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Fundamentals of Lubrication
INDIAN OIL CORPORATION LTD
ASPERITIES
3
INDIAN OIL CORPORATION LIMITED
Types of lubrication
BOUNDARY LUBRICATION
ELASTO HYDRODYNAMIC LUBRICATION
HYDRODYNAMIC LUBRICATION
MIXED FILM LUBRICATION
Boundary Lubrication
HIGH ADHESIVENESS HIGH FILM STRENGTH
HIGH LUBRICITY OR OILINESS
PROPER VISCOSITY OR CONSISTENCY
Fluid Film Lubrication
Excellent chemical stability Ability to separate from water , dust and other contaminants Reasonable degree of lubricity, adhesiveness and film strength
Mixed Film Lubrication
Elasto - Hydrodynamic Lubrication
LUBRICANT •
Lubricant can be defined as any material, when interposed between two surfaces in rubbing contact, is capable of reducing friction.
LUBRICANT = BASE OIL + ADDITIVE
ADDITIVES Lubricant Additive can be defined as any speciality chemical which when blended into a base oil, imparts or modifies its properties. - Careful balance of both base oils and the performance enhancing additives goes in designing a lubricant which is a complex and complicated task.
FORMULATOR IS A WIZARD OF CHEMISTRY
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INDIAN OIL CORPORATION LIMITED
Correct lubrication is RIGHT LUBRICANT RIGHT PLACE
RIGHT TIME & IN RIGHT MANNER What are the other functions of lubricants ???
FUNCTIONS OF LUBRICANTS •
Friction & wear control
• Contaminant control
• Corrosion control • Heat transfer • Conserves Energy
LUBE OIL Anticorrosion Antioxidant
Anti-wear
Antifoam
BASE OIL
Detergents & Dispersants
VI Improvers
PPDs Demulsibility
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INDIAN OIL CORPORATION LIMITED
CLASSIFICATION OF LUBRICATING OILS CRANKCASE OILS 1. 2. 3. 4. 5. 6. 7.
SAE ENGINE OIL CLASSIFICATIONS API ENGINE SERVICE CLASSIFICATIONS ILSAC ENGINE OIL CLASSIFICATION CCMC CLASSIFICATION ACEA CLASSIFICATION US MILITARY SPECIFICATIONS IS SPECIFICSATIONS
GEAR OILS 1. 2. 3.
4. 5.
SAE GEAR OIL CLASSIFICATION API SERVICE DESIGNATION U.S MILITARY DESIGNATION UK DEFENCE SPECIFICATIONS IS SPECIFICATIONS
ENGINE OILS SAE VISCOSITY GRADES CLASSIFICATION SAE VISCOSITY LOW TEMP (deg. C)
GRADE 0W 5W 10W 15W 20W 25W 20 30 40 50 60
BORDERLINE KIN. VISCOSITY
VISCOSITY (cP)
PUMPING TEMP
at 100 deg C
MAX
(deg C)
MIN
MAX
3250 at ( - ) 30 3500 at ( - ) 25 3500 at ( - ) 20 3500 at ( - ) 15 4500 at ( - ) 10 6000 at ( - ) 5 -
( - ) 35 ( - ) 30 ( - ) 25 ( - ) 20 ( - ) 15 ( - ) 10 -
3.8 3.8 4.1 5.6 5.6 9.3 5.6 9.3 12.5 16.3 21.9
< 9.3 < 12.5 < 16.3 < 21.9 < 26.1
GEAR OILS SAE CLASSIFICATIONS SAE VISCOSITY MIN TEMP (deg C) VISCOSITY at 100 deg C GRADE FOR VISCOSITY OF (cSts) 150 cP MIN MAX
70W 75W 80W 85W 90 140 250
( - ) 55 ( - ) 40 ( - ) 26 ( - ) 12 -
4.1 4.1 7.0 11.0 13.5 24.0 41.0
24 41 -
GEAR OIL API SERVICE CLASSIFICATION CLASSIFICATION
TYPE
APPLICATION
GL-1
STRAIGHT MINERAL OIL
AUTOMOTIVE MANUAL TRANSMISSION
SERVO' GRADES
SERVO GEAR SM
(TRACTORS & TRUCKS)
GL-2
GL-3
GL- 4
GL - 5
CONTAINS FATTY
WORM GEAR DRIVES
-
MATERIALS
INDUSTRIAL GEAR OIL
CONTAINS MILD
SPIRAL BEVEL GEARS
EP ADDITIVES
9NOT WIDELY USED)
MIL - L- 2105 SPEC
SPIRAL BEVELS & HYPOID GEARS
SERVO GEAR HP
50 % OF GL5 ADDITIVE LEVEL
UNDER MODERATE CONDS
SERIES
MODERATE AND SEVERE
SERVO GEAR
-
MIL - L- 2105D SPEC RECOMMENDATION FOR MOST PASSENGER CARS
CONDITIONS
SUPER SERIES
AND TRUCK BUILDERS
GL-6
TECHNICALLY OBSOLETE FOR SERVICE CONDITIONS REQUIRING MORE ANTI-SCORING PROTECTION THAN PROVIDED BY GL-5
-
