Basics of Lubricants Lubrication

8/10/2019 Basics of Lubricants Lubrication

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Meaning of lubrication

Friction - is createdwhen there isrelative motion between two surfaces

Resistance to motionis defined asfriction

Lubrication is use of a material

between surfaces to reduce friction Any material usedis called a lubricant

Hussam Adeni [email protected]


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Methods of lubrication

Two main methods

Hydrodynamic lubrication

Boundary lubrication


Also called complete or full flow

Occurs when two surfaces arecompleted separated by a fluid film



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Methods of lubrication cont..

Two main methods




Occurs when Hydrodynamic lubricationfails.

By adsorption or chemical reaction



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Types of Lubricant - Physical

Liquid

Solid

Semi solid

Gases



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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 byforming 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 andfailure.



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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 andmoisture

Very important to increase life ofcomponent 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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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 40C and 100C 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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Viscosity index

Measure of fluids change of viscosity

with temperature. Empirical number

Higher the VI lower will be thechange of viscosity with temperature

Indicator of temperature range ofoperations



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Pour Point

Lowest temperature at which the fluid

will flow Indicates lowest operating

temperature

Measured in C



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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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Total Base Number (TBN)

Measured the acid neutralizingreserve 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 445

ASTM D 2250

ASTM D 97

ASTM D 92 (COC)

ASTM D 93 (PMCC)ASTM D 664


Kinematic viscosity

Viscosity indexPour PointFlash Point

Total Base Number(TBN)


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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 additivesWhat they do in Engine Oils

Protect metal surfaces

- (rings, bearings, gears, etc.)

Extend the range of lubricantapplicability

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 Agent

Reduce friction & wear.

Prevent scoring & seizure

ZDDP, Organic Phosphates, acidphosphates, organic sulfur and chlorinecompounds etc.

Chemical reaction with metal surfaceand forms a film.

Prevents metal-to-metal contact



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Additive type

Purpose

Typical

compounds

Function

Corrosion and Rust Inhibitor

Prevent corrosion and rusting of themetallic parts in contact with lubricant

ZDDP, Metal phenolates, Basic Metalsulphonates, fatty acid & Amines.

Preferential adsorbtion of polarconstituent on metal surface.

Provide protective film

Neutralize corrosive acids



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Additive type

Purpose

Typical

compounds

Function

Detergents

Keep surface free of deposits

Metallo organic compounds of Sodium,Calcium and Magnesium phenolates

Phosphonates and sulphonates

Chemical reaction with sludge andvarnish percursors to neutralize themand keep them soluble



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Additive type

Purpose

Typical

compounds

Function

Dispersant

Keep insoluble contaminantsdispersed in the lubricant

Alkylsuccinimides, alkylsuccinic estersand mannich reaction products

Contaminants are bonded by polarattraction to dispersant molecules.

Prevented from agglomerating

Kept in suspension due to solubility ofdispersant



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Additive type

Purpose

Typical

compounds

Function

Friction modifier

Alters coefficient of friction

Organic fatty acids and amides.

Lard Oil, high molecular weightorganic phosphorus.

Phosphoric acid esters

Preferential adsorbtion of surfaceactive materials



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Performance additives- Automotive Lubricants

Additive type

Purpose

Typical

compounds

Function

Pour Point Depressant

Enable lubricant to flow at lotemperature

Alkylated naphthalene

Phenolic polymers, Ploymethacrylates

Maleate/fumerate copolymer esters

Modify wax crystal formation to reduceinterlocking



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Additive type

Purpose

Typical

compounds

Function

Seal swell Agent

Swell elastomeric seals, gaskets

Organic phosphates

Aromatic hydro carbons

Chemical reaction with with elastomerto cause slight swell.



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Additive type

Purpose

Typical

compounds

Function

Viscosity modifier

Reduce the rate of viscosity changewith temperature

Polymers and copolymers of olefins,methacrylates, dienes

Alkylated styrenes.

Polymers expand with increasing

temperatures

This counteract oil thinning



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Additive type

Purpose

Typical

compounds

Function

Antifoamant

Prevent lubricant from forming apersistent foam

Silicone polymers

Organic copolymers

Reduce Surface tension to speedcollapse of foam



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Additive type

Purpose

Typical

compounds

Function

Antioxidant

Retard oxidative decomposition

ZDDP,

Hindered phenols, Aromatic Amines,sulfurized phenols

Decompose peroxides

Terminates free-radical reactions



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Additive type

Purpose

Typical

compounds

Function

Metal deactivator

Reduce catalytic effect of metals onoxidation rate

Organic complexes containingnitrogen or sulfur

Amines, sulphides and Phosphates

Forms inactive film on metal surfaces

by complexing with metallic ions



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Lubricant - Nomenclatureand 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


