Lubrication

Lubrication
Applications and Selection

Objective of lubrication
Lubricate
Avoid metal to metal contact between movement elements
through the lubricant film
Î reduces friction and wear
Î saves energy
Cool
Reducing friction reduces the heat generated when two
surfaces rub together
Lubricants are often used to transfer heat from a hot area
to a cooler one
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Holcim Group Support Lubrication_Application & Selection M25_Lubrication Management
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Objective of lubrication
Corrosion protection
Lubricants coat metal surfaces to
give a physical barrier against attack
Lubricants may contain inhibitors
(bases) to neutralise any corrosive chemicals (acids)
Maintain cleanliness
A machine will operate less efficiently
if it is contaminated with dust or dirt
Lubricants can flush these contaminants out
Some lubricants contain detergents
which ‘suspend’ dirt particles in the oil
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Elements to be lubricated
Bearings
Slide bearings and roller friction bearings, slides guides
Gears
Spur gears, helical gears, worm gears, open gears
Cylinders
Pumps, Engines, Compressors
Hydraulic system
As power transmission, hydraulic unit elements
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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
Full fluid film lubrication

The surface are completely separated by a
load carrying film
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Lubrication Regimens
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Solid lubricant
Solids such as graphite and
molybdenum disulfide are
Base Material widely used when normal
S
lubricants do not possess
Mo sufficient resistance to load or
Base Material
temperature extremes.
In the form of dry powder there

materials are effective
Base Material lubricant additives due to their
lamella structure. The lamellas
are oriented parallel to the
Base Material surface in the direction of
motion
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Elastohydrodynamic lubricant film
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Frictional Moment
The frictional moment M of a
roller bearing is the sum total
of rolling friction, sliding friction
and lubricant friction.
The magnitude of the moment
(M) depends on the loads,
speed and lubrication
viscosity.
The black triangle to the left of
the dot-dash line shows that
with low speed and high loads
a considerable mixed friction
share (RM) can be added to M0
and M1
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ISO Viscosity Grades (ISO VG)
Industrial lubricants are usually classified according
to their ISO Viscosity Grade
This is based on their kinematic viscosity at 40 oC ±
10%
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Other viscosity grade systems
American Gear Manufacturers
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

systems with ISO Viscosity
Grades is shown opposite
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Viscosity and temperature
Viscosity increases as the 200
Kinematic viscosity (cSt)

temperature decreases
a lubricant having the correct 150
viscosity at the operating
temperature may be too viscous for 100
cold start
Viscosity decreases as the 50
temperature increases
a lubricant having the correct 0
0 50 100
viscosity at room temperature may
be too ‘thin’ at the operating Temperature (°C)
temperature
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Viscosity Index (VI)
Viscosity Index (VI) describes
how viscosity changes with
temperature
XHVI base oil (VI ~ 150) The higher the VI, the smaller
Viscosity (log scale)
the change in viscosity with

temperature
HVI base oil (VI > 95)
Mineral base oils:
‘high VI’ = 80 - 120
LVI base oil (VI < 30) ‘low VI’ = 0 - 40
Industrial lubricants:
VI is typically 95 – 100
40 100
Temperature (°C)
Addition of VI improvers or the
use of synthetic base fluids:
VI of 140 - 200
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Viscosity Index is a measurement of the rate of change
of viscosity with temperature. This change is common to
all fluids – some more, some less. Heating tends to
make them thinner – cooling , thicker. The higher the VI,
the less tendency for the viscosity to change.
High VI oils are often preferred for service in which a
relatively constant viscosity is desired under conditions
of varying temperature - e.g kiln bearings, synthetic oil
with VI < 130.
The Viscosity Index is calculated from viscosities at
40°C and 100°C in accordance with the ISO or ASTM
Test Method D567 or D2270.
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Mineral Oil
VI ~ 80-100
Synthetic Oil (e.g.