INDUSTRIAL OILS International Organisation for Standards Viscosity grade
ISOVG CLASSIFICATIONS
INDUSTRIAL OILS ISOVG CLASSIFICATIONS ISO
VISCOSITY (cSts)
GRADE
RANGE AT 40 deg C
2 3 5 7 10 15 22 32 46
1.98 -2.42 2.88 - 3.52 4.14 - 5.06 6.12 - 7.48 9.00 - 11.0 13.5 - 16.5 19.8 - 24.2 28.8 - 35.2 41.4 - 50.6
ISO
VISCOSITY (cSts)
GRADE RANGE AT 40 deg C
68 100 150 220 320 460 680 1000 1500
61.2 - 74.8 90 - 110 135 - 165 198 - 242 288 - 352 414 - 506 612 - 748 900 - 1100 1350 - 1650
CLASSIFICATION OF GREASES BASED ON CONSISTANCY ( NLGI NO)
NLGI GRADE 000 00 0 1 2 3 4 5 6
ASTM PENITRATION 60 STROKES 445 - 475 400 - 430 355 - 385 310 - 340 265 - 295 220 - 250 175 - 205 130 - 160 085 - 115
AS NLGI GRADE DECREASES, GREASE WILL BE SOFTER
DIFFERENT OILS
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AUTOMOTIVE OILS INDUSTRIAL OILS SPECIALITY OILS GREASES TRANSFORMER OILS
INDIAN OIL CORPORATION LIMITED
OILS BEING USED
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ENGINEOIL-CF4/ CH4 HYDRAULICOILS -SYSTEM OILS RAILROAD OILS AUTO-HYDRAULIC OILS- ULTRA SERIES GEAR OILS- MESH , SYNTHETIC, MESH PLUS TURBINE OILS- PRIME SERIES INDIAN OIL CORPORATION LIMITED
OILS BEING USED
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GREASES – GEM SERIES GENERAL MCHINERY-LUBREX 22 FIRERESISTANT-HFB68/ HFDU68
INDIAN OIL CORPORATION LIMITED
FUNCTIONS OF ENGINE OIL
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REDUCE FRICTIONAL RESISTANCE PROTECT AGAINST CORROSION & WEAR ASSIST SEALING ACT AS A COOLANT KEEP THE SLUDGE IN SUSPENSION
INDIAN OIL CORPORATION LIMITED
ENGINE PARTS LUBRICATED
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main bearings connecting rod bearings cylinders, pistons and rings camshaft bearings cams and valve tappets timing gears valve gears INDIAN OIL CORPORATION LIMITED
ENGINE LUBRICATION SYSTEM
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one or more oil pumps outlet relief valves internal and external ducts for conveying the oil under pressure to the points requiring lubrication. oil filteration system oil cooling system
INDIAN OIL CORPORATION LIMITED
Engine Principles and Layout Rocker Arm Valve Push Rod Valve Lifter Camshaft
Cams
Timing Gears
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INDIAN OIL CORPORATION LIMITED
APR1 19
Engines and Lubrication Approximate Temperature of Internal Surfaces Temperature Range (OC)
Area of the Engine
Exhaust Valve Head Exhaust Valve Stem Combustion Chamber Gases Combustion Chamber Wall Piston Crown Piston Rings Piston (Wrist) Pin Piston Skirt Top Cylinder Wall Bottom Cylinder Wall Main Bearings Connecting Rod Bearings
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INDIAN OIL CORPORATION LIMITED
650-730 635-675 2300-2500 204-260 204-426 149-315 120-230 93-204 93-371 Up to 149 Up to 177 93-204
ENGINE LUBRICATION MECHANISM
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thick film lubrication (bearings)
mixed film lubrication (piston skirt)
boundary lubrication (top ring zone area)
INDIAN OIL CORPORATION LIMITED
Performance Categories API Performance Categories for Diesel Engine Oils Category CI-4 Heavy Duty
CH-4 CG-4 CF-4 CF-2 CF
Obsolete
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12-19-01
CE CD-II CD CC CB CA
