Lubrication Training - Basics of Lubrication

Types of Lubrication

Hydrodynamic

Boundary

Mixed
Hydrodynamic Lubrication
Occurs when machine parts are completely
separated by a full and continuous film of lubricant
Contact between the parts does not occur.
Full-fluid-film lubrication is hydrodynamic lubrication,
the oil adheres to the moving part and is drawn into
the area between the rotating surfaces, where it
forms a pressure, or hydrodynamic, wedge.
A less common form of full-fluid-lubrication is
hydrostatic lubrication, where the oil is supplied to
the bearing area under pressure to separate the
sliding surfaces.
Hydrodynamic Lubrication
Boundary Lubrication
Under certain conditions such as shock loading,
heavy loads, high temperature, slow speed and
critically low viscosity, the lubricant is no longer
hydrodynamic
Frequent contact between the surfaces, resulting in
a significant rise in temperature and subsequent
destruction of the contacting surfaces.
Under these circumstances, the fluid film is no
longer capable of adequately protecting the
surfaces.
EP capabilities in the lubricant are essential
Solid additives are mixed into the grease
Mixed Lubrication
Although not a true mode of lubrication in the
sense of hydrodynamic or boundary, mixed
lubrication occurs more frequently then is
realized.
Mixed lubrication is a transitional mode of
lubrication between hydrodynamic and boundary
Mixed lubrication is characterized by the
likelihood of intermittent surface contact
EP and anti-wear are essential properties in the
lubricant
How is a lubricant made?

Select a base fluid:

MINERAL OIL
or
SYNTHETIC FLUID?
Selecting a base fluid:

MINERAL OIL

Paraffinic or Naphthenic
Readily available
Comparatively low cost
Limited performance.
Selecting a base fluid:

SYNTHETIC FLUIDS

PAO, PAG, Ester

Synthetically manufactured
Comparatively high cost
Improved performance
Longevity
Temperature
Viscosity Index
Selecting a base fluid:

OTHER SYNTHETIC FLUIDS

Silicones
Fluorinated
Ultra Performance
Ultra Temperature
Long Life
Lube for Life
Base fluid selected:

Mineral or Synthetic

NOW SELECT THE

REQUIRED
VISCOSITY.
Selecting the required viscosity:

Generally thinner fluids are used for:

Lighter loads

Faster speeds.
Selecting the required viscosity:

Generally thicker fluids are used for:

Heavier loads

Slower speeds

So how do we measure viscosity?.

 400C & 1000C

mm2 per second

=centistokes (cSt)
High
Low Viscosity
Viscosity (Thick)
(Thin)
What are the units of viscosity?

mm2s = centistokes (cSt) = ISO VG (at 400C)

32 cSt - typical low viscosity (thin)

680 cSt - typical high viscosity (thick)
ISO VG 15-22-32-46-68-100-150-220-320-460-680-1000 etc
Product enhancements:
Extreme Pressure (EP) Additives

CHEMICAL SOLID
SOLUTIONS LUBRICANTS
Chlorine Graphite
Sulphur Molybdenum disulphide
Phosphorous (MoS2)
PTFE (Teflon)
Product enhancements
OXIDATION INHIBITORS
Longer wet life

CORROSION INHIBITORS
Improves corrosion protection.

TACKY ADDITIVES
Improves adhesion
 Thickener Systems turn fluids into greases
Improved Performance Lithium complex
-Temperature Calcium complex
Soap Aluminium complex
-Mechanical stability Thickeners

Lithium soap Calcium

General
soap Aluminium soap
Purpose
Thickener Properties
Lithium
Good multi-purpose, good mechanical stability,
limited other properties
Lithium Complex
Excellent high temp & mechanical stability
capability
Calcium Complex
Excellent load carrying and water resistance
Aluminium Complex
Excellent temperature capability & water
resistance
Other Thickener Systems
Other grease thickeners:

Bentonite clay
Silica
PTFE.
How is the grease thickness checked ?

NLGI PENETRATION TEST

NATIONAL
LUBRICATING
GREASE
INSTITUE of America.
 NLGI Numbers - WHAT DO THEY MEAN?
NLGI No 6 BLOCK GREASE Old Technology

NLGI No 5 SEMI-SOLID ELASTIC-LIKE Very rarely used, but can be found

GREASE in marine or shipping applications

NLGI No 4 VERY TACKY GREASE Rarely used now, but found

sometimes found in heavy open
gears or mining equipment
NLGI No 3 HEAVIER GREASE Used mainly for hand applied or
caulking guns
NLGI No 2 85% OF MARKET Generally used in grease guns

NLGI No 1 THINNER GREASE Generally used in grease guns,

slightly more pump- able for short
pipe lines
NLGI No 0 TREACLE LIKE GREASE Used in semi-auto and auto
systems with shorts pipelines
SEMI FLUID/ Generally applied by
Used in semi-auto and automatic
NLGI No 00 SEMI FLUID GREASE
FLUID GREASE Automatic Lubricator
systems
NLGI No FLUID GREASE Used in some gearboxes and semi
000 & auto lube systems with longer
pipe lines
HOW IS GREASE THICKNESS MEASURED?

Premium EP 2 Premium EP 1 Premium EP 000

NLGI 6

NLGI 5
NLGI 4
NLGI 3

NLGI 2
NLGI 1
NLGI 0
NLGI 00

NLGI 000
Summary
Base fluid
Mineral or synthetic
Viscosity
EP additives
Chemical and/or solids
Corrosion inhibitors
Oxidation inhibitors
Thickeners for greases.
BASIC FUNCTION OF A PRECISION BEARING

TO SUPPORT A ROTATING SHAFT

Outer Race
Balls or
Rollers

Shaft

Inner Race Lubricant

BASIC FUNCTION OF A PLAIN BEARING
TO SUPPORT A ROTATING SHAFT

Plain Bush
Lubricant

Shaft
BASIC FUNCTION OF A SLIDE

TO SUPPORT A SLIDING LOAD

 ALL BEARINGS/SLIDES HAVE ONE SURFACE
MOVING AGAINST ANOTHER

FRICTIONAL HEAT

WHY LUBRICATE?
FRICTIONAL HEAT FRICTIONAL WEAR

WHY LUBRICATE?
 Introduction of a lubricant film

REDUCES FRICTIONAL HEAT & WEAR

BASIC FUNCTION OF A LUBRICANT.

Reasons for bearing failure

Other reasons
21%
Improper
mounting
27%

Improper
lubrication Material
43% fatigue
9%
Breakdown of improper lubrication section

Over
lubrication
60%
Lack of
lubrication
40%
Potential failures due to over lubrication

Standard grease gun can develop 3,000 psi

High pressure grease guns can develop >6,000 psi
Potentially resulting in excessive drag causing:
Increased power demand
Ball/roller skid
Increased friction
Excessive heat
Excessive race wear
Degradation of the lubricant.
Correct Application of a lubricant
LITTLE & OFTEN!
Precision Bearings:
Typically fill 1/3 to 1/2 of vacant
area in bearing
High speed bearings require
approx. 1/3 fill
Plain Bearings
Typically fill until clean grease
shows.
Thank You

Any Questions?