Polyglycol)
VI ~ 150-275
A flat curve is
indicating a high VI.
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Viscosity
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Oil Performance – Type of Oil
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Properties different oils
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Synthetic Oils
The most significant advantages Synthetic oils, however, also
of synthetic oils are: show some disadvantages :
Thermal and oxidation stability Interaction with other synthetic
oils (not mixable)
Favorable viscosity /
temperature behavior Interaction with other material
e.g. seals, paintings etc.
High flash point
Toxicity
High aging stability
Higher price
Good low temperature behavior
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Selection and Application of Lubricating Oils
Mineral Oils
C - DIN 51517 Part 1. Non-ageing mineral oils without additives.
Primarily used for circulation lubrication.
CL – DIN 51517 Part 2. Additivated mineral oils to increase anti-
corrosive and anti-ageing properties. Primarily used for circulation
lubrication. According to their viscosity, these oil types show good
low and high temperature properties.
CLP – DIN 51517 Part 3. Additivated mineral oils to increase anti-
corrosive and anti-ageing resistance and to reduce wear in the
mixed friction zone. Used for dip-feed and circulation lubrication,
when requirements made on wear protection are extremely high.
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Mineral Oils
H – Hydraulic fluids.
HL – DIN 51524 Part 1. Additivated mineral oils to improve anti-

corrosion and anti-ageing properties.
HLP – DIN 51524 Part 2. Same as hydraulic oils HL plus
additional additives to reduce wear due to fretting corrosion in
mixed friction zones.
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K – DIN 51503 (refrigerator oils). Mineral oils or oils composed of
allied hydrocarbones to lubricate and cool refrigerating machine
compressors.
L-TD – DIN 51515. Additivated lubricating oils with improved anti-
corrosion and anti-oxidation properties. To be used for the
lubrication and control of steam turbines, stationary gas turbines or
machines driven by these, such as generators, compressors,
pumps and gears.
VB, VC and VDL – DIN 51506. Mineral oils with or without
additives for the use in air compressors with an oil lubricated
pressure chamber, without injection cooling. The oil can be also
used in vacuum pumps.
Z – DIN 51510. Pure mineral oils, primarily used for steam-driven
sliding parts of steam engines with a steam inlet temperature less
than 380 C.
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Viscosity
Viscosity is the most important property of a lubricating
oil. It is a measure of the internal friction, describing the
resistance to relative motion between the molecules
under sheer stress.
Viscosity depends on pressure and temperature.
It is commonly reported in centistokes (cST), measured
at either 40ºC and 100 ºC due to ISO – International
Organization for Standardization (kinematic viscosity).
The number in the product name for most products
represents the viscosity of the oil e.g.
Shell Omala 320 – ISO VG 320 gear oil or
Aral Degol BG 460 – ISO VG 460 gear oil.
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Viscosity Guide
Maximum Viscosities cSt
22,000 Probably maximum pouring viscosity
Optimum Viscosities cSt At Operating Temperature

25 Hydraulic Systems
30 Plain Bearings
40 Spur & Helical Gears (e.g. ISO-VG 220 @ 65ºC)
75 Worm Gears (e.g. 460 @ 75ºC)
Minimum Viscosities cSt At Operating Temperature

13 Hydraulic Systems
13 Plain Bearings
21 Spherical Roller Bearings
33 Spur & Helical Gears
4 Minimum Viscosity to support a dynamic load
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Additives
Viscosity Index Improver
What do the additives do? Oxidation inhibitors
Rust inhibitors
Additives are added to lubricants
to positively influence the Metal deactivators
properties that the oil already Antiwear additives
has. Extreme pressure
additives
They add features to improve Friction modifiers
the service life, wider operating Detergents
temperature range, provide rust, Dispersants
foam and wear protection. They Pour point depressants
enable the oil to do things that it
Anti-foam agents
could not accomplish by itself.
Tackifiers
Emulsifiers
Biocides
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Viscosity Index Improver
ITIVE
D
What it does AD
Reduces rate of change of viscosity with temperature
Allows an oil to be fluid at low temperatures, yet maintain
thickness at high temperatures.
How it works
The additive’s 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
Solidification at low temperatures is due to:

