lubrication.ppt
- 1. Basics of Lubricants and he lubrication Medhat Fayed
- 2. 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
- 3. Methods of lubrication cont.. • Two main methods • Hydrodynamic lubrication • Boundary lubrication • Boundary lubrication • Occurs when Hydrodynamic lubrication fails.By adsorption or chemical reaction • Boundary lubrication (h<Ra)
- 10. Speed limit value for bearing 000 bearing type oil lubes Greases lube radial 500 340 cylindrical 500 300 spherical 290 145 thrust 280 140
- 11. Timing
- 13. Types of Lubricant - Physical • Liquid • Solid • Semi solid • Gases
- 14. 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
- 15. Typical lubricants - Application • Engine oils • Gear Oils • Turbine Oils • Hydraulic Oils • Metal working oils • Cutting oils • Forming Oils • Rust preventives
- 16. Typical lubricants - Application • Heat Transfer Oils • Heat Treatment Oils • Quenching Oils • Tempering Oils • Refrigeration Oils • Rubber Process Oils • Ink process Oils
- 17. 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
- 18. What Is Engine Grade Oil American Petroleum Institute (API) Society of Automotive Engineers (SAE)
- 19. A Brief History of Motor Oil 1846 Crude oil refining process discovered Single Grade oil Multi Grade oil Synthetic oil first sold commercially in 1970
- 20. Properties Physical Flash Point Pour Point Viscosity Chemical Basic properties Detergents
- 21. Diagnosis D97, D5950, D5985 Pour Point D445 Kinematic Viscosity @25؛ and 40؛ C D2622, D4294, D3120 Sulfur D92, D93 Flash Point D1500 Color D2887 BP Distribution D5293 Viscosity by Cold Crank Simulator D5762 Nitrogen by Boat Inlet D5800 Evaporation Loss D1298, D4502 Density D1401 Demulsibility (Water Separation) D6417 Volatility D6304 Water D6045 Color Determination Test
- 22. How Do Combustion Engines Work? A General Combustion Engines take the Linear motion of a piston and convert it into Rotation. You can see the piston moving side to side, connected to the piston is the rod, which is then connected to the Crank, which delivers your rotation to whatever you need it for. You get the piston to move by combusting fuel and air creating a high pressure forcing the piston down on the “power stroke”. An engine speed is rated in RPM (Revolutions per Minute). Crank Rod Piston Combustion Chamber
- 23. Why do engines need oil Lubrication of moving parts Engines move anywhere from 2000RPM-6000RPM in Street vehicles and up to 19,000RPM + in Race Engine. Parts would not last with metal to metal contact. You need a barrier between parts to cut down friction, oil is your barrier. Cooling Oil also acts as a heatsink for the engine, and as stated above, you need oil to cut down friction, if there was no oil the heat caused from friction would be enough to destroy any engine. Cleaning Oil acts in another way, it removes dust particles that enter the engine, and some of the carbon build up in the engine. This is one of the reasons it is important to change your oil.
- 24. Lubrication regimes in the engine The key operating tribological parameter in any system is the lubricant film thickness separating the interacting component surfaces. It is defined as the relative magnitude of the lubricant film compared to the combined surface roughness of the two surfaces, the so- called film thickness ratio, or parameter, l. Where h is the film thickness and s is the root mean square (rms) surface roughness.
- 25. Challenges in Implementing Optimal Lubrication
- 27. Function of a lubricant • Lubricate - Reduce friction • Cooling - Heat transfer • Cleaning - Detergency • Noise pollution - dampening • Sealing – prevent leakage • Protection – prevent wear
- 28. 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
- 30. 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.