2000


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Viscosity Grade Classification

Systems

ISO Industrial Oils

cSt @ 40C

AGMA Industrial Gear Oils

cSt @ 40C

SAE Engine Oils

cSt @100C, cP @150C

cP @ -10

C to -40

C

SAE Gear Oils

cSt @100C

cP @ -12C to -55C

1500

1000800

600500

400

300

200

150

10080

6050

40

30

2015

10

cSt @ 40CSUS @ 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

5W&0W

140

90

85W

80W

75W

400

100

60

200

300

500

1000

2000

3000

10000

5000

400

ISO VG AGMA SAE SAE Eng ine Gear

Oils Oils


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Lubricant - Specifications

Crankcase oils - SAE numbers

Crankcase oils - Performance levels

Crankcase oils OEM Specifications Viscosity classification

Grease specification



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Major specifyingorganizations

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 forengine oils

Designated With corresponding viscosity

For high temperature application Warmer areas/regions SAE 20

SAE 30

SAE 40 SAE 10

SAE 50

SAE 60Hussam Adeni [email protected]


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SAE viscosity grades forengine 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 WHussam Adeni [email protected]


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SAE viscosity grades forMono grades - Engine Oils

Mono grades are designatedwith single SAE number

SAE 10, 20, 30, 40, 50 SAE 5W,10W, 15W,20W,25W

Can be used either in summer seasonor 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 forMulti grades - Engine Oils

Multi grades are designatedwith 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 summermonths or seasons

Available in Engine oils & Gear oil



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SAE Crankcase Oil - Viscosityclassification Summer Service


Low temp viscosities High temp viscosities

SAEViscosityGrade

Enginecranking Max.cPs at Temp

(C)

Max. Temp forpumping

viscosity of60,000 cP(C)

Vis. at 100C, cSt High shear(cP) 150C &106S- MinMin Max

Summer Service

20 -- - 5.6


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API Automotive Gasoline EngineService Categories SA, SB,


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-38Sequence 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


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API Automotive Gasoline EngineService Categories SA, SB,

Hussam Adeni

[email protected]

Category Related IndDefinitions


SG 1989 Models CRC-L-38Sequence VE

Sequence IIDCaterpillar IH2

Sequence IIIE

SH1994 Models CRC-L-38

Sequence VESequence 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.


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API Automotive Diesel EngineService Categories CA, CB,

Hussam Adeni

[email protected]

Category RelatedUS Mil spec


CA MIL-L-2104A CRC L-38 Caterpillar L-1 Fuel 0.4% S

CB MIL-L-2104A

Supplement 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 Diesel6V53T

CE None CRC L-38Mack T-6

Caterpillar 1 G2Mack T-7

Cummins NTC 400

CF None CRC L-38 Caterpillar 1M-PC


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API Automotive Diesel EngineService Categories CA, CB,

Hussam Adeni

[email protected]

Category Related IndSpec


CF-2 None CRC L-38 Detroit Diesel 6V92TA Caterpillar 1M-PC

CF-4 None CRC L-38

Mack 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-4None RFWT

EOAT

Cummins M11 EGR

Mack T-8E, T-10Caterpillar 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


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ISO 3448 Kin Vis - CSt 40Cvs SUS 100F (40C)

Hussam Adeni

[email protected]

Midpoint Minimum Maximum SUS 100F

VG 2 2.2 1.98 2.42

VG 3 3.2 2.88 3.52

VG 5 4.6 4.14 5.06VG 7 6.8 6.12 7.48

VG 10 10 9 11 60

VG 15 15 13.5 16.5 75

VG 22 22 19.8 24.2 105

VG 32 32 28.8 35.2 150

VG 46 46 41.4 50.6 215


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ISO 3448 Kin Vis - CSt 40Cversus SUS 100F (40C)

Hussam Adeni

[email protected]

Midpoint Minimum Maximum SUS 100F

VG 68 68 61.2 74.8 315

VG 100 100 90 110 465

VG 150 150 135 165 700VG 220 220 198 242 1000

VG 320 320 288 352 1500

VG 460 460 414 506 2150

VG 680 680 612 748 3150

VG 1000 1000 900 1100 4650

VG 1500 1500 1350 1650 7000


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National Lubricating GreaseInstitute - NLGI Numbers

Hussam Adeni

[email protected]

NLGI Grade Number ASTM worked penetration 77F(25C)

000 445 - 475

00 400 - 430

0 355 - 385

1 310 - 340

2 265 - 295

3 220 - 2504 175 - 205

5 130 - 160

6 85 - 115


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Thank you

Documents

Basics of Lubricants Lubrication