Wax crystals settling out
Oil too viscous to move
Most oils lubricate down to approximately 10°C 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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Pour Point Test
Temperature at which no movement is observed for 5 seconds.
Wax comes out of solution in small crystals as the oil nears pour
point. Small crystals grow in size until they are large enough to
stop the oil from moving.
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Pour Point Depressant
ITIVE
D
What it does AD
Depresses the lowest temperature at which an

oil will pour
How it works
Prevents small wax crystals from growing into large
crystals which would stop the flow of oil.
Example
Polymethylmethacrylates
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Oxidation
Oxidation is a chemical reaction between oxygen and the
hydrocarbon molecules in oil. It is a chain reaction - the further it
progresses, the faster the lubricant deteriorates.
Oxidation turns oil into:
sludge
gums
varnish
acid
Oxidation increases the viscosity of the oil
Oxidation is accelerated by:

Catalysts - such as metals, dust, water
Oxygen - from high rates of air entrainment
High temperature (thermal degradation)
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Oxidation increases exponentially with temperature
Example: Mineral Oil – Service life
Temperature °C Service Life (Hours) Days
80 10000 416
90 5000 208
100 2500 104
110 1250 52
120 625 26
130 313 13
“Rule of Thumb”
Every 10°C rise in temperature above 70°C halves the life
expectancy of the oil.
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Anti-Oxidant
ITIVE
D
What it does AD
Prevents varnish, sludge and acid formation
Retards aging of oil
Lengthens service or storage life of oil
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

to break, using ASTM D-1401.
Specified oil water

Oil emulsion must break
40 ml after agitation and
settling of max. 20 min.
Water
40 ml
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Demulsibility
Additives that are added to the
oil for other reasons are often
emulsifiers e.g. motor oil (in
order to maintain a stable
emulsion of oil and water up to
approx. 1% water content)
Non-detergent oils have
generally better demulsibility.
Desirable for Sometimes demulsibility
additives are added to oils
Hydraulics
(e.g. Industrial Gear Oils)
Turbines
Gears Generally, highly refined
Circulating oils straight mineral oils have
inherently good demulsibility.
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Demulsifier
ITIVE
D
What it does AD
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
resulting in mechanical failure.
Foaming characteristics can be determined at specified temperatures. This
allows a determination of the foaming tendency and the stability of the
foam.
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Foam
Foam is an accumulation of air bubbles on the surface of an oil. It
looks like beer.
Foaming occurs when pressure is reduced on an oil containing air
or by cavitation on oil pump.
Foaming may result in reduced film strength if it is circulated to a
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
ITIVE
D
What it does AD
Helps foam to dissipate more rapidly.
Decreases surface tension by dispersing polar molecules in the
oil.
How it works
Promotes combination of small bubbles into large bubbles which
break up more easily.
Examples
Silicones
Methacrylates (Foam Inhibitor and Air Release Agent)
Note: Some foam inhibitors, such as silicones, have an adverse

effect on “air release”
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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
Air gets into oil from:

Churning gears
Leaky suction lines
Low fluid levels
Bubbles only after the entrained air has risen to the surface
and turned into foam
Improper system design
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Deaeration (AirRefease) Agent
ITIVE
D
What it does AD
Helps to release entrained air
How it works
Promotes combination of small bubbles into large bubbles
which break up more easily
Examples
Methacrylates (Foam Inhibitor and Air Release Agent)
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Rust and Corrosion Inhibitor
ITIVE
D
What it does AD
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 ITIVE
D
AD
Tackiness is a measure of how well an oil adheres to a surface.