- 31. Cleaning • Cleans carbon and varnish deposits • Flushes the entire system removing • Soot • Deposits • Acids • Wear products • Moisture • Removes external contaminants dust, moisture (external)
- 32. Noise reduction • Reduce noise • By preventing metal to metal contact • Dampens noise • As between camshaft and tappet
- 33. Sealing • Oil film • Between piston ring and liner • Helps in creating a gas tight seal
- 34. Protection • Protection against acids and moisture • Very important to increase life of component and equipment
- 35. Properties of lubricants • Kinematic viscosity • Viscosity index • Pour Point • Flash Point • Total Base Number (TBN)
- 36. 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)
- 37. Kinematic Viscosity - Recommendations • Low Viscosity oils used • High speeds • Low pressure • Low temperature • High Viscosity oils used • Low speeds • High pressure • High temperature
- 38. 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
- 39. Properties of lubricants • Pour Point • Lowest temperature at which the fluid will flow • Indicates lowest operating temperature • Measured in ˚C
- 40. 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
- 41. 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
- 42. 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 index Pour Point Flash Point Total Base Number (TBN)
- 43. What are additives Lubricant additives classified on their functional capability Enhance existing property Suppress undesirable property Impart new property
- 44. 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
- 45. Surface Protective additives Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifier
- 46. Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Anti wear & EP Agent Reduce friction & wear. Prevent scoring & seizure ZDDP, Organic Phosphates, acid phosphates, organic sulfur and chlorine compounds etc. Chemical reaction with metal surface and forms a film. Prevents metal-to-metal contact
- 47. Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Corrosion and Rust Inhibitor Prevent corrosion and rusting of the metallic parts in contact with lubricant ZDDP, Metal phenolates, Basic Metal sulphonates, fatty acid & Amines. Preferential adsorbtion of polar constituent on metal surface. Provide protective film Neutralize corrosive acids
- 48. Surface Protective additives - Automotive Lubricants 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 and varnish percursors to neutralize them and keep them soluble
- 49. Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Dispersant Keep insoluble contaminants dispersed in the lubricant Alkylsuccinimides, alkylsuccinic esters and mannich reaction products Contaminants are bonded by polar attraction to dispersant molecules. Prevented from agglomerating Kept in suspension due to solubility of dispersant
- 50. Surface Protective additives - Automotive Lubricants Additive type Purpose Typical compounds Function Friction modifier Alters coefficient of friction Organic fatty acids and amides. Lard Oil, high molecular weight organic phosphorus. Phosphoric acid esters Preferential adsorbtion of surface active materials
- 51. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Pour Point Depressant Enable lubricant to flow at lo temperature Alkylated naphthalene Phenolic polymers, Ploymethacrylates Maleate/fumerate copolymer esters Modify wax crystal formation to reduce interlocking
- 52. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Seal swell Agent Swell elastomeric seals, gaskets Organic phosphates Aromatic hydro carbons Chemical reaction with with elastomer to cause slight swell.
- 53. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Viscosity modifier Reduce the rate of viscosity change with temperature Polymers and copolymers of olefins, methacrylates, dienes Alkylated styrenes. Polymers expand with increasing temperatures This counteract oil thinning
- 54. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Antifoamant Prevent lubricant from forming a persistent foam Silicone polymers Organic copolymers Reduce Surface tension to speed collapse of foam
- 55. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Antioxidant Retard oxidative decomposition ZDDP, Hindered phenols, Aromatic Amines, sulfurized phenols Decompose peroxides Terminates free-radical reactions
- 56. Performance additives - Automotive Lubricants Additive type Purpose Typical compounds Function Metal deactivator Reduce catalytic effect of metals on oxidation rate Organic complexes containing nitrogen or sulfur Amines, sulphides and Phosphates Forms inactive film on metal surfaces by complexing with metallic ions
- 57. 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
- 58. API GROUPS Group I- Solvent refined. (Older technology) Group II- Hydrocracked (most oils) Group III- Further hydrowaxed (Castrol Syntec) Group IV- Polyalphaolefin (PAO), Mobil 1
- 59. Viscosity © epc graphics Viscosity is a lubricant’s resistance to flow. The viscosity of an industrial lubricant is normally given in: – cSt (centistokes) or mm²/second – measure of kinematic viscosity Viscosity is the main feature which influences the efficiency of
- 60. Calibrated orifice 40°C or 100 °C Measured by timing oil flow through a calibrated orifice @ 40°C (104 F) and/or 100°C (212 F) Viscosity Measurement
- 61. Effect of Temperature on Viscosity • Viscosity is a measure of a fluid’s resistance to flow (“how thick it is”) • Viscosity of a fluid is a function of temperature 0 50 100 0 20 40 60 80 100 120 140 160 180 200 TEMPERATURE (C) KINEMATIC VIS COS ITY c S t uh….a liquid gets thinner as it gets hotter!!!)
- 62. Fluid Molecules Why is Friction Reduced? There is less “friction” between fluid molecules moving over each other than between the two surfaces moving across each other.
