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Lubrication

Applications and Selection

Objective of lubrication
Lubricate


Avoid metal to metal contact between movement elements


through the lubricant film
reduces friction and wear
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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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
Base Material
S
Mo

Base Material

molybdenum disulfide are


widely used when normal
lubricants do not possess
sufficient resistance to load or
temperature extremes.

In the form of dry powder there


Base Material

Base Material

materials are effective


lubricant additives due to their
lamella structure. The lamellas
are oriented parallel to the
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
10

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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 increases as the

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


a lubricant having the correct


viscosity at room temperature may
be too thin at the operating
temperature

Kinematic viscosity (cSt)

Viscosity and temperature


200
150
100
50
0

50
Temperature (C)

100

13

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Viscosity Index (VI)


Viscosity Index (VI) describes

how viscosity changes with


temperature
Viscosity (log scale)

XHVI base oil (VI ~ 150)

The higher the VI, the smaller

the change in viscosity with


temperature

HVI base oil (VI > 95)

Mineral base oils:





LVI base oil (VI < 30)

high VI = 80 - 120
low VI = 0 - 40

Industrial lubricants:


40

Temperature (C)

VI is typically 95 100

100
Addition of VI improvers or the

use of synthetic base fluids:


 VI of 140 - 200
14

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Viscosity Index (VI)


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

40C and 100C in accordance with the ISO or ASTM


Test Method D567 or D2270.

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Viscosity Index (VI)


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
of synthetic oils are:
Thermal and oxidation stability

Synthetic oils, however, also


show some disadvantages :
Interaction with other synthetic

oils (not mixable)

Favorable viscosity /

Interaction with other material

temperature behavior

e.g. seals, paintings etc.

High flash point

Toxicity

High aging stability


Good low temperature behavior

Higher price

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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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Selection and Application of Lubricating Oils


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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Selection and Application of Lubricating Oils


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 40C and 100 C 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
Optimum Viscosities cSt

Probably maximum pouring viscosity


At Operating Temperature

25

Hydraulic Systems

30

Plain Bearings

40

Spur & Helical Gears (e.g. ISO-VG 220 @ 65C)

75

Worm Gears (e.g. 460 @ 75C)

Minimum Viscosities cSt

At Operating Temperature

13

Hydraulic Systems

13

Plain Bearings

21

Spherical Roller Bearings

33

Spur & Helical Gears

Minimum Viscosity to support a dynamic load


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Additives
Viscosity Index Improver

What do the additives do?

Oxidation inhibitors

Additives are added to lubricants


to positively influence the
properties that the oil already
has.
They add features to improve
the service life, wider operating
temperature range, provide rust,
foam and wear protection. They
enable the oil to do things that it
could not accomplish by itself.

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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Viscosity Index Improver


What it does



IVE
T
I
D
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 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

Solidification at low temperatures is due to:

Wax crystals settling out



Oil too viscous to move

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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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


What it does


IVE
T
I
D
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
80
90
100
110
120
130

Service Life (Hours)


10000
5000
2500
1250
625
313

Days
416
208
104
52
26
13

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




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.

Oil
40 ml
Water
40 ml

Specified oil water


emulsion must break
after agitation and
settling of max. 20 min.

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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





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

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

IVE
T
I
D
AD

What it does



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


What it does


IVE
T
I
D
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

IVE
T
I
D
AD

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

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 oils 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

E
V
I
T
DI
D
A

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

E
V
I
T
DI
D
A

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

IVE
T
I
D
AD

What it does



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

IVE
T
I
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

IVE
T
I
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)


What it does





IVE
T
I
D
AD

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

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)

IVE
T
I
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

E
V
I
T
DI
D
A

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

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

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


lubrication is possible

the grease film and not


removed, especially with
grease lubrication of minimal
quantity

Less risk of leakage and

simpler seal design


Sealing effect is reinforced by

used grease overflow (grease


collaring)

At present, limiting speeds or

speed factors are lower than


with oil injection and oil/air
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

E
V
I
T
DI
D
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

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

ATF Automatic Transmission Fluid

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Grease

9
9
9
9

9
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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:
NLGI Grade

Walk penetration
DIN 51804 / 1
(0.1 mm)

Structure

Application Generally

000
00
0

445475
400430
355385

fluid
almost fluid
extremely soft

Mainly for gear reducer


lubrication

310340
265295
220250

very soft
soft
moderate

Roller and plain bearing


lubrication

stiff
very stiff
extremely stiff

Grease for labyrinth


seals and fittings

1
2
3
4
5
6

175205
130160
85115

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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 (40C)

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 125C.

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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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Comments on Proprietary Additives


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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Comments on Proprietary Additives


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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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.

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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.

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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.

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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.

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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.

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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

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.
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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.
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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.

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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


higher starting friction admissible

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

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


force on bearing

Grease with a large amount of thickener, penetration class 2 to 4


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

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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 105 mbar, depending on temperature and base oil,


rolling bearing greases according to DIN 51 825, consult bearing manufacturer.

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Grease properties (1/2)

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Grease properties (2/2)

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Rolling-element Bearings
Requirement

Problem

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 70C

Low to moderate loads and speeds

Short life due to high temperatures (up to 150C)

Medium to high speeds

Short life due to high temperatures ( up to 160C continuous )

Moderate to high loads and low to moderate speeds

Short life due to very high temperatures ( up to 180C continuous )

Moderate to high loads and high speeds

Short life due to very high temperatures ( up to 200C continuous )

Low to moderate loads and speeds

Harsh chemical environment

Heavy duty and chemically resistant grease

Low to moderate loads and speeds

Short life due to extremely high temperatures ( up to 230C continuous)

Short life due to extremely high temperatures ( up to 250C continuous)

Resistant against solvents and other aggressive chemicals

Need for operation in very high vacuum environment

Service temperatures from -35 to +250C

Lubricant failure because of aggressive environmental influence

Service temperatures from -35 to +250C

Service temperatures from -40 to +200C

Service temperatures from -40 to +230C

Service temperatures from -40 to +150C

Medium to high speeds

Service Temperatures from -40 to + 130 C

Noise

Short life due to wet environment

High loads

Short life due to very high speeds

Service Temperatures from -50 to + 130 C

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