Lubricants Fundamentals Ioci

INDIAN OIL CORPORATION LTD

Fundamentals of

Lubrication

ASPERITIES

INDIAN OIL CORPORATION LIMITED

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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

Excellent chemical stability Ability to separate from water , dust and other

contaminants Reasonable degree of lubricity, adhesiveness and film

strength

Fluid Film Lubrication

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

Lubricant Additive can be defined as any specialitychemical 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.

ADDITIVES

FORMULATOR IS A WIZARD OF CHEMISTRY


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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

BASE OIL

Antifoam

Anticorrosion

Antioxidant

Anti-wear

Demulsibility

PPDs

VI Improvers

Detergents & Dispersants


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CLASSIFICATION OF LUBRICATING OILSCRANKCASE OILS1. SAE ENGINE OIL CLASSIFICATIONS

2. API ENGINE SERVICE CLASSIFICATIONS

3. ILSAC ENGINE OIL CLASSIFICATION

4. CCMC CLASSIFICATION

5. ACEA CLASSIFICATION

6. US MILITARY SPECIFICATIONS

7. IS SPECIFICSATIONS

GEAR OILS1. SAE GEAR OIL CLASSIFICATION

2. API SERVICE DESIGNATION

3. U.S MILITARY DESIGNATION

4. UK DEFENCE SPECIFICATIONS

5. IS SPECIFICATIONS

SAE VISCOSITY LOW TEMP (deg. C) BORDERLINE

GRADE VISCOSITY (cP) PUMPING TEMP

MAX (deg C) MIN MAX

0W 3250 at ( - ) 30 ( - ) 35 3.8 -5W 3500 at ( - ) 25 ( - ) 30 3.8 -10W 3500 at ( - ) 20 ( - ) 25 4.1 -15W 3500 at ( - ) 15 ( - ) 20 5.6 -20W 4500 at ( - ) 10 ( - ) 15 5.6 -25W 6000 at ( - ) 5 ( - ) 10 9.3 -20 - - 5.6 < 9.330 - - 9.3 < 12.540 - - 12.5 < 16.350 - - 16.3 < 21.960 - - 21.9 < 26.1

KIN. VISCOSITY

at 100 deg C

ENGINE OILSSAE VISCOSITY GRADES CLASSIFICATION

SAE VISCOSITY MIN TEMP (deg C)GRADE FOR VISCOSITY OF

150 cP MIN MAX

70W ( - ) 55 4.1 -75W ( - ) 40 4.1 -80W ( - ) 26 7.0 -85W ( - ) 12 11.0 -90 - 13.5 24

140 - 24.0 41250 - 41.0 -

VISCOSITY at 100 deg C(cSts)

GEAR OILSSAE CLASSIFICATIONS

CLASSIFICATION TYPE APPLICATION SERVO' GRADES

GL-1 STRAIGHT MINERAL OIL AUTOMOTIVE MANUAL

TRANSMISSION SERVO GEAR SM

(TRACTORS & TRUCKS)

GL-2 CONTAINS FATTY WORM GEAR DRIVES -

MATERIALS INDUSTRIAL GEAR OIL

GL-3 CONTAINS MILD SPIRAL BEVEL GEARS -

EP ADDITIVES 9NOT WIDELY USED)

GL- 4 MIL - L- 2105 SPEC SPIRAL BEVELS & HYPOID GEARS SERVO GEAR HP

50 % OF GL5 ADDITIVE LEVEL UNDER MODERATE CONDS SERIES

GL - 5 MIL - L- 2105D SPEC

RECOMMENDATION FOR MODERATE AND SEVERE SERVO GEAR

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

GEAR OILAPI SERVICE CLASSIFICATION

INDUSTRIAL OILS

International Organisation for Standards

Viscosity grade

ISOVG CLASSIFICATIONS

ISO VISCOSITY (cSts) ISO VISCOSITY (cSts)

GRADE RANGE AT 40 deg C GRADE RANGE AT 40 deg C

2 1.98 -2.42 68 61.2 - 74.83 2.88 - 3.52 100 90 - 1105 4.14 - 5.06 150 135 - 1657 6.12 - 7.48 220 198 - 24210 9.00 - 11.0 320 288 - 35215 13.5 - 16.5 460 414 - 50622 19.8 - 24.2 680 612 - 74832 28.8 - 35.2 1000 900 - 110046 41.4 - 50.6 1500 1350 - 1650