Service Definition 2002 Low Emission, Four Stroke Engine with EGR and Low Sulfur Fuel 1998 Low Emission, Four Stroke Engine Both High and Low Sulfur Fuel 1994 Low Emission, Four-Stroke Engines Using 0.05% Sulfur Fuel 1991 Low Emission Engines Severe Duty Two-Stroke Cycle Engines Turbocharged Engines or High Sulfur Fuel 1983 and Later Turbocharged Engines Two-Stroke Cycle Engines Turbocharged Engines or High Sulfur Fuel Moderate Duty - Diesel and Gasoline Moderate Duty or High Sulfur Fuel Light Duty, Low Sulfur Fuel
INDIAN OIL CORPORATION LIMITED
HD4 2
Performance Categories Relative Performance of Each API Category Used Oil Viscometrics
Oxidation Oil Aeration
Sludge
Shear Stability
Ring and Liner Wear
Filter Plugging
Oil Consumption
Piston Deposits
Corrosion
Valvetrain Wear
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CI-4 CH-4 CG-4 CF-4 CF
Soot Thickening INDIAN OIL CORPORATION
12-19-01
LIMITED
HD4 379
SERVO DIESEL ENGINE OILS
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Servo Pride 30 / 40 Servo Pride Super 15W40 Servo Premium CF4 15W40 Servo Pride XL( CH4) 15W40 Servo Pride Supreme ( CI4) 15W40
INDIAN OIL CORPORATION LIMITED
SYSTEM OILS
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USAGE OF SYSTEM HLP OILS SUPERIOR IN OXIDATION LEVELS GROUP- II BASED OILS LONGER LIFE OILS REDUCTION OF GRADES AND INTER MIXING BETTER DEMULSIBILTY CHARACTERS INDIAN OIL CORPORATION LIMITED
ADVANTAGES OF RR606 MG
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CYLINDER LINER WEAR REDUCED BY 13.3% PISTON RING WEAR REDUCED BY 7% CONNECTING ROD BEARING WEIGHTLOSSIS IS 44% LOWER CARBON DEPOSIT REDUCED BY 21% SFC REDUCED BY 3% HIGHER TBN LIFE MEANS LOWER LUBE OIL CONSUMPTION INDIAN OIL CORPORATION LIMITED
SAVINGS BY RR606MG SFC IS 2.6-3.0 LTRS/ 100KM FROM 4-5 LTRS/100 KM CONSUMPTION 15YEARS BACK- 25000 KL ESTIMATED CONSUMPTION32000KL ACTUAL CURRENTCONSUMPTION-17500KL SAVINGS ON ACCOUNT OF LUBE OIL- 6400KL
APPROXIMATE VALUE- Rs 64 crore SAVINGS ON FUEL IS 5% OF100000 MT
APPROXIMATE VALUE IS –Rs 450 Crore 40
INDIAN OIL CORPORATION LIMITED
NEW GENERATION OILS
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RR 606MG PLUS- LUDHIANA
RR 606MG ALTERANATE VII- JHANSI
RR 520 MG
INDIAN OIL CORPORATION LIMITED
RR 606 MG PLUS& VII SERIES
TO FURTHER REDUCE SFC, SLC TO SUSTAIN HIGHER LOADS LONGER DRAIN PERIODS HIGHER TBN RETENTION VALUES ASH LESS ADDITIVES
Since trial is under progress detailed data is not available
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INDIAN OIL CORPORATION LIMITED
ULTRA SERIES OF OILS
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ENHANCE THE DRAIN PERIOD CURRENT RECOMMENDED IS 1000 HRS DRAIN PERIOD TO BE INCREASED TO 1800 HRS
INDIAN OIL CORPORATION LIMITED
GEAR OILS- MESH SERIES
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SHIFTED TO SYNGEAR OIL- SYTHETIC OILS CURRENT OTHER GRADES USED IN MESH SP OILS RECOMMENDED IS SERVO MESH PLUS SERIES OILS – ANTI MICRO PITTING OILSSEMI SYNTHETIC OILS INDIAN OIL CORPORATION LIMITED
MICROPITTING
A new form of tooth surface wear Conventional gear oils are inadequate to control this type of wear under severe operating conditions Characterized by the presence of fine surface pits, showing Fractured lower surfaces Driving stress for micro pitting arises from the Roughness of the gear surfaces Therefore, surface roughness & lubricant additives have an important impact
MICROPITTING IS AN UNIFORM ROLLING CONTACT
FATIGUE WEAR PHENOMENON, OBSERVED IN CASE OF HARDENED GEARS, OPERATING UNDER MIXED OR BOUNDARY LUBRICATION REGIMES
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INDIAN OIL CORPORATION LIMITED
SERVOMESH PLUS • Anti micro pitting resistant industrial gear oils
