Principles of Lubrication
Principles of Lubrication
Principles of Lubrication
By Fayek Shakran
Course Content
Principles of Lubrication
Oil & Grease Lubrication Oil Analysis Lubricant storage and handling Task-Lubricant selection
Right lubricant to the right place, on the right machine, in the right amount, at the right time.
Principles of Lubrication
How ?
Friction
Force that opposes motion between two surfaces in contact.
When one body slides across another a resistive force must be overcome.
Friction
Friction is Caused by Micro welds
Types of friction:
a. Static (usually the greatest) b. Sliding c. Rolling (usually the least)
Friction
Causes of Solid Friction
Surface roughness
Flatter areas
Friction
Lubrication
Lubrication
1 prevention of metal-to-metal contact by means of an intervening layer of fluid
These lubricants are used to a large extent in the lubrication of aircraft internal combustion engines & moving parts.
World Organizations
World Organizations
Lubrication
Type of lubricants
Solid- Semisolid Fluid
Classification of Lubricants
Animal Vegetable Mineral Synthetic
These are highly stable at normal temperatures Animal lubricants may not be used for internal combustion because they produce fatty acids Examples of vegetable lubricants are: Castor oil Olive oil Cottonseed oil
Animal and vegetable oils have a lower coefficient of friction than most mineral oils but they rapidly wear away steel
Lubricating oils
Lubricants
All liquids will provide lubrication of a sort, but some do it a great deal bettor than others.
Oil Requirement :
Provide high quality products, supported by successful field experience. Work to lower maintenance. - Work to Lower cost of operation through value added services. Provide products to help Machine for long operation.
Lubricating oils
The advantages of a lubricating oil .
are improved heat dissipation from the friction point its excellent penetrating and wetting properties.
main disadvantage
Complex design is required to keep the oil at the friction point and prevent the danger of leakage.
gears
chains
sliding bearings hydraulic systems
Oil Lubrication Purpose of Oils Oil reduces friction between moving parts
Lubrication slippery surface between moving parts Seal between piston rings and cylinder surface Cool especially bearings (dissipate heat) Clean contaminates held in suspension (wear particles)
Change oil before winter lay-up so contaminates are removed and do not damage the machine during storage
Different lubricants show different behavior regarding these requirements.
Purpose of Oils
Lubricating oils
Lubricating oils consist of a base oil and additives which determine their performance characteristics. The additives, however, determine its actual performance by influencing the base oils.
The additives to oxidation stability. anticorrosion properties. wear protection. emergency lubrication properties. wetting behavior. emulsibility. stick-slip behavior. viscosity-temperature behavior.
Main tasks, remain lubrication and protection against friction and wear.
Petroleum (mineral) lubricants are produced from the refinement of existing petroleum -Synthetic lubricants are produced from chemical synthesis. -These oils are generally superior to petroleum (mineral) lubricants in most circumstances. -Synthetic oils perform better than mineral oils.
Synthetic Lubricants
Because of the high operating temperatures of gas-turbine engines, it became necessary to develop lubricants which would retain their characteristics at temperatures that cause petroleum lubricants to evaporate and break down.
Synthetic lubricants do not break down easily and do not produce coke or other deposits
Synthetic Oil
Advantages of synthetic Oil Disadvantage to synthetic oils
notable at either very low or very high temperatures. Good oxidation stability lower coefficient of friction permits operation at higher temperatures. The better viscosity index and lower pour points permit operation at lower temperatures
The major is the initial cost, which is approximately three times higher than mineralbased oils. However, the initial premium is usually recovered over the life of the product, which is about three times longer than conventional lubricants. The higher cost makes it inadvisable to use synthetics in oil systems experiencing leakage
Petroleum Lubricants
Petroleum lubricants stand high in metal-wetting ability, and they possess the body, or viscosity characteristics.
oils have many additional properties that are essential to modern lubrication, such as: -good water resistance. -Inherent rust-preventive characteristics. -Natural adhesiveness. -Relatively good thermal stability. -Ability to transfer frictional heat away from lubricated parts.