What it does
Keeps oil from flying off fast moving metal surfaces (improves
the oil’s adhesiveness)
How it works
Large polymers “stick” to surfaces and are not thrown off as
easily as the light lubricating oil
Large polymers also “stick “ to the lubricating oil keeping it in
place (increase of viscosity)
Examples:
Poly-methacrylates
Poly-isobutylenes
Natural Resins / Polymers
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Detergent IV E
DIT
A D
Detergents like dispersants are blended into lubricants to remove

and neutralize harmful products within the lubricant. In addition,
detergents form a protective layer on the metal surfaces to prevent
deposition of sludge and varnish.
In engines, this can reduce the amount of acidic materials
produced. Detergent additive protection ability is measured by its
base number or its reserve alkalinity.
Metallic basis for detergents includes barium, calcium, and
magnesium and sodium.
Much like the detergents we use at home to aid in a cleaning
process, detergent additives help keep the components clean in a
machine. Typical applications for detergent additives include
primarily diesel and gasoline engines.
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Detergent IV E
DIT
A D
What it does
Prevents oxidation products (sludge) from
sticking to metal surfaces
May also remove deposits already formed on
these surfaces e.g. in motors at high temperature
How it works
Reacts chemically with the metal surface
forming a film
This film repels sludge/resin and prevents them
sticking to it
Examples:
Metallo-organic compounds of sodium,
Calcium and magnesium phenolates,
Phosphonates and sulphonates
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Dispersant
ITIVE
D
What it does AD
Keeps oxidation products suspended in the oil.
Slows formation of sludge and resins.
How it works
Reacts chemically with oxidation products (sludge, resins, etc.)
Coats sludge/resin particles with a protective film, which stops them
from joining and becoming large particles and thus slows coagulation.
Examples:
Polymerizates, such as nitrogenous polymethacrylates,
Alkylsuccinimides
Alkylsuccinic esters
High molecular weight amines and amides
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Anti-Wear ITIVE
D
AD
Abrasive Wear is the result of hard particles coming in contact with

internal components. Such particles include dirt and a variety of
wear metals. Introducing a filtration process can reduce abrasive
wear. It is also important to ensure vents, breathers, and seals are
working properly.
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Anti-Wear ITIVE
D
AD
What it does
Minimizes wear caused by metal to metal contact during conditions of
mild boundary lubrication (e.g. stops and starts, oscillating motion)
Only functions when load, pressure and/or temperature are high enough
to activate the additives
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
Zinc Dithio (Di) Phosphorous (ZDDP)
Dithiophosphates (ashless)
Dithiocarbamates (ashless)
Phosphites
Sulphur Phosphorous Compounds
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Anti-Wear Test
“Four Ball” Tester
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Extreme Pressure (EP) ITIVE
D
AD
What it does
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 82°C.
Corrosive to yellow metals at temperatures greater than 70°C. (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
Heat generated at points of metal-to-metal contact leads to new
compounds with a lower shear stability than the base metal.
The new compound forms a slick layer. A continuous process of
shearing-off and re-building.
Examples
Dithiophosphates (ashless)
Dithiocarbamates (ashless)
Phosphites
Sulphur-Phosphorous Compounds
Chlorine Compounds
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Extreme Pressure (EP) ITIVE
D
AD
Limitations
High quality additives in lubrication oils and greases have a
positive effect on the fatigue life of bearings.
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.
EP-additives of sulphur-phosphorous types may become
aggressive and instead reduce the fatigue life, and for
temperatures above 80 °C such additives cannot be generally
recommended.
from SKF CADalog Helpfile
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Extreme Pressure Tests
“FZG” Tester
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Extreme Pressure Tests
“Timken” Tester
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Friction Modifier IV E
DIT
A D
What it does
Reduce friction between metal surfaces.
Can reduce the fuel consumption of an engine
How it works
Molecules with a high polarity are absorbed on metal surfaces
and separate the surfaces.
Solid lubricants form a friction-reducing film on the surface.
Examples
Organic fatty acids and amides
Lard oil
High molecular weight organic phosphorus
Phosphoric acid esters
Solid lubricants
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Metal Deactivator
IV E
DIT
A D
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
and product features are designed to reduce friction and
wear over the widest possible temperature ranges and
time spans.
THICKENER + LUBRICATING OIL + ADDITIVES

