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Fuchs Indonesia
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Grease
A solid to semi-fluid product of a thickening agent in a liquid lubricant. Other ingredients imparting general
properties may be included
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• Advantages • Disadvantages
Convenience
Resistance
Protection
Cleanliness
Low Cooling Rate
Contamination
Performance
Limitations
Grease
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Grease Composition
Base Oil70 - 95%
Thickener10 - 20%
Additives5 - 10%
Grease
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Lubricating Greases - Basics and Applications
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Components Used in Grease FormulationBase oils Thickeners Additives
Mineral oils
Synthetic mineral oils
Di-esters
Silicones
Phospate esters
Fluorocarbon
Fluorinated silicone
Chlorinated silicone
Sodium soap
Calcium soap
Lithium soap
Aluminium soap
Barium soap
Aluminium complex
Lithium complex
Bentonite clay
Silica
Carbon/graphite
Polyurea
PTFE
Polyethylene
Indanthrene dye
Phthalocyanine dye
Anti-oxidants
Anti-wear additives
EP additives
Corrosion inhibitors
Friction modifiers
Metal deactivators
VI improvers
Pour-point depressants
Tackiness additives
Water repellants
Dyes
Structure modifiers
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Typical Oils Used in Lubricating Greases• Petroleum
Paraffinic – good VI and thermal stability to 350oF max. temp.
Naphthenic – good low temperature performance to –65oF min
• Synthetic
Nominal Serviceable Temp. Range. oF
Diester - 100 to 400
Fluorosilicone - 50 to 450
Hydrocarbon - 80 to 350
Polyalkylene glycol - 40 to 350
Polyol ester - 50 to 400
Silicone - 100 to 450
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Base Oil For Grease
• Depends on required characteristics of grease.
Flow, viscosity, temp. range and speed.
• Paraffinic and napthenic mineral oils
• Synthetics used for special applications – very
low/very high temp.
• Base oil function is to lubricate
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Thickener Types
•Metal soaps
Lithium, calcium, sodium, barium, aluminium, etc
Complex (I.e. Lithium complex, alumunium complex, Calcium complex)
• Inorganics/non soap
Clays, megalite, montmorilonite, hectorites, bentonites
• Organics
Polyurea
• Fluoro Organic
PTFE
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• Act as a carrierTo release fluid
• Water Resistance
1. Washout Resistance - the ability of the lubricant to stay in the bearing while operating partially or fully submerged (ASTM D1264).
2. Water Absorption - the ability of the grease to deal with the presence of water by either absorbing or resisting the washing and diluting action of the water.
3. Spray Resistance - the ability of the grease to resist displacement from a direct impingement of the water on the greased surface (ASTM D4049).
• Heat Resistance
Thickener Influences
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Grease Additives
Zinc dialkyIdithiophosphates
Dithiocarbamates (Zn, Sb, Pb)
Phosphate esters
Sulfurized fatty acids
Sulfurized hydrocarbons
Chlorinated hydrocarbons
• Anti-Wear/Extreme Pressure Agents
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Aryl amines
Zinc dialkyldithiophosphates
Hinderes phenols
Zinc and amine dithiocarbamates
• Anti-oxidants
Grease Additives
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Sulfonates (Ca, Ba, Li, Mg, Na, Pb, amine salts)
Napthenates (Zn, Ba, Pb)
Carboxylic acid derivatives
Triazoles
Sodium Nitrite
• Rust and Corrosion Inhibitors
Grease Additives
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Molybdenum disulfide
Graphite
PTFE
Powdered fluorocarbons
• Friction Modifiers
Grease Additives
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Polyolefins and olefin copolymers
• Adhesion Promoters
Grease Additives
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Penetration
NLGI Number ASTM Worked Penetration
000 445-475
00 400-430
0 355-385
1 310-340
2 265-295
3 220-250
4 175-205
5 130-160
6 85-115
The depth, in tenths of a millimeter, that a standard cone sinks into a material under prescribed conditions of weight, time and temperature. This depth is described as NLGI numbers.