• Carefully blended with HVI solvent neutral base stocks • Optimized with tailor made additive package to ensure many other performance parameters of S-P series oils in addition to
superior antimicropitting and wear protections • Protects against scuffing without promoting corrosive wear and fatigue failures
• Passes through special micro pitting tests THE OILS ARE APPROVED BY M/S FLENDER AG OF GERMANY
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INDIAN OIL CORPORATION COMMERCIALLY AVAILABLE IN ISOVG GRADES OF 220 / 320/460 LIMITED
TURBINE OILS- PRIME OILS
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IMPROVEMENT DONE IS INDEGENIOUS BASE OIL STOCKS SULPHUR % IS THE ORDER OF 200 ppm AGAINST IMPORTED STOCKS OF 2000 ppm SEMI-SYNTHETIC IN NATURE SATURATES % IS HIGH LOWER OXIDATION LEVELS LESS OF ELEMENTAL- METALS INDIAN OIL CORPORATION LIMITED
GREASES
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SERVO GREASE WR2- WATER RESISTANCE SERVO PLEX SHC 120- SYNTHETIC GREASE SERVO CHAIN TEXT- SYNTHETIC OILS – HIGH TEMPERATURE SERVO CHAIN KOTE – CHAIN LUBRICATION
INDIAN OIL CORPORATION LIMITED
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INDIAN OIL CORPORATION LIMITED
TRANSFORMER OILS
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SERVO ELECTRA BIS335-1993 SPECIFICATION. Approved by Central power research institution (CPRI) NON CONVENTIONAL-ACID TREATMENT Hydro Catalytic Techniques, which resulted in high quality base oil with inherent property of low pour point, and superior Hydrophobic INDIAN OIL CORPORATION LIMITED
TRANSFORMER OIL Kinematic Vis. @ 400 C : 14.84 Density : 0.835 Flash Point : 165 Min. Pour point : (-)10 min Interfacial tension,N/m : 0.050 min Neutalisation value,TAN : nil Corrosive sulphur : non corrosive BD Voltage,ms,KV : 71 Di electic, dissipation factor : 0.0001
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INDIAN OIL CORPORATION LIMITED
TRANSFORMER OIL Specific resistance 1012 degreeC) OXIDATION STABILITY Water content ppm
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: 3920 (ohm @27 :0.01mgKOH/gm : 14
GASSING TENDENCY IS 1/3 RD OF THE NORMAL CONVENTIONAL OILS
INDIAN OIL CORPORATION LIMITED
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INDIAN OIL CORPORATION LIMITED
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INDIAN OIL CORPORATION LIMITED
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INDIAN OIL CORPORATION LIMITED
DISPOSAL OF OILS
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BURNING INCERENATING BURYING UNDER GROUND
INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Lubrication is any procedure that has the effect of reducing friction and wear Friction
– resistance to motion encountered during sliding Wear
– loss or destruction of surface material 58
INDIAN OIL CORPORATION LIMITED
History • Egyptians used fluids to lubricate sledges as early as 2400 B.C. • Natural oils widely used as lubricants up to the 19th Century
• Mineral oils introduced during 19th century (industrial revolution) • Additives and synthetic lubricants introduced during the 20th Century, particularly after World War II 59
INDIAN OIL CORPORATION LIMITED
CAUSES OF FRICTION
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Molecular attraction between bodies in contact Interlocking of the opposing surface irregularities Surface waviness
INDIAN OIL CORPORATION LIMITED
TYPES OF FRICTION Static
Kinetic...................