- 63. The formation of an oil wedge in a plain bearing Metal-to-metal contact Oil wedge supports load Connecting Rod Example
- 64. SYNTHETIC OILS MINERAL OILS Large Molecules thicken at low temp Small molecules vaporize at high temp All molecules same size H-C-C-C-C-C-H H H H H S H H O N H Impurities oxidize C10H20 C10H20 C10H20 C10H20
- 65. • 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 10 100 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
- 66. Lubricant - Specifications • Crankcase oils - SAE numbers • Crankcase oils - Performance levels • Crankcase oils – OEM Specifications • Viscosity classification • Grease specification
- 67. 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
- 68. 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
- 69. 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
- 70. 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
- 71. 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
- 72. SAE Crankcase Oil - Viscosity classification – Winter Service 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 Min Min Max Winter Service 0W 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
- 73. SAE Crankcase Oil - Viscosity classification – Summer Service 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 Min Min Max Summer Service 20 -- - 5.6 <9.3 2.6 30 -- - 9.3 <12.5 2.9 40 -- - 12.5 <16.3 3.5 40 -- - 12.5 <16.3 3.7 50 -- - 16.3 <21.9 3.7 60 -- - 21.9 <26.1 3.7
- 74. API Automotive Gasoline Engine Service Categories – “SA, SB,…” Category Related Ind Definitions 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 IIA Sequence V Sequence IIIA Fuel -1% S SD 1968 Models CRC L-38 Sequence IV Caterpillar L-1 Sequence IIB Sequence VB Caterpillar IH Sequence IIIB Falcon Rust SE 1972 Models CRC-L-38 Sequence IIID Sequence IIB Sequence VC Sequence IIIC Sequence VD SF 1980 Models CRC-L-38 Sequence IIIE Sequence IID Sequence VD Sequence IIID
- 75. API Automotive Gasoline Engine Service Categories – “SA, SB,…” Category Related Ind Definitions Engine Test Requirements SG 1989 Models CRC-L-38 Sequence VE Sequence IID Caterpillar IH2 Sequence IIIE SH 1994 Models CRC-L-38 Sequence VE Sequence IID Sequence IIIE Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete. SJ 1997 Models CRC-L-38 Sequence VE Sequence IID Sequence IIIE SL 2001 Models Sequence IIIF Sequence VIII Sequence IVA Sequence VG SM 2004 Models Sequence IIIG Sequence VIII Sequence IVA Sequence VG Category SJ, SL, SM, are currently valid.
- 76. API Automotive Diesel Engine Service Categories – “CA, CB,…” 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-2104A Supplement 1 CRC L-38 Caterpillar L-1 Fuel – 0.4% S CC MIL-L-2104B MIL-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/E 2 stroke Hvy Dty CRC L-38 Caterpillar 1 G2 Detroit Diesel 6V53T CE None CRC L-38 Mack T-6 Caterpillar 1 G2 Mack T-7 Cummins NTC 400 CF None CRC L-38 Caterpillar 1M-PC
- 77. API Automotive Diesel Engine Service Categories – “CA, CB,…” Category Related Ind Spec Engine Test Requirements 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-38 Mack T-8 Sequence IIIE RFWT Caterpillar 1N CH-4 None Mack T8E RFWT Sequence IIIE Mach T-9 Caterpillar 1P, 1K Cummins M 11 CI-4 None RFWT EOAT Cummins M11 EGR Mack T-8E, T-10 Caterpillar 1R, 1K Sequence IIIF CI-4Plus None RFWT EOAT Cummins M11 EGR Mack T-8E, T-10,T-11 Caterpillar 1R, 1K Sequence IIIF CA to CE obsolete; CF onwards are currently valid
- 78. ISO 3448 – Kin Vis - CSt 40˚C vs SUS 100˚F (40˚C) Midpoint Minimum Maximum SUS 100˚F VG 2 2.2 1.98 2.42 VG 3 3.2 2.88 3.52 VG 5 4.6 4.14 5.06 VG 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
- 79. ISO 3448 – Kin Vis - CSt 40˚C versus SUS 100˚F (40˚C) Midpoint Minimum Maximum SUS 100˚F VG 68 68 61.2 74.8 315 VG 100 100 90 110 465 VG 150 150 135 165 700 VG 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
- 80. National Lubricating Grease Institute - NLGI Numbers NLGI Grade Number ASTM worked penetration 77˚F (25˚C) 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
- 81. Thank you