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Factors In Deciding NLGI Grades• Speed
The higher the speed the harder the grease, so for high
speeds use no. 3. The maximum outer race speed for grease-
lubricated rolling bearings is about 15 m/s (3000 ft/min)
• Bearing size
Use a harder grease in a large bearing, No.3 or even no.4
• Sealing
If there is a particular need for effective sealing, use a harder
grease, No.3 or No.4
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Factors In Deciding NLGI Grades
• Shock loads or vibration
Shock load or vibration tends to cause grease to slump into
the moving components causing churning. A harder grease
minimizes the problem, so use No.3 or No.4. (Note that normal
steady loading does not strongly influence the grade)
• Temperature
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Some basic rules:
Low speeds Greases with high base oil viscosity and high loads and EP and / or solid lubricants
like Graphite or MoS2
High speeds Greases with low base oil viscosity
Oscill. movement Greases with white solid lubricants
High or low Greases with synthetic base oilstemperatures
Grease SelectionGrease Selection
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Important factors on Grease selection
1. Bearing design
2. Bearing speed
3. Load
4. Temperature
5. Environmental conditions
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Grease Incompatibility
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Base fluid compatibility
Öl-Typ
Mineralöl Polyalfa-olefin
Poly-glykol
Ester,synth.
Natives Öl Alkoxy-fluoröl
Silikonöl
Mineralöl + + - + + - -
Polyalfa-olefin + + - + + - -Polyglykol - - + - - - -Ester,synth. + + - + + - -Natives Öl + + - + + - -Alkoxy-fluoröl - - - - - + -Silikonöl - - - - - - +
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Calculation of lubricant consumptionCalculation of lubricant consumption
Effective lubrication is the combination of a suitable lubricant, right re-lubrication intervals and the optimum re-lubrication quantity.
„The more, the better“ is (nearly) always wrong. Over-lubrication leads to preliminary bearing failure and causes additional costs.
Frequent re-lubrication with small quantities is better than seldom re-lubrication in huge quantities. Optimization is necessary, because frequent re-lubrication needs more time.
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When calculating the optimum grease quantity, the free volume in the bearing as well as free space in the housing has to be considered.
First fill of bearing:
Fill the bearing completely, fill free space in the housing only with a quantity which allows, that grease coming out of the bearing during operation can remain in the housing to avoid undesired heating of the grease and the bearing. Sometimes sealing discs can be helpful.
Calculation of lubricant consumption:Calculation of lubricant consumption:
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Exceptions:
very high speeds:fill bearing and housing only to one third to avoid
ineffective working of the grease
very low speeds:fill bearing and housing completely to ensure
lubrication of all parts. In this case inner friction of the grease can be neglected.
Calculation of lubricant consumptionCalculation of lubricant consumption
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Calculation of the free bearing volume:Calculation can be done with the dimensions and weights given by the suppliers of the bearings with the following formula:
V ≈ π/4 . B . (D² - d²) . 10-3 - G . 1000 / 7,8 [cm³]
V - free bearing volume in cm³ d - Inner diameter in mmB - Bearing width in mm G - Weight in kgD - Outer diameter in mm
Calculation of lubricant consumptionCalculation of lubricant consumption
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Basic quantities when using grease guns:
One stroke with a conventional (DIN) or withSYSTEM REINER-Grease Gun gives ca. 1,5 - 2 ccm of grease.
Calculation of lubricant consumptionCalculation of lubricant consumption
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Re-lubrication quantities and -intervals depend very much on the real operating conditions. Therefore, exact calculation is extremely difficult.
In the past data of practical applications were collected which were used as a data base for calculations for specific application fields. These calculations use factors for special operating conditions which were found by studying numerous similar applications.