Rolling............................................
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INDIAN OIL CORPORATION LIMITED
FRICTION & WEAR Friction regime
Coefficient of Friction
Wear
Dry Friction (Sliding)
0.3
high
Dry Friction (Rolling)
0.005
very low
Mixed friction (rolling)
0.005 - 0.3
noticeable
Fluid friction
0.005 - 0.1
practically zero
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INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION MODES OF LUBRICATION
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HYDRODYNAMIC MIXED FILM ELASTO HYDRODYNAMIC BOUNDARY
INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Hydrodynamic Moving Surface
Hydrodynamic Pressure
Stationary Surface
Liquid ‘wedge’ formed under the inclined plate causes lift
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INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Hydrodynamic Low Load high speed
laminar flow static
Lubricant film thickness greater than surface asperities
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INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Mixed High load Low speed
Some surface contact
Lubricant film thickness of similar order to surface asperities
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INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Elasto-hydrodynamic W “Model” Gear tooth surfaces Unloaded
W Loaded
Very thin layer of oil under extreme pressure
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Elastic deformation of gear tooth surfacesINDIAN OIL CORPORATION LIMITED
Example: Loaded Gears
FUNDAMENTALS OF LUBRICATION Boundary Very High Load Very low speed
Lubricant Film
Surface Contact
Lubricant film thickness less than surface asperities
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INDIAN OIL CORPORATION LIMITED
FUNDAMENTALS OF LUBRICATION Coefficient of Friction
Lubrication Regimes Boundary Lubrication Mixed Lubrication
1.0 0.1 0.01 0.001
Full Fluid Film Lubrication
0.0001 1
10
100 1,000
100,000
ZN/P
Z= Viscosity N= Speed P= Pressure
PRIMARY FUNCTIONS OF A LUBRICANT
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Reduce Friction Reduce Wear Removal of Heat ( Due to Frictional Work, Combustion Heat)
INDIAN OIL CORPORATION LIMITED
IMPORTANT PROPERTIES
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Proper fluidity under operating conditions Film strength to withstand loads Chemical Stability Lubricity or oiliness or slipperiness to the degree required Adhesiveness to bearing surfaces Purity , freedom from contaminants Noncorrosive characterstics INDIAN OIL CORPORATION LIMITED
IMPORTANT PROPERTIES
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Rust proofing capability Resistance to water washout Resistance to foaming Good sealing properties Low change in fluidity due to change in temperatures Fire resistance Low volatility Good emulsifying qualities Availability at reasonable cost
INDIAN OIL CORPORATION LIMITED
CLASSIFICATION OF LUBRICANTS
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PHYSICAL STATE SOLID : Graphite Powder , Molebdenum disulphide , Talc Liquid: Mineral Oils, Vegetable Oils, Synthetic Oils Gases : Air, Helium, Carbon dioxide Plastics: Greases INDIAN OIL CORPORATION LIMITED
APPLICATIONS
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Gases : Lighter bearings like gyroscopes , Rotating mount of large telescopes Solids: They are used of extreme conditions of temperature, vacuum, loads & nuclear radiations. Liquids: For most of the Industrial & Automotive application mineral oil based lubricants are used. Greases: Greases are used for those applications where liquids do not stay in place.