2 Flash Point
Temperature which the oil give off enough vapor to form a combustible mixture above the surface.
3 Viscosity
Viscosity a measure of a resistance to flow
5 Pour Point
The pour point of an oil is the temperature at which the oil will just flow without disturbance when chilled.
6 Carbon-Residue Test
The purpose of the carbon-residue test is to study the carbonforming properties of a lubricating oil.
8 Precipitation number
The precipitation number recommended by the ASTM (American Society for Testing and Materials) is the number of milliliters of precipitate formed when 10 mL of lubricating oil is mixed with 90 mL of petroleum naphtha under specific conditions and then centrifuged
Lubricant Additives
-Additives are most effective in overall performance of an oil . -A poor oil cannot be converted into a quality oil by additives. -There are limits to the amount of additives that can be added. additive may function in any of the following three ways:
Protecting lubricated surfaces. Additives coat the lubricated surfaces and prevent wear or rust Improving performance. Viscosity index improvers and antifoaming agents are examples. Protecting the lubricant itself. Antioxidants reduce the tendency of oil to oxidize and form sludge.
Oil Viscosity
Viscosity
viscosity a measure of a resistance to flow
With lubricating oils, viscosity is one of the most fundamental properties, and much of the story of lubrication is built around it.
Thick fluids, like molasses, have relatively high viscosities; they do not flow readily. Thinner fluids, such as water, flow very easily and have lower viscosities. Lubricating oils are available in a wide variety of viscosities
Viscosity
Viscosity
Viscosity
pump
Stribeck Curve
Boundary Lubrication When a complete fluid film does not develop between potentially rubbing surfaces Mixed Film Hydrodynamic Lubrication
Hydrodynamic Lubrication
hydrodynamic film occurs when there is sufficient lubricant between the lubricated surfaces at the point of loading to form a fluid wedge that separates the sliding surfaces.
Elastohydrodynamic
Under even heavier loads and moderate to high sliding speeds, surfaces deform elastically and thin oil films are "trapped" between them
Hydrodynamic Lubrication
New device
Oil-Filter
Oil-Filter
Hydrodynamic Lubrication
New device
Lubricating Greases
Lubricating Greases
Lubricating greases consist of a lubricating oil, a thickening agents and one or more additives.
Lubricating Greases
Lubricating Greases
The function of grease is to remain in contact with and lubricate moving surfaces without leaking out under gravity or centrifugal action, or be squeezed out under pressure.
Todays new-generation greases are expected to do much more than lubricate. They must meet a wide range of demanding performance requirements. Long, trouble-free service life, even at high temperatures Rust and corrosion prevention Dependable, low-temperature start-up Resistance sling and water wash.
Lubricating Greases
Lubricating greases consist of a lubricating oil, a thickener and one or more additives. The thickener is responsible for the characteristics of the grease
Complex greases generally have a higher drop point. More resistant to oxidation. Synthetic thickeners are most resistant to temperature. Extensive testing is done to verify properties.
The advantage of a lubricating grease over an oil is that it Remains at the friction point for a longer time. less effort is required in terms of design. Its disadvantage is that grease neither dissipates heat nor removes wear particles from the friction point.
Lubricating Greases
WATER WASHOUT RESISTANCE
% Weight Loss of Grease Measured Typical Grease (Lithium) - 5% Water Resistant Grease <2% Exceptional < 0.5%
ASTM D1264 (DIN 51807)
(3) Machinery operating under extreme conditions such as high temperatures and pressures, shock loads, or slow speed under heavy load. (4) Worn components. Grease maintains thicker films in clearances enlarged by wear and can extend the life of worn parts that were previously oil lubricated.
Grease Characteristics
viscosity Dropping point penetration
Contaminants.
Evaporation Oxidation stability. Pump ability. Bleeding, migrationis Corrosion- and rust-resistance
High & Low temperature effects.
