Basic Of Lubricants and Lubrication
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Transcript of Basic Of Lubricants and Lubrication
Meaning of lubrication
• Friction - is created when there is relative motion between two surfaces
• Resistance to motion is defined as friction
• Lubrication is use of a material between surfaces to reduce friction
• Any material used is called a lubricant
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Methods of lubrication
• Two main methods• Hydrodynamic lubrication• Boundary lubrication
• Hydrodynamic lubrication• Also called complete or full flow• Occurs when two surfaces are
completed separated by a fluid film
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Methods of lubrication cont..
• Two main methods• Hydrodynamic lubrication• Boundary lubrication
• Boundary lubrication• Occurs when Hydrodynamic lubrication
fails.• By adsorption or chemical reaction
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Types of Lubricant - Physical
• Liquid• Typical lubricants are liquid/fluids• Mineral oil or synthetic oils
• Solid• Graphite, MoS2
• Semi solid• Greases
• Gases• Atomised 2 stroke oils
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Typical lubricants - Application
• Engine oils• Gear Oils• Turbine Oils• Hydraulic Oils• Metal working oils
• Cutting oils• Forming Oils
• Rust preventives
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Typical lubricants - Application
• Heat Transfer Oils• Heat Treatment Oils
• Quenching Oils• Tempering Oils
• Refrigeration Oils• Rubber Process Oils• Ink process Oils
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Lubricant - Components
• Base Oils• Mineral by-products of crude oil refining
process.• Base oils are polymerized or
synthesized further and called synthetic• Additives
• Natural• Synthetic
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Function of a lubricant
• Lubricate - Reduce friction• Cooling - Heat transfer• Cleaning - Detergency• Noise pollution - dampening• Sealing – prevent leakage• Protection – prevent wear
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Lubricate – reduce friction
• The effects of friction• Metal to metal contact• Leads to wear and tear• Generates heat• Results in Power loss
• Lubricant reduces friction by forming a film• Reduces ill effect of friction
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Cooling
• When fuel is burnt in an engine• 33% is useful power• 33% removed by cooling water• 33% by lube oil and radiation
• Lube oil removes heat from all areas and brings it to the engine sump.
• Improper cooling can lead to over heating, lead to wear, distortion and failure.
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Cleaning
• Cleans carbon and varnish deposits• Flushes the entire system removing
• Soot• Deposits• Acids• Wear products• Moisture
• Removes external contaminants dust, moisture (external)
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Noise reduction
• Reduce noise• By preventing metal to metal contact
• Dampens noise• As between camshaft and tappet
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Sealing
• Oil film• Between piston ring and liner• Helps in creating a gas tight seal
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Protection
• Protection against acids and moisture
• Very important to increase life of component and equipment
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Properties of lubricants
• Kinematic viscosity• Viscosity index• Pour Point• Flash Point• Total Base Number (TBN)
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Properties of lubricants
• Kinematic viscosity• Measure of internal resistance to flow• “Thickness” of fluid (in laymen terms)• Decreases with increase in temperature• Important in lubricant selection• Increase in used oil indicates oxidation • Specified at 40˚C and 100˚C• Measured in Centi Stokes (CSt)
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Kinematic Viscosity - Recommendations
• Low Viscosity oils used• High speeds• Low pressure• Low temperature
• High Viscosity oils used• Low speeds• High pressure• High temperature
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Properties of lubricants
• Viscosity index• Measure of fluids change of viscosity
with temperature.• Empirical number• Higher the VI lower will be the change
of viscosity with temperature• Indicator of temperature range of
operations
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Properties of lubricants
• Pour Point• Lowest temperature at which the fluid
will flow• Indicates lowest operating
temperature• Measured in ˚C
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Properties of lubricants
• Flash Point• Lowest temperature at which the vapor
above the liquid will ignite under flame• Indicated safe maximum temperature of
operation.• Indicator of volatility• Test method - COC and PMCC• Measured in ˚C
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Properties of lubricants
• Total Base Number (TBN)• Measured the acid neutralizing reserve
in oil.• Important for deciding discard of oil• Decreases due to
• Oxidation of oil• Water contamination• Fuel contamination
• Measured in Mg KOH/gm of oil
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Lab Tests - for lubricants
ASTM D 445ASTM D 2250ASTM D 97ASTM D 92 (COC)ASTM D 93 (PMCC)ASTM D 664
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Kinematic viscosityViscosity indexPour PointFlash Point
Total Base Number (TBN)
What are additives
Lubricant additives classified on their functional capability Enhance existing property Suppress undesirable property Impart new property
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What are additives – What they do in Engine Oils
Protect metal surfaces - (rings, bearings, gears, etc.)
