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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
(Thin)

Viscosity
(Thick)

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
SOLUTIONS
Chlorine
Sulphur
Phosphorous

SOLID
LUBRICANTS
Graphite
Molybdenum disulphide
(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
-Temperature
-Mechanical stability

General
Purpose

Soap
Thickeners

Lithium complex
Calcium complex
Aluminium complex

Lithium soap Calcium


soap Aluminium
soap

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
GREASE

Very rarely used, but can be found


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

SEMISEMI
FLUID/
FLUID GREASE

NLGI No 00

FLUID GREASE

NLGI No
000

FLUID GREASE

Generally
applied
by and automatic
Used
in semi-auto
systems
Automatic
Lubricator
Used in some gearboxes and
semi & auto lube systems with
longer pipe lines

HOW IS GREASE THICKNESS MEASURED?

Premium EP 2
NLGI 6
NLGI 5
NLGI 4
NLGI 3
NLGI 2
NLGI 1
NLGI 0
NLGI 00
NLGI 000

Premium EP 1

Premium EP 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

Breakdown of improper lubrication section

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?

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