Difficulties arise from the determination of these correction factors as well as from the use of specialised greases with a performance being much higher than that of conventional Li-soap-mineral-oil greases.
Calculation of lubricant consumptionCalculation of lubricant consumption
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Correction factors for re-lubrication intervals
f1 - Dust and moisture (0.1 ... 0.9)f2 - Shocks, vibrations (0.1 ... 0.9)f3 - Temperature higher than 70°C (0.1 ... 0.9)f4 - High load (0.1 ... 1.0)f5 - Air flow through the bearing (0.1 ... 0.7)
The reduced re-lubrication interval is then calculated by multiplying all these single factors:
tfq = f1. f2
. f3. f4
. f5. tf
Calculation of lubricant consumptionCalculation of lubricant consumption
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ASTM Grease Tests
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Mechanical dynamic testing of lubricating greasesMechanical dynamic testing of lubricating greasesFE 8-bearings
FBT-balls
Emcor-machines
Timken-machine with specimen
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Lubricating GreasesLubricating GreasesProperties:
Consistency (NLGI-grade)
Temperature range
EP-properties
Base oil viscosity and type
Thickener
Solid lubricants
Classification (DIN 51502):
e.g. K P F 2 K -20
Classification
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Grease Troubleshooting Guide
Application Symptom Possible Cause Check For
Noise Condition of bearing Worn or brinelled bearing
Over greasing Too frequent application
Bearing packed too full
Excessive grease charge
Starvation Insufficient application frequency
Incorrect product Wrong base oil viscosity
Seals Mechanical damage
Incorrect installation
Over greasing Too frequent application
Excessive amount applied
Incorrect product Too soft for application or softening in service
Incompatibility of grease Admixture of grease
Excessive leakage
High bearing temp.
Bearings Rolling contact
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Application Symptom Possible Cause Check For
Excessive wear Deficient load carrying (EP)
Starvation
Contamination (dirt,dust)
Bearing life exceeded
Improper installation
Grease too stiff (channeling)
High temperature High operating temperature
Misalignment Correct alignment
Overheating Improper distribution Grease too stiff
Incorrect grooving
Starvation Infrequent application
Defective lubricator
Excessive wear
Bearings Plain
Incorrect grease Mechanical stability
Starvation Infrequent application
Defective lubricator
Incorrect grease Load carrying (EP)
Temperature range
Bearings Rolling contact
Frequent bearing replacement
Grease Troubleshooting Guide
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Application Symptom Possible Cause Check For
Grease too soft Product penetration
Milling down of product
Incompatibility of greases Admixture of greases
Noisy gearbox Lack of lubrication Improper lubricant level
Grease to stiff
Lack of lubrication Improper lubricant level
Grease too stiff
Overheating
Churning High grease level
Grease too stiff
Tooth breakage
Pitting
Wear and scoring Lack of lubrication Improper lubricant level
Grease too stiff
Incorrect product used Consistency, EP, quality and base oil viscosity
Abbrasive wear Lubricant contamination
Not usually lubricant related
Mostly poor design and fatigue related While not generally lubricant related, a heavier grease or base oil may retard progression of pitting
Alignment Not lubricant related
Excessive leakageGears Enclosed
Grease Troubleshooting Guide
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Application Symptom Possible Cause Check For
Gear wear Lack of lubrication Incorrect lubricant
Incorrect application frequency
Build up on gears or in roots Excessive lubricant Application frequency
Lubricant type
Airborne dirt
Sliding Surfaces
Universal Joints
Electric Motors Electric malfunction
High temperature
Couplings
Non-uniform motion Lack of lubrication Application frequency
Proper grease type
Excessive wear Insufficient lubrication Lubricant EP, temperature quality
Application frequency
Grease slumpability
Excessive grease leakage Application frequency and quantity
Dry coupling Excessive grease leakage Damaged seals
Grease consistency
Keyway openings
Initial fill
Gears Open
Grease Troubleshooting Guide
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Thank you