tackifier
IVE
T
I
D
AD
Keeps oil from flying off fast moving metal surfaces (improves
the oils adhesiveness)
How it works
Examples:
Poly-methacrylates
Poly-isobutylenes
Natural Resins / Polymers
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Detergent
E
V
I
T
DI
D
A
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Detergent
E
V
I
T
DI
D
A
What it does
How it works
Examples:
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Dispersant
IVE
T
I
D
AD
What it does
How it works
Examples:
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Anti-Wear
IVE
T
I
D
AD
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Anti-Wear
IVE
T
I
D
AD
What it does
How it works
Reacts chemically with metal surfaces forming a film over the surface
under normal operating conditions.
Additive film wears out instead of the metal surface.
Examples
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Anti-Wear Test
Four Ball Tester
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The additives reacts with the metal surface to form a soft slippery
chemical layer which prevent sever wear and welding.
Prevents microscopic welding between metal surfaces under high
pressure or temperature.
EP gear oils limit operating temperatures to under 82C.
Corrosive to yellow metals at temperatures greater than 70C. (previously
was a concern that phosphorous would react with bronze. New technology has reduced the
corrosive attack by use of non active sulfur)
How it Works
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Limitations
The longer lives with additives are only valid when carefully
tested and approved lubricants with EP or other additives are
used. The ability of the additives to promote a smoothening effect
of the raceway during running in, is of utmost importance.
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Friction Modifier
E
V
I
T
DI
D
A
What it does
How it works
Examples
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Metal Deactivator
E
V
I
T
DI
D
A
What it does
Eliminate catalytic influences on oxidation and corrosion
How it works
Absorption of a protective film on metal surfaces, which
prevents the contact between the base metal and the
corrosive substances.
Examples
Triarylphosphites
Sulphur combinatiations
Diamines
Dimerkaptane thiadiazole derivates
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Greases
Greases are cohesive lubricants whose composition
5-20%
75-95%
0-15%
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Greases Characteristics
A grease is expected to:
Reduce friction and wear
Provide corrosion protection
Seal bearings from water and contaminants
Resist leakage, dripping and throw off
Resist change in structure or consistency during service
Maintain mobility under conditions of application
Be compatible with seals
Tolerate or repel moisture
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Disadvantages:
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Thickeners
Main Advantage(s)
multipurpose
high temperature
Aluminum Complex
high temperature
high temperature
Polyurea
Barium Complex
extreme pressure
Calcium Complex
Solid Lubricants
Graphite
anti-wear
Zinc Oxide
white colour
Calcium Carbonate
anti-rust, EP
anti-wear, load-carrying
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Use of Additives
Engine
ADDITIVE
Detergents
Dispersants
Anti-Oxidants
Rust Inhibitors
Anti-Wear
E.P. Agents
VI Improvers
Pour Point
Depressants
Anti-Foam
Dyes
Friction Modifiers
Oils
9
9
9
9
9
ATF
General
Hydraulic
Industrial
Automotive
Purpose Oil
Oil
Gear Oil
Gear Oil
9
9
9
9
9
9
9
9
9
9 9
9 9
9
9 9
9 9 9
9 9 9
9
9 9
9
9
9
9
9
9
Some
Some
9
9
9
9
Grease
9
9
9
9
9
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Walk penetration
DIN 51804 / 1
(0.1 mm)
Structure
Application Generally
000
00
0
445475
400430
355385
fluid
almost fluid
extremely soft
310340
265295
220250
very soft
soft
moderate
stiff
very stiff
extremely stiff
1
2
3
4
5
6
175205
130160
85115
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2 EP
68
3 EP
100
4 EP
150
5 EP
220
6 EP
320
7 EP
460
8 EP
680
8 A EP
1000
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Grease Compatibility
Occasionally, grease substitution in an application may be
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Grease Compatibility
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better.
Blended lubricants contain a balance of additives that
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to be pumped.
Most delivery systems for oil utilize pumps that work in
the 50 psi (2.3 bar) - 250 psi (17.2 bar) range. Grease,
on the other hand, requires a pump that will deliver
pressure above 1500 psi (103 bar).
In the hands of an untrained operator, an ordinary
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Greasing
How important is proper motor bearing lubrication?
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Greasing
Overgreasing causes a "churning" action of ball
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Greasing
Excess grease is moved into the cavities of the bearing
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Greasing
A better way of adding the grease is to spread the
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Greasing
Several factors influence the quantity of grease that would go into a
The Dodge Type-E bearing has a shield and lip seal configuration,
type of
seal, by design, will allow for discharge of grease
without damage at the outer perimeter of the seal. You
could consider this a type of shielded bearing configuration.
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Greasing
A SEALED bearing is not designed to be purged. If it is applied
too much grease and too quickly, you can rupture the seal and
compromise the life of the bearing.
The SKF formula also provides a good starting point. Again, the
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Greasing
This information can then be laminated and fixed to the
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Greasing
Also, assign that color code to the applicable motor or
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Grease of penetration class 3 to 4, grease quantity~ 30% of the free bearing space or
class 2 to 3, grease quantity < 20% of the free bearing space
Mounting condition
Inclined or vertical position of bearing axis
Maintenance
Frequent re-lubrication
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Heat resistant grease with synthetic base oil and heat resistant
(e.g. synthetic) thickener
Low temperature
Grease with low-viscosity base oil and suitable thickener, penetration class 1 to 2
Dusty environment
Condensate
Splash water
Radiation
Up to absorbed dose rate 2 104 J/kg, rolling bearing greases to DIN 51 825
up to absorbed dose rate 2 107 J/kg, consult bearing manufacturer FAG, SKF
Vibratory stressing
Vacuum
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Rolling-element Bearings
Requirement
Problem
Noise
High loads
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