Grease Compatibility
This is another area in which different manufacturers give differing recommendations. However, to provide guidance on the amount of grease to be added for different size motors, a grease weight versus shaft diameter curve was determined to provide the most useful information.
Ultra-Lube
Proper lubrication of bearings is a difficult problem to tackle. Unless the lubrication technician is able to hear the sound of the bearing during actual lubrication, it's a guessing game. Now the guesswork is over. The Ultra-Lube allows you to hear the voice of the bearing as it is being lubricated. It easily attaches to a grease gun, turning it into a sensitive listening device. The Ultra-Lube provides the user with feedback about the current lubrication status of components about to be lubricated. The Ultra-Lube is attached to and becomes an integral part of the grease-gun. Upon connecting the gun to the grease nipple the operator is able to listen to the electronically amplified noise through the headset and is able to discern problems associated with lack of lubricant or too much lubricant. No additional procedure is necessary other than to continue to grease components in the normal manner.
90 Deg
45 Deg
Lubricant Handling/Storage
All lubricants are the end product of much careful research, refining, and testing. During storage after delivery, however, several things can happen to impair quality. -Careless handling. -Contamination. -Exposure to abnormal temperatures. -Confusion of stocks. all these factors can result in wastage, damage to machinery, deterioration of lubricants, higher maintenance costs, and loss of production.
Outdoor Storage
Outdoor storage should be avoided if possible
Keep bungs tight
Use drum covers
Lay drums on their sides
Before removing the bungs, dry the drum heads and wipe them clean of any contaminant
Indoor Storage
-Storage temperatures should remain moderate at all times. -Oil house should be located away from industrial contamination. -Should be kept clean at all times. -Regular cleaning schedules being maintained.
-Avoid all unnecessary contacts, use protective equipment to prevent contact. -Remove promptly any petroleum product that gets on the skin. -Do not use gasoline, naphtha, turpentine, or similar solvents to remove oil and grease from the skin. -Use waterless hand cleaner or mild soap with warm water and a soft brush. -Use only clean towels, not dirty rags. -Remove all contaminated clothing immediately. -Launder or dry-clean it thoroughly before reuse. -Use protective hand cream, and reapply it each time hands are washed. -After work hours, use simple cream to replace fats and oils removed from the skin by washing. -Wash hands and arms at the end of the work day and before eating. -Get first aid for every cut and scratch. -Avoid breathing oil mist or solvent vapors. -Keep work area clean. -Clean up spilled petroleum products immediately. Keep them out of sewers, streams, and waterways. -Contact the medical staff on all potential health-hazard problems.
Petrochemical companies will usually develop their standards to take these criteria.
Company policy must ensure that all its products in their prescribed use and subsequent disposal shall not create a significant hazard to the public health or environment.
Audit Checklist
Audit Checklist
90% by greases
9,5% by oils
D = external bearing diameter [mm] d = internal bearing diameter [mm] n = revolution per minute [rpm] D+d dm= medium bearing diameter [mm] =
2
for each temperature rise of 15C i.e. with a temperature rise from e.g. 70C up to 85C the service life of the grease is cut by half.
85
70
55
i.e. with a temperature drop from e.g. 70C down to 55 C the service life of the grease is doubled.
Second foam filter stops oil mist during exhalation, evenly distributes air.
Contamination
Its the most frequent problem that affects sample integrity.
Wear metals Water Unusual color Particular matter
1. Increased fluid usage life 2. Reduced component wear 3. Less machine down-time 4. Optimal machine performance
All this will result in significant cost savings for your plant.