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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Comparison of Grease over Oil Lubrication
Advantages: Disadvantages:
Reduced design complexity No heat dissipation possible
Less maintenance is often Contaminants are captured by

required, since lifetime the grease film and not
lubrication is possible removed, especially with
grease lubrication of minimal
Less risk of leakage and
quantity
simpler seal design
At present, limiting speeds or
Sealing effect is reinforced by
speed factors are lower than
used grease overflow (grease
with oil injection and oil/air
collaring)
lubrication
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Grease Base Oils
Mineral Oils
Ester Oils
Polyglycol Oils
Polyphenylether Oils
Silicone Oils
Perfluoroalkylether Oils
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Grease Thickeners and Additives TIV E
DDI
A
Thickeners Main Advantage(s)
Metal Soaps (Ba, Li, Ca) multipurpose
Bentonite (Clay) / Silica high temperature
Aluminum Complex high temperature
Plastic (PE, PTFE, FEP) high temperature
Polyurea vibration, sealed for life
Barium Complex extreme pressure
Calcium Complex water resistance, corrosion protection
Solid Lubricants Reason for Use

Graphite anti-wear
Zinc Oxide white colour
Calcium Carbonate anti-rust, EP
Molybdenum Disulphide (“Moly”) anti-wear, load-carrying
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Use of Additives
Engine General Hydraulic Industrial Automotive
Grease
ADDITIVE Oils ATF Purpose Oil Oil Gear Oil Gear Oil
Detergents
9 9
Dispersants
9 9
Anti-Oxidants
9 9 9 9 9 9 9
Rust Inhibitors
9 9 9 9 9 9 9
Anti-Wear
9 9 9 9 9 9
E.P. Agents
9 9 9
VI Improvers
9 9 Some Some
9 9 9 9 9 9
Pour Point
Depressants
Anti-Foam
9 9 9 9 9 9
Dyes
9 9
Friction Modifiers
9 9 61
ATF – Automatic Transmission Fluid
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Grease Consistency Classes - NLGI
Consistency is the degree of hardness of a grease and it may vary
considerably with temperature. It has been classified by the “National
Lubricating Grease Institute (NLGI)” into the following categories:
Walk penetration
NLGI Grade DIN 51804 / 1 Structure Application Generally
(0.1 mm)
000 445…475 fluid

Mainly for gear reducer
00 400…430 almost fluid
lubrication
0 355…385 extremely soft
1
310…340 very soft
2 Roller and plain bearing
265…295 soft
3 lubrication
220…250 moderate
4 175…205
stiff
5 130…160 Grease for labyrinth
very stiff
6 85…115 seals and fittings
extremely stiff
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Grease Consistency Classes - AGMA
The American Gear Manufacturers Association (AGMA) developed a
numbering system to define gear oil viscosities required for various speed
reducer types and applications.
The AGMA Grades are shown below along with the equivalent ISO VG.
AGMA Number ISO Viscosity Grade cSt (40ºC)

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 Definition and Terms
Shear Stability - is the ability of a grease to resist a change in

consistency during mechanical working. Under high rates of
shear, grease structures tend to change in consistency (usually
softer).
Oil Separation - is the percentage of oil which separates from the

grease under static (i.e. storage) conditions. It cannot predict
separation tendencies under dynamic conditions (i.e. in use).
High Temperature Stability - is the ability of a grease to retain its

consistency, structure and performance at temperatures in excess
of 125°C.
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Grease Compatibility
Occasionally, grease substitution in an application may be