INDIAN OIL CORPORATION LIMITED
CLASSIFICATION BASED ON APPLICATION
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Engine Oils Gear Oils Hydraulic Oils Compressor Oils Turbine Oils Cutting Oils Circulation bearing oils INDIAN OIL CORPORATION LIMITED
CLASSIFICATION OF LUBRICANTS BASED ON VISCOSITY
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SAE Classification for Automotive Engine Oils & Gear Oils ISO VG Classification for Industrial Oils NLGI Classification for Greases
INDIAN OIL CORPORATION LIMITED
SAE CLASSIFICATION - ENGINE OILS
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INDIAN OIL CORPORATION LIMITED
SAE CLASSIFICATION OF AUTOMOTIVE GEAR OILS
SAE VISCOSITY MIN TEMP FOR GRADE VISC OF 150000 cP °C
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VISC AT 100°C cSt MINIMUM
MAXIMUM
70W 75W
-55 -40
4.1 4.1
-
80W 85W 90 140 250
-26 -12 -
7.0 11.0 13.5 24.0 41.0
24.0 41.0 -
INDIAN OIL CORPORATION LIMITED
ISO VG CLASSIFICATION Midpoint Viscosity Limit cSt ISO o cSt @ Visosity @ 40 C o Grade 40 C Min. Max.
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Midpoint Viscosity Limit cSt ISO o Viscosity cSt @ @ 40 C o Grade 40 C Min. Max.
2
2.2
1.98
2.42
68
68
61.20
74.80
3
3.2
2.88
3.52
100
100
90.00
110.00
5
4.6
4.14
5.06
150
150
135.00
165.00
7
6.8
6.12
7.48
220
220
198.00
242.00
10
10.0
9.00
11.00
320
320
288.00
352.00
15
15.0
13.50
16.50
460
460
414.00
506.00
22
22.0
19.80
24.20
680
680
612.00
748.00
32
32.0
28.80
35.20
1000
1000
900.00
1100.00
46
46.0
41.40
50.60
1500
1500
1350.00
1650.00
INDIAN OIL CORPORATION LIMITED
NLGI CLASSIFICATION
80
o
NLGI No.
ASTM Penetration at 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
84-115 INDIAN OIL CORPORATION LIMITED
HOW LUBRICANTS ARE MADE
BASE OIL
Additives
ADDITIVES: Detergents,Dispersants,Oxidation Inhibitors,VI Improvers,Antifoam,Antiwear
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INDIAN OIL CORPORATION LIMITED
BASE OIL PRODUCTION
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Base oils are produced from crude Oil. Distillation is done to adjust viscosity & flash point Refining to improve aging tendency & VT Charactersitics Dewaxing is done to improve low- temperature properties. Base Oils & Additives blended together to get required properties for a specific application.
INDIAN OIL CORPORATION LIMITED
SERVO NOMENCLATURE
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SERVOPRIME – SERVOSYSTEMSERVOMESH – SERVOPRESSSERVOSPIN –
FOR FOR FOR FOR FOR
TURBINES ( PRIME MOVER) HYDRAULIC SYSTEMS INDUSTRIAL GEARS COMPRESSORS TEXTILE/GRINDING HIGH SPEED SPINDLES SERVOSTEEL – FOR STEEL INDUSTRY BEARINGS SERVOFRIZ – FOR REFRIGERATION COMPRESSOR SERVONEUM FOR PNEUMATIC TOOLS SERVOWAYFOR MACHINE TOOL GUIDE WAYS SERVOCYL FOR STEAM CYLINDER SERVO SM FOR SUGAR MILL BEARINGS SERVOSHAFT FOR MARINE SHAFT BEARINGS INDIAN OIL CORPORATION LIMITED
SERVO NOMENCLATURE
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SERVOCUT FOR CUTTING – CUTTING FLUIDS SERVOTHERM FOR HEAT TRANSFER SYSTEMS SERVOQUENCH FOR QUENCHING OPERATIONS SERVO MARINE FOR MARINE ENGINES SERVO GEM FOR GENERAL ELECTRICAL & MECHANICAL SERVOCOAT OPEN GEAR COATING LUBRICANT SERVORP FOR RUST PREVENTION SERVOVACUUM FOR VACUUM PUMPS SERVOSYNGEAR FOR GEARS – SYNTHETIC OIL SERVOSYNCO FOR COMPRESSORS- SYNTHETIC OIL SERVO GEAR FOR AUTO GEARS
INDIAN OIL CORPORATION LIMITED