Extend the range of lubricant applicability
Extend lubricant life
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Surface Protective additives
Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifier
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Surface Protective additives - Automotive Lubricants
Additive type Purpose
Typical compounds
Function
Anti wear & EP AgentReduce friction & wear.Prevent scoring & seizureZDDP, Organic Phosphates, acid
phosphates, organic sulfur and chlorine compounds etc.
Chemical reaction with metal surface and forms a film.
Prevents metal-to-metal contact
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Surface Protective additives - Automotive Lubricants
Additive type Purpose
Typical compounds
Function
Corrosion and Rust InhibitorPrevent corrosion and rusting of the
metallic parts in contact with lubricantZDDP, Metal phenolates, Basic Metal
sulphonates, fatty acid & Amines.
Preferential adsorbtion of polar constituent on metal surface.
Provide protective filmNeutralize corrosive acids
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Surface Protective additives - Automotive Lubricants
Additive type Purpose Typical compounds
Function
DetergentsKeep surface free of depositsMetallo organic compounds of Sodium,
Calcium and Magnesium phenolatesPhosphonates and sulphonatesChemical reaction with sludge and
varnish percursors to neutralize them and keep them soluble
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Surface Protective additives - Automotive Lubricants
Additive type Purpose
Typical compounds Function
DispersantKeep insoluble contaminants
dispersed in the lubricantAlkylsuccinimides, alkylsuccinic esters
and mannich reaction productsContaminants are bonded by polar
attraction to dispersant molecules.Prevented from agglomeratingKept in suspension due to solubility of
dispersant
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Surface Protective additives - Automotive Lubricants
Additive type Purpose Typical compounds
Function
Friction modifierAlters coefficient of friction Organic fatty acids and amides.Lard Oil, high molecular weight
organic phosphorus.Phosphoric acid estersPreferential adsorbtion of surface
active materials
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Performance additives - Automotive Lubricants
Additive type Purpose
Typical compounds
Function
Pour Point DepressantEnable lubricant to flow at lo
temperatureAlkylated naphthalenePhenolic polymers, PloymethacrylatesMaleate/fumerate copolymer esters Modify wax crystal formation to reduce
interlocking
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Performance additives - Automotive Lubricants
Additive type Purpose Typical compounds Function
Seal swell AgentSwell elastomeric seals, gasketsOrganic phosphatesAromatic hydro carbonsChemical reaction with with elastomer
to cause slight swell.
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Performance additives - Automotive Lubricants
Additive type Purpose
Typical compounds
Function
Viscosity modifierReduce the rate of viscosity change
with temperaturePolymers and copolymers of olefins,
methacrylates, dienesAlkylated styrenes.Polymers expand with increasing
temperatures This counteract oil thinning
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Performance additives - Automotive Lubricants
Additive type Purpose
Typical compounds Function
AntifoamantPrevent lubricant from forming a
persistent foamSilicone polymers Organic copolymersReduce Surface tension to speed
collapse of foam
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Performance additives - Automotive Lubricants
Additive type Purpose Typical compounds
Function
AntioxidantRetard oxidative decompositionZDDP, Hindered phenols, Aromatic Amines,
sulfurized phenols Decompose peroxidesTerminates free-radical reactions
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Performance additives - Automotive Lubricants
Additive type Purpose
Typical compounds
Function
Metal deactivatorReduce catalytic effect of metals on
oxidation rateOrganic complexes containing
nitrogen or sulfurAmines, sulphides and PhosphatesForms inactive film on metal surfaces
by complexing with metallic ions
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Lubricant - Nomenclature and Specifications Nomenclature
•Crankcase oils - SAE numbers •Viscosity classification – ISO 3448•Grease – NLGI Numbers