necessary to correct problems arising from the original product in
service. If the thickeners are incompatible, the mixture will fall short
of the properties of the individual greases.
In all cases, it is strongly advised that the old grease is purged or
cleaned out from the system before a new one is introduced.
However, compatibility between greases is temperature dependent.
As the temperature rises, the problems associated with
incompatibility also increase.
With competitors products it is strongly advised to treat them
as incompatible unless strong evidence exists to the contrary.
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Grease Compatibility
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Comments on Proprietary Additives
There are a variety of Proprietary or "Retrofit" additives
sold that claim to enhance the performance or
properties of lubricants.
In many cases these additives are the same as those
already present in the blended lubricants. While the
selling gimmicks may look effective, often the properties
being measured are not required in the application.
For example, you do not need EP additives in an engine
oil because Extreme Pressure conditions do not exist.
Further, in the case of engines, the Original Equipment
Manufacturers (OEM's) specifically request that these
additives be excluded from the lubricant.
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It is important to remember that "more" is not always
better.
Blended lubricants contain a balance of additives that
are designed for specific applications.
These additives compete for the same metal surfaces.
Addition of extra compounds may upset the balance and
cause more harm than good.
The properties that are most often affected by these
additives include anti-foam, corrosion and viscosity.
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The US Federal Government completed a study of
"Aftermarket Additives" and concluded that
“None of the products tested were able to provide the
benefits claimed in their advertising".
As a general rule, use of these type of additives will void
most OEM and lubricant supplier warranties.
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Greasing (Gun Hazards)
In order to move grease to the application point, it needs
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
grease gun can deliver a pressure of up to 15,000 psi
(1030 bar)! A bearing seal, on the other hand, will rarely
rate higher than 500 psi (35 bar). Once the seal on the
bearing is compromised, the bearing is well on its
way to early failure.
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Grease Gun Hazards
A compromised bearing seal encourages dirt ingestion
and over lubrication due to its lack of "back pressure"
(this is especially true when greasing a bearing "blind"
from a remote zerk fitting). The secondary negative
effects produced are extra consumption of grease, and
extra time required for cleanups of equipment with the
overflowed grease, inviting dirt and contaminants to
stick to it. Respect the power of a lowly manual grease
gun.
Always ensure that the dispensing nozzle of the grease
or oil gun is cleaned before use, and that the fitting it is
being attached to is also clean. This will safeguard
against unnecessary introduction of dirt into the bearing.
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EV
Coupling Grease Application
When changing the lubricating grease in a geared motor coupling,
always apply a full coating of grease to the teeth of the coupling.
Never fill the coupling housing completely with a
grease gun due to expansion of the grease as
the motor comes up to running temperature.This
expansion of the grease will apply internal coupling pressure
pushing the motor shaft off magnetic center and onto the thrust
surface of your bearing, causing bearings to overheat and lead to
early bearing failure.
Even after hand packing the coupling, the motor should
be run up to operating temperature then shut down and
the grease plug removed to allow excess grease and
pressure to be released.
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Greasing
How important is proper motor bearing lubrication?
Consider what can happen when a motor bearing is
over greased:
Excess grease leaks out of bearing seals and deposits on
the stator and rotor windings. This grease creates a
thermal barrier between the windings and their cooling air,
leading to increased motor temperature.
When dust and dirt adhere and build up on this grease,
motor temperatures can skyrocket causing the
winding insulation to deteriorate and "short out" the
motor. It just takes a 10 degree C increase in motor
temperature to cut the motor's life in half.
73
EV
Greasing
Overgreasing causes a "churning" action of ball
bearings within their housing, increasing the
temperature of the grease and bearings.
This can lead to lubrication failure and a reduction in
bearing hardness and a subsequent bearing failure. It
can lead to the inner race heating up, slipping on the
shaft, misalignment, and shorting out of the motor
windings.
Avoid overfilling bearing housings with grease. When a
bearing rotates, it is lubricated by a thin film of grease.
74
EV
Greasing
Excess grease is moved into the cavities of the bearing
and housing. If these cavities are already filled with
grease, the excess has nowhere to go and remains in
the bearing where it is "churned".
This causes overheating which can lead to separation of
the oil from the thickener, evaporation, oxidation and
leakage. The lubrication interval in many cases
recommended by the manufacturer of equipment by
every 1000 hours whereupon 100 grams of grease is
injected into the bearings. In practice, this will cause a
rapid failure of the bearing.
75
EV
Greasing
A better way of adding the grease is to spread the
period of greasing to a week, injecting only a small
amount at a time. This allows the excess lubricant to be
expelled from the bearing without causing overheating.
While equipment manufacturers recommend a quantity
and interval from discussions with the bearing