Objectives
-Condition Monitoring Program -Improve equipment reliability/readiness -Lower maintenance costs -Reduce resource usage -Maintenance diagnostic toolpredictive maintenance
Methods of Analysis
Methods of Analysis
Contamination Wear metals Water color Particular matter Elements Tested For
Aluminum Antimony Barium Boron Calcium Chromium Copper Iron Lead Magnesium Molybdenum Nickel Phosphorus Potassium Silicon Silver Sodium Tin Titanium Zinc
70
60
78
83
50
40 48
30 20
10 0.002 3.0
6.0
% WATER IN OIL
Mobil Oil evaluation on bearing fatigue life 0.002% water reduces fatigue life 48% 6.0% water reduces fatigue life 83% 0.002% water is 1 drop of water in a quart of oil
Sampling Methods
ISO 21 /17
> 5 m > 15 m
250,000 16,000
19/15
Sensitivity:
Important
Type of system:
> 5 m > 15 m
130,000 8,000
18/14
Typical components
Critical High performance and high pressure long life systems, i.e., aircraft, machine tool Industrial servo valves Super critical Silt sensitive control system with very high reliability. Laboratory or aerospace High perf. servo valves
> 5 m > 15 m
16,000 1,000
15/11
Typical components Sensitivity: Type of system:
> 5 m > 15 m
4,000 250
13/9
Typical components
Air Contaminant
Air can exist in oil in three different states: dissolved. entrained . foam. Causes of Excessive Air Contamination
-When a lubricating oil becomes contaminated with water -loss of antifoam additives -suction leaks -poor reservoir design -using the wrong viscosity
Effects of Air Contamination Air contamination can have negative effects on the machine and the lubricant. Air can damage a lubricating oil by increasing the rate of oxidation reducing its heat transfer coefficient and reducing its film strength
Machine wear can be generated by air contamination by several mechanisms film thickness become compressible.
In hydraulics, entrained air can create other problems as well, such as spongy operations, loss of controls and an increased likelihood of surface deposits in valves.
Contamination Control
Keep it Clean-Cool-Dry
Storage solutions
ISO 22/19
Desiccant Breathers
Color Coding
Personnel training
Monitor/improve
Component Life
C o n t a m i n a t i o n
21/17 20/15
19/16 18/15 17/14
-------157.7 lb/yr
78.9 lb/yr -----------19.7 lb/yr
2,500
10,000
25,000
16/13 15/12
14/11 13/10 12/09
Plain or journal bearings are used for high radial loads and low- to high speeds. Typical applications include turbines, large milling systems, engine cranks, compressors, gearboxes, shaft bearing supports, ...
Z*N/P
u = * d * n where
u = surface speed d = bore diameter, meters n = shaft speed, revolutions per second = 3.1415
= w/I*d
Where
= pressure, kN/m2 l = bearing width d = shaft diameter w = load, kN
Note:
This is intended only to be a rough approximation for the sake of illustrating the principles behind lubricant selection. Please consult with a lubrication engineering professional prior to attempting to make any change in the lubricant selection for any actual operating machines
In the Industry We Serve, Most Bearings Fail Due To Some Form of CORROSION
Bronze wheel
Troubleshooting
Symptom: Oil pressure decrease, oil temp. steady Cause:
Symptom: Slight drop in oil pressure, steady or slight rise in oil temp. Cause: Faulty air-induction systems Leaking cooling systems Loose cross-over fuel lines Abnormal wear rates of moving metal parts
Oil Recycling
Reprocessing is the most common method of recycling used oil in the U.S. Each year processors treat approximately 750 million gallons of used oil. Seventy-five percent of used oil is being reprocessed and marketed to: 43% asphalt plants; 14% industrial boilers (factories); 12% utility boilers (electric power plants, homes, etc.); 12% steel mills; 5% cement/lime kilns; 5 % marine boilers (tankers or bunker fuel); 4% pulp and paper mills; 6% other.
Saves Money
By Using Oil/lubricant products (Good One) Oil/lubricant filters Repairs by early detection
LUBRICATION
Right lubricant is applied to the right place, on the right machine, in the right amount, at the right time.
Types of Greases
Calcium grease.
Calcium or lime grease, the first of the modern production greases can lubricate satisfactorily to temperatures around 93 EC (200 EF).
lime grease does not emulsify in water and is excellent at resisting wash out.
manufacturing cost is relatively low maximum temperature of around 110 EC (230 EF).
Types of Greases
Aluminum gre ase. Aluminum grease is normally clear and produced from high-viscosity oils.