Performance •Crankcase oils - Performance levels•Crankcase oils – OEM Specifications•US Military – US-MIL-2104
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• Viscosity Grade Classification Systems
ISO – Industrial Oils• cSt @ 40°C
AGMA – Industrial Gear Oils• cSt @ 40°C
SAE – Engine Oils• cSt @100°C, cP @150°C
• cP @ -10°C to -40°C
SAE – Gear Oils• cSt @100°C
• cP @ -12°C to -55°C
2000 1500 1000 800 600 500 400 300 200 150 100 80 60 50 40 30 20 15 10 cSt @ 40C SUS @ 100F
100
60
200
300
500
1000
2000
3000
5000
1500
1000
680
460
320
220
150
100
68
46
32
22
15
10
1
2
3
4
5
6
7
8
8A
50
40
30
20
15W
10W 8 5W&0W
140
90
85W
80W
75W
400
100
60
200
300
500
1000
2000
3000
10000
5000
400
ISO VG AGMA SAE SAE Engine Gear
Oils Oils
Lubricant - Specifications
• Crankcase oils - SAE numbers • Crankcase oils - Performance levels• Crankcase oils – OEM Specifications• Viscosity classification• Grease specification
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Major specifying organizations
• SAE – Society of Automotive Engineers (USA)
• API - American Petroleum Institute• US Military Specs – US - MIL – 2104 - • CCMC – European Specification • ISO – International Standard Organization –
ISO 3348• NLGI – National Lubricating Grease Institute
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SAE viscosity grades for engine oils
Designated • With corresponding viscosity• For high temperature application• Warmer areas/regions
• SAE 20 • SAE 30• SAE 40• SAE 10• SAE 50• SAE 60
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SAE viscosity grades for engine oils
Designated • With corresponding viscosity• For low temperature application• Colder areas/regions
• SAE 0 W • SAE 5 W• SAE 10 W• SAE 15 W• SAE 20 W• SAE 25 W
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SAE viscosity grades for Mono grades - Engine Oils
Mono grades are designated with single SAE number SAE 10, 20, 30, 40, 50
• SAE 5W,10W, 15W,20W,25W • Can be used either in summer season or in
winter seasons.• Gradual shift to multi grades.• Shift also due to lower oil consumption by
multi grades• Available as Engine oil and Gear Oils
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SAE viscosity grades for Multi grades - Engine Oils
Multi grades are designated with two SAE number
Widely in use today• SAE 10w/30, 15w/30, 25w/50 • SAE 5W/30, 20W/40• Suitable for use in winter and summer
months or seasons• Available in Engine oils & Gear oil
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SAE Crankcase Oil - Viscosity classification – Winter Service
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Low temp viscosities High temp viscosities
SAE Viscosity Grade
Engine cranking Max. cPs at Temp
(˚C)
Max. Temp for pumping viscosity of 60,000 cP(˚C)
Vis. at 100˚C, cSt High shear (cP) 150˚C & 106 S-¹ MinMin Max
Winter Service0W 6200@ -35 -40 3.8 - --
5W 6200@ -30 -35 3.8 -10W 7000@ -25 -30 4.1 -15W 7000@ -20 -25 5.6 -20W 9500@ -15 -20 5.6 -25W 13000@ -10 -15 9.3
SAE Crankcase Oil - Viscosity classification – Summer Service
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Low temp viscosities High temp viscosities
SAE Viscosity Grade
Engine cranking Max. cPs at Temp
(˚C)
Max. Temp for pumping
viscosity of 60,000 cP(˚C)
Vis. at 100˚C, cSt High shear (cP) 150˚C & 106 S-¹ MinMin Max
Summer Service20 -- - 5.6 <9.3 2.630 -- - 9.3 <12.5 2.940 -- - 12.5 <16.3 3.540 -- - 12.5 <16.3 3.750 -- - 16.3 <21.9 3.760 -- - 21.9 <26.1 3.7
API Automotive Gasoline Engine Service Categories – “SA, SB,…”
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Category Related IndDefinitions
Engine Test Requirements
SA Straight Min None
SB Inhibited only CRC L-4 Sequence IIA Sequence IIIA
SC 1964 Models CRC L-38 Sequence IV
Sequence IIASequence V
Sequence IIIAFuel -1% S
SD 1968 Models CRC L-38Sequence IVCaterpillar L-1
Sequence IIBSequence VBCaterpillar IH
Sequence IIIBFalcon Rust
SE 1972 Models CRC-L-38Sequence IIID
Sequence IIBSequence VC
Sequence IIICSequence VD
SF 1980 Models CRC-L-38Sequence IIIE
Sequence IIDSequence VD
Sequence IIID
API Automotive Gasoline Engine Service Categories – “SA, SB,…”
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Category Related IndDefinitions
Engine Test Requirements
SG 1989 Models CRC-L-38Sequence VE
Sequence IIDCaterpillar IH2
Sequence IIIE
SH 1994 Models CRC-L-38Sequence VE
Sequence IID Sequence IIIE
Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete.