manufacturer, in practice, most of the specified
quantities and time intervals are at best from previous
good knowledge.
76
EV
Greasing
Several factors influence the quantity of grease that would go into a
bearing at the selected interval. Critical factors include:
1. Design of the bearing (plain, roller, ball or spherical
roller).
2. Type of shield used in the bearing.
3. Size and speed from which to calculate dN values.
4. Viscosity of the lubricant in the grease.
The Dodge Type-E bearing has a shield and lip seal configuration,
with an option for an additional two-stage lip seal. This
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.
77
EV
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
calculated value must be adjusted to accommodate the
environment.
It is needed to consider for the application the variability in volumes
dispensed by different grease guns. While different models and
styles of grease gun are most likely to dispense varying volumes,
even nominally the same make and model of grease gun may have
shot-to-shot variability.
It is important to calibrate each gun. To do this, simply dispense 10
or 20 shots of grease from each gun and weigh how much is
dispensed. Then divide by the number of shots to obtain a
calibration constant for each specific grease gun.
78
EV
Greasing
This information can then be laminated and fixed to the
gun so that whenever a PM is issued (now in ounces or
grams), the lube technician can use the calibration
constant for that gun to convert the prescribed grease
volume in ounces on the work order, to shots based on
the grease gun he or she is using.
It is normal to use different or incompatible grease types
for different applications and equipment in the plant (for
example: lithium based greases, synthetic greases,
etc.), you will benefit greatly by implementing a color
coding system. Assign a color code to a specific grease
type then mate that color with it's corresponding grease
gun.
79
EV
Greasing
Also, assign that color code to the applicable motor or
bearing as well. By assigning a color code or similar
system, you will significantly reduce the chance of
mixing incompatible greases and insure that the proper
grease is being used on your equipment. This system
works well for your additive packages, filters and
breathers and any other system where specific products
are used for specific applications.
80
EV
Criteria for grease selection
Running properties
Low friction, also during starting Grease of penetration class 1 to 2 with synthetic base oil of low viscosity
Low constant friction at steady – state condition, but Grease of penetration class 3 to 4, grease quantity~ 30% of the free bearing space or
higher starting friction admissible class 2 to 3, grease quantity < 20% of the free bearing space
Low noise level Low noise grease (high degree of cleanliness) of penetration class 2
Mounting condition
Inclined or vertical position of bearing axis Grease with good adhesion properties of penetration class 3 to 4
Outer ring rotating, inner ring stationary, or centrifugal Grease with a large amount of thickener, penetration class 2 to 4
force on bearing
Grease fill quantity depending on speed
Maintenance
Frequent re-lubrication Soft grease of penetration class 1 to 2
Infrequent re-lubrication, for-life re-lubrication Grease retaining of penetration class 2 to 3 under stressing, upper operating
temperature limit higher than operating temperature
81
EV
Criteria for grease selection
Environmental condition
High temperature, for-life re-lubrication Heat resistant grease with synthetic base oil and heat resistant
(e.g. synthetic) thickener
High temperature, re-lubrication Grease which does not form any residues at high temperatures
Low temperature Grease with low-viscosity base oil and suitable thickener, penetration class 1 to 2
Dusty environment Stiff grease of penetration class 3
Condensate Emulsifying grease, e.g. sodium or lithium soap base greases
Splash water Water-repellent grease, e.g. calcium soap base grease of penetration class 3
Aggressive media (acids, bases, etc.) Special grease, please bearing and lubricant manufacturer
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 EP lithium soap base grease of consistency class 2, frequent relubrication.
With moderate vibratory stresses, barium complex grease of consistency class 2
with solid lubricant additives or lithium soap base grease of consistency class 3.
Vacuum Up to 10–5 mbar, depending on temperature and base oil,
rolling bearing greases according to DIN 51 825, consult bearing manufacturer.
82
EV
Grease properties (1/2)
83
EV
Grease properties (2/2)
84
EV
Rolling-element Bearings
Problem Requirement
Short life due to high loads Multi-purpose grease with MoS2
Extreme pressure and water resistant grease
Ability to operate at extremely low temperatures ( to –70°C Low to moderate loads and speeds
Short life due to high temperatures (up to 150°C) Medium to high speeds
Short life due to high temperatures ( up to 160°C continuous ) Moderate to high loads and low to moderate speeds
Short life due to very high temperatures ( up to 180°C continuous ) Moderate to high loads and high speeds
Short life due to very high temperatures ( up to 200°C continuous ) Low to moderate loads and speeds
Harsh chemical environment
Short life due to extremely high temperatures ( up to 230°C continuous) Heavy duty and chemically resistant grease
Low to moderate loads and speeds
Short life due to extremely high temperatures ( up to 250°C continuous) Resistant against solvents and other aggressive chemicals
Need for operation in very high vacuum environment Service temperatures from -35 to +250°C
Lubricant failure because of aggressive environmental influence Service temperatures from -35 to +250°C
Service temperatures from -40 to +200°C
Service temperatures from -40 to +230°C
Noise Service temperatures from -40 to +150°C
Medium to high speeds
Service Temperatures from -40 to + 130 °C
Short life due to wet environment High loads
Short life due to very high speeds Service Temperatures from -50 to + 130 °C
85
EV

