Testmethods for Lubricant Related Influences

on the Gear Load Capacity

FZG-Test Procedures with the
standard FZG back to back test rig

TU Mnchen
Lubricants Russia 2006, 2nd international conference
B.-R. Hhn

G. Steinberger
0/144.21.36

TU Mnchen
B.-R. Hhn

standard FZG back-to-back test rig

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1/144.21.36

TU Mnchen
B.-R. Hhn

scuffing

wear

micropitting

pitting

lubricant related gear failure modes

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test gears type A for scuffing test

TU Mnchen
B.-R. Hhn

load and speed distribution of test gears type A

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3/144.21.36

test gears type C for wear, micro-pitting and pitting test

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load and speed distribution of test gears type C

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4/144.21.36

scuffing: local welding of flanks due to breakaway of lubricating film

- no fatigue damage
- scoring/ scuffing already after short-time overload possible
consequences:
- increase of temperature, power loss and abrasion
- increase of additional dynamic forces up to tooth breakage

TU Mnchen
B.-R. Hhn

scuffing

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5/144.21.36

wear: continuous removal of material from the surface with each mesh
desired:
- smoothing of flanks
- improvement of contact pattern (running-in)
undesired:
- change of tooth form
- removal of hardened layer
cosequences:
- increase of additional dynamic forces
- in advanced stages: tooth breakage

Rht

profile deviation

TU Mnchen
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removal of
hardened layer

minimum thickness
at tooth tip

wear

risk of tooth
breakage

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6/144.21.36

new

5 mm

E
D
5 m

C
B
dedendum flank
A
load cycles

consequential damages: - change of involute profile due to profile deviations

increase of dynamical additional forces + gear noise
influence on occurrence of pitting
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mircro-pitting

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7/144.21.36

fatigue damage, caused by rolling contact stress

shell-shaped spallings on the gear flank surface

result:

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increasing of the internal dynamics

progressive damaging until tooth breakage

pitting

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8/144.21.36

Standard FZG scuffing test A/8.3/90 according to ISO 14635

Test parameters
Gear type A
Pitch line velocity vt = 8.3 m/s
Dip lubrication with starting oil temperature of 90 C in each load stage
No cooling
Driving pinion
Load stepwise increased until scuffing occurs

Failure criterion
Visual method:

more than one pinion face width scuffed

Gravimetric method: wear more than 10 mg above average wear rate

TU Mnchen
B.-R. Hhn

FZG scuffing test

G. Steinberger
9/144.21.36

Load stage 1

10

11

12

1600

550

gear type A
vt =8,3m/s
oil start=90C

450
400
300

1200

200
150

visual inspection

800

100
weight loss measurement

50

Pinion torque T1 [Nm]

Hertzian stress pc [N/mm 2 ]

2000

400
15min.

10
0

Time

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FZG scuffing test procedure

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10/144.21.36

load stage
1-4 5 6 7

10

11

12

mg
high wear rate (scuffing)

100

failure load stage

80
weight change m

Scuffing line

beginning
high wear rate

60
40

average wear

Scuffing lines

low wear rate

20

30
60
90
transmitted work A

120

150 kWh

Scuffing

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FZG scuffing test evaluation

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11/144.21.36

Test results
Failure load stage of tested oil

Calculation of scuffing temperature according to DIN 3990

Typical scuffing performance

typical scuffing load stage

lubricant type

typical
ISO VG

ATF

32 46

24

58

9 11

turbine oil

32 68

35

68

9 11

industrial gear oil

100 320

57

8 12

> 12

transmission oil

100 220

> 12

axle oil

150 220

> 12

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non EP mild EP

FZG scuffing test results

EP oil

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12/144.21.36

TU Mnchen
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modifications of the
standard FZG scuffing test A/8,3/90

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13/144.21.36

TU Mnchen
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comparison of different scuffing test methods