INDUSTRIAL OILSISOVG CLASSIFICATIONS

CLASSIFICATION OF GREASES

BASED ON CONSISTANCY ( NLGI NO)

NLGI ASTM PENITRATION GRADE 60 STROKES

000 445 - 475 00 400 - 430 0 355 - 385 1 310 - 340 2 265 - 295 3 220 - 250 4 175 - 205 5 130 - 160 6 085 - 115

AS NLGI GRADE DECREASES, GREASE WILL BE SOFTER


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DIFFERENT OILS

AUTOMOTIVE OILS INDUSTRIAL OILS SPECIALITY OILS GREASES TRANSFORMER OILS


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OILS BEING USED

ENGINEOIL-CF4/ CH4 HYDRAULICOILS -SYSTEM OILS RAILROAD OILS AUTO-HYDRAULIC OILS- ULTRA SERIES GEAR OILS- MESH , SYNTHETIC, MESH

PLUS TURBINE OILS- PRIME SERIES


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OILS BEING USED-

GREASES – GEM SERIES GENERAL MCHINERY-LUBREX 22 FIRERESISTANT-HFB68/ HFDU68


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FUNCTIONS OF ENGINE OIL

REDUCE FRICTIONAL RESISTANCE PROTECT AGAINST CORROSION & WEAR ASSIST SEALING ACT AS A COOLANT KEEP THE SLUDGE IN SUSPENSION


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ENGINE PARTS LUBRICATED

main bearings connecting rod bearings cylinders, pistons and rings camshaft bearings cams and valve tappets timing gears valve gears


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ENGINE LUBRICATION SYSTEM

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


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Engine Principles and Layout

Timing Gears

Valve Lifter

Camshaft

Valve

Push Rod

Rocker Arm

Cams


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Approximate Temperature of Internal Surfaces

Exhaust Valve Head 650-730Exhaust Valve Stem 635-675Combustion Chamber Gases 2300-2500Combustion Chamber Wall 204-260Piston Crown 204-426Piston Rings 149-315Piston (Wrist) Pin 120-230Piston Skirt 93-204Top Cylinder Wall 93-371Bottom Cylinder Wall Up to 149Main Bearings Up to 177Connecting Rod Bearings 93-204

Area of the Engine Temperature Range (OC)

Engines and Lubrication


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ENGINE LUBRICATION MECHANISM

thick film lubrication (bearings)

mixed film lubrication (piston skirt)

boundary lubrication (top ring zone area)


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Performance CategoriesAPI Performance Categories for Diesel Engine Oils

HD4 2

CI-4 2002 Low Emission, Four Stroke Engine with EGR and Low Sulfur Fuel

CH-4 1998 Low Emission, Four Stroke Engine Both High and Low Sulfur Fuel

CG-4 1994 Low Emission, Four-Stroke Engines Using 0.05% Sulfur Fuel

CF-4 1991 Low Emission EnginesCF-2 Severe Duty Two-Stroke Cycle EnginesCF Turbocharged Engines or High Sulfur Fuel

Obsolete

Category Service Definition

HeavyDuty

12-19-01

CE 1983 and Later Turbocharged EnginesCD-II Two-Stroke Cycle EnginesCD Turbocharged Engines or High Sulfur FuelCC Moderate Duty - Diesel and GasolineCB Moderate Duty or High Sulfur FuelCA Light Duty, Low Sulfur Fuel

36 INDIAN OIL CORPORATION LIMITED

Performance CategoriesRelative Performance of Each API Category

12-19-01 HD4 379

Oxidation

Oil Aeration

Shear Stability

Filter Plugging

Piston Deposits

Corrosion

Soot Thickening

ValvetrainWear

OilConsumption

Ring and Liner Wear

Sludge

Used Oil Viscometrics

CI-4

CH-4

CG-4

CF-4

CF


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SERVO DIESEL ENGINE OILS

Servo Pride 