Lubrication - Application and Selection

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Applications and Selection

Full fluid film lubrication

 In the form of dry powder there

 Saybolt Universal Seconds

 A comparison of these other

 Viscosity increases as the 200

Kinematic viscosity (cSt)

the change in viscosity with

Synthetic Oil (e.g.

 HL – DIN 51524 Part 1. Additivated mineral oils to improve anti-

Optimum Viscosities cSt At Operating Temperature

Minimum Viscosities cSt At Operating Temperature

 Solidification at low temperatures is due to:

Lubricating oils Pour Point (° C)

 Temperature at which no movement is observed for 5 seconds.

 Depresses the lowest temperature at which an

 Oxidation increases the viscosity of the oil

 Oxidation is accelerated by:

Temperature °C Service Life (Hours) Days

 Demulsibility – test time required for a specified oil-water emulsion

Specified oil water

 Air gets into oil from:

 Note: Some foam inhibitors, such as silicones, have an adverse

 Air gets into oil from:

 Helps to release entrained air

Tackiness is a measure of how well an oil adheres to a surface.

 Detergents like dispersants are blended into lubricants to remove

 Abrasive Wear is the result of hard particles coming in contact with

“Four Ball” Tester

from SKF CADalog Helpfile

 THICKENER + LUBRICATING OIL + ADDITIVES

A grease is expected to:

 Provide corrosion protection

 Seal bearings from water and contaminants

 Resist change in structure or consistency during service

 Maintain mobility under conditions of application

 Be compatible with seals

 Tolerate or repel moisture

 Less maintenance is often  Contaminants are captured by

Solid Lubricants Reason for Use

000 445…475 fluid

AGMA Number ISO Viscosity Grade cSt (40ºC)

 Shear Stability - is the ability of a grease to resist a change in

 Oil Separation - is the percentage of oil which separates from the

 High Temperature Stability - is the ability of a grease to retain its

 Occasionally, grease substitution in an application may be

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In the form of dry powder there

Saybolt Universal Seconds

A comparison of these other

Viscosity increases as the 200

HL – DIN 51524 Part 1. Additivated mineral oils to improve anti-

Solidification at low temperatures is due to:

Temperature at which no movement is observed for 5 seconds.

Depresses the lowest temperature at which an

Oxidation increases the viscosity of the oil

Oxidation is accelerated by:

Demulsibility – test time required for a specified oil-water emulsion

Air gets into oil from:

Note: Some foam inhibitors, such as silicones, have an adverse

Air gets into oil from:

Helps to release entrained air

Detergents like dispersants are blended into lubricants to remove

Abrasive Wear is the result of hard particles coming in contact with

THICKENER + LUBRICATING OIL + ADDITIVES

Provide corrosion protection

Seal bearings from water and contaminants

Resist change in structure or consistency during service

Maintain mobility under conditions of application

Be compatible with seals

Tolerate or repel moisture

Less maintenance is often Contaminants are captured by

Shear Stability - is the ability of a grease to resist a change in

Oil Separation - is the percentage of oil which separates from the

High Temperature Stability - is the ability of a grease to retain its

Occasionally, grease substitution in an application may be