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14/144.21.36

A/8.3/90

A10/16.6R/90

S-A10/16.6R/90

800
14

700

13

600

12

500

11
400

10
9
8
7
6
4
2

300
200
100
0
C1

C2
GL3

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C3

G1A

G3

GL4

G4
GL4+

G6

G7
GL5

results of industrial and transmission gear oils

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1000
scuffing temperature int S in C

900

S-A10/16,6R/90

800

A10/16,6R/90

700

A/8,3/90

600
500
400
300
200
100
0
3

TU Mnchen
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8
9
load stage

10

scuffing integral temperature

for different test methods

11

12

13

14

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Standard DGMK slow speed wear test C/0.05/90:120/12

Test parameters
Gear type C
Dip lubrication
Driving pinion
test conditions

C/0.05/90/12

C/0.05/120/12

C/0.57/90/12

0.05 m/s

0.05 m/s

0.57 m/s

pinion speed

13 rpm

13 rpm

150 rpm

wheel speed

8.7 rpm

8.7 rpm

100 rpm

oil temperature

90 C

120 C

90 C

pinion torque
(load stage 12)

378.2 Nm

378.2 Nm

378.2 Nm

2 x 20 h

2 x 20 h

1 x 40 h

pitch line velocity

running time
test result
TU Mnchen
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weight loss of pinion and wheel

FZG wear test

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17/144.21.36

Variable-speed motor

Torque measuring coupling

Speed reducer

Test gear

Slave gear

Test wheel
Test pinion
Temperature sensor

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Load coupling

modified FZG test rig for wear test

Load lever with weights

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90C

120C

90C
160

gear type C
2
pC=1853N/mm
TPinion =378.2Nm

0,5
0,4

0,57m/s (150rpm)
140
120

weight loss measurement

100

0,3

80
60

0,2

profile deviation measurement

40

0,1
0,05m/s (13rpm)
0
0

20

40

60

80

100

20

Pinion speed n1 [rpm]

Pitch line velocity vt [m/s]

0,6

0
120

Time [h]

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FZG wear test procedure

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oil = 90 C

700

oil = 120 C

oil = 90 C

mg

High wear

high wear
500
medium wear

wear sum

400
300

200
low wear

Medium wear

100
0

20
40
running time

60

80

100

h 120

Low wear

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FZG wear test evaluation

G. Steinberger
20/144.21.36

Test results
Wear category of tested oil

Specific wear rate of tested oil

Introduction of specific wear rate into wear calculation
according to Plewe

Wear category
Wear category

Sum wear per each test period

low

< 50 mg

medium

< 200 mg

high

< 500 mg

very high

> 500 mg

TU Mnchen
B.-R. Hhn

FZG wear test results

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21/144.21.36

standard test GT
(FVA 54/I-IV)
test rig
test gears

short test GFKT

(DGMK 575)

FZG test gear rig, a = 91.5 mm

type FZG-C-GF, Ra = 0.5 0.1 m

lubrication

spray lubrication

dip lubrication

amount of
lubricant

total amount 25 l,
about 2 l/min

1.5 l in the test gear

box

test course

KS 5...10 +
endurance test

KS 7, KS 9

test results

failure load stage,

GF-class (GFT),
information on long
time behaviour

GF-class (GFKT)

total test time

6...8 weeks

1 week (2 runs),
screening test method

TU Mnchen
B.-R. Hhn

FZG micropitting test methods

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22/144.21.36

endurance test

stage test

10

10

10

10

10

10

running-in, 1h

load stage

9
8

7
6
5

3
failure criterion:
ffm > 7.5 m

failure criterion:
ffm > 20 m or pitting

running time
running
runningtime
timeper
perload
loadstage
stage

running
runningtime
timeper
persequence
sequence

16
16hh

80
80hh

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FZG micropitting test procedure

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23/144.21.36

load stage test

endurance test

running time 16 h / load stage check every 80 h

mean profile deviation ffm

20
[m]

failure limit,
endurance
test

16
14
12

failure limit,
load stage
test

FZG
micropitting test
C / 8,3 / 90
lubricants:
ISO VG 32

10

micropitting
load capacity:

8
6
4

test terminated
because of pitting

2
0

5
6
7
8
9
10
8
795 945 1094 1245 1395 1547 1245

TU Mnchen
B.-R. Hhn

10

10

10
1547

10

10

FZG micropitting test evaluation and results

GFT - low
GFT - medium
GFT - high
load stage
pC [N/mm2]

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aim:

short test method, screening test

to evaluate the GFT of lubricants
valid for lubricants with different viscosity
good correlation to FZG-micropitting test

optimised
concerning:

duration
costs
lower amount of lubricant

FZGmicropitting
short test

TU Mnchen
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FZG-micropitting short test

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25/144.21.36

3 running-in, 1h

load stage

9
failure criterion:
ffm > 7.5 m

max.
max.running
runningtime:
time:33
33hh
max. duration: 3 days
with repetition: 1 week
running time

running
runningtime
timeper
perload
loadstage
stage

16
16hh

TU Mnchen
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FZG-micropitting short test procedure

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DGMK-FZG Micro-Pitting Short Test

ffm av. max. profile deviation [m]

Running time 16 h / load stage

20

Steinberger
01.06.2002

18

Test conditions:

16

GFKT C / 8.3 / 90

14
12

Roughness of thooth
flanks in all tests:
Ra = approx. 0.50 m
Ra = (Ra1+Ra2)/2

10
8
6

Candidate lubricants:
GFKT-low
GFKT-medium
GFKT-high

4
2
0
5

76

8
8
9
Load stage

10 10 11 11 12

TU Mnchen
FZG-micropitting short test evaluation and results
B.-R. Hhn

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27/144.21.36

lubricant GFKT-medium

lubricant GFKT-high

TU Mnchen
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FZG-micropitting short test examples

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 PT C/9/90

standard pitting test (single stage test)

PT C/10/90

PTX C/10/90
PTX C/SNC/90

PT C/LLS/90

practice relevant pitting test (single stage or

application test)

pitting test with load collective

PT C/HLS/90

PITS C i80 TS

pitting test with oil ageing

PITS C i95 TS

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pitting test methods

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standard pitting test PT

(FVA-information sheet no. 2/IV)

practice relevant pitting test PTX

(FVA-information sheet no. 371)

FZG back-to-back test rig, dip lubrication with constant oil

temperature (90 C), pitch line velocity 8,3 m/s
failure criterion: 4 % pitting on one pinion flank or 15 m profile deviation
result: load cycles for 50 % failure probability LC50
z

gear type C-PT

no flank modifications
grinded - Ra = 0.3 0.1 m
micropitting

gear type C-PTX

practice relevant flank modifications
superfinished - Ra = 0.1 0.05 m
less or no micropitting

single stage test

load stage MS9 (T1 = 302 Nm) or
MS10 (T1 = 372 Nm), depending on
viscosity

single stage test

load stage MS10 (T1 = 372 Nm),
independent from viscosity

extension to application test possible

load stage MS9 (T1 = 302 Nm) or
MS11 (T1 = 450 Nm), depending
on result of single stage test

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comparison of FZG pitting test methods

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30/144.21.36

Failure Probability in %

80

60

40

20

10
2
106

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LC50

8
107

FZG pitting test result

NPi

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TU Mnchen
B.-R. Hhn

FZG pitting test results

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2500

ZLp50T =

hertzian stress pC [N/mm2]

2200

HP50T,50%
HPdauer,50%

2000

new SN curve for

tested lubricant

1800
1700

MS 9

1600

HP50T,50%

1500
1400

HPdauer,50%

1300

SN curve (straight lubricant)

acc. to DIN 3990

1200
1100
105

106

107

5107

108 N


109

load cycles at pinion

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modified SN-curve concerning pitting test result

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FZG scuffing test

FZG wear test

FZG micropitting test

FZG pitting test

TU Mnchen
B.-R. Hhn

Summary

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