SJ 1997 Models CRC-L-38Sequence VE
Sequence IID Sequence IIIE
SL 2001 Models Sequence IIIFSequence VIII
Sequence IVA Sequence VG
SM 2004 Models Sequence IIIGSequence VIII
Sequence IVA Sequence VG
Category SJ, SL, SM, are currently valid.
API Automotive Diesel Engine Service Categories – “CA, CB,…”
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Category Related US Mil spec
Engine Test Requirements
CA MIL-L-2104A CRC L-38 Caterpillar L-1 Fuel – 0.4% S
CB MIL-L-2104ASupplement 1
CRC L-38 Caterpillar L-1 Fuel – 0.4% S
CC MIL-L-2104BMIL-L-46152B
CRC L-38 Sequence IID Caterpillar IH2
CD MIL-L-2104C/D/E,MIL-L-45199B, Series 3
CRC L-38 Caterpillar I G2
CD-II MIL-L-2104D/E2 stroke Hvy Dty
CRC L-38 Caterpillar 1 G2 Detroit Diesel 6V53T
CE None CRC L-38Mack T-6
Caterpillar 1 G2Mack T-7
Cummins NTC 400
CF None CRC L-38 Caterpillar 1M-PC
API Automotive Diesel Engine Service Categories – “CA, CB,…”
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Category Related IndSpec
Engine Test Requirements
CF-2 None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC
CF-4 None CRC L-38Mack T-7
Cummins NTC-400 Caterpillar 1K
CG-4 None CRC L-38Mack T-8
Sequence IIIERFWT
Caterpillar 1N
CH-4 None Mack T8ERFWT
Sequence IIIEMach T-9
Caterpillar 1P, 1KCummins M 11
CI-4 None RFWTEOAT
Cummins M11 EGRMack T-8E, T-10
Caterpillar 1R, 1KSequence IIIF
CI-4Plus None RFWTEOAT
Cummins M11 EGRMack T-8E, T-10,T-11
Caterpillar 1R, 1KSequence IIIF
CA to CE obsolete; CF onwards are currently valid
ISO 3448 – Kin Vis - CSt 40˚C vs SUS 100˚F (40˚C)
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Midpoint Minimum Maximum SUS 100˚F
VG 2 2.2 1.98 2.42VG 3 3.2 2.88 3.52VG 5 4.6 4.14 5.06VG 7 6.8 6.12 7.48VG 10 10 9 11 60VG 15 15 13.5 16.5 75VG 22 22 19.8 24.2 105VG 32 32 28.8 35.2 150VG 46 46 41.4 50.6 215
ISO 3448 – Kin Vis - CSt 40˚C versus SUS 100˚F (40˚C)
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Midpoint Minimum Maximum SUS 100˚F
VG 68 68 61.2 74.8 315VG 100 100 90 110 465VG 150 150 135 165 700VG 220 220 198 242 1000VG 320 320 288 352 1500VG 460 460 414 506 2150VG 680 680 612 748 3150VG 1000 1000 900 1100 4650VG 1500 1500 1350 1650 7000
National Lubricating Grease Institute - NLGI Numbers
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NLGI Grade Number ASTM worked penetration 77˚F (25˚C)
000 445 - 47500 400 - 4300 355 - 3851 310 - 3402 265 - 2953 220 - 2504 175 - 2055 130 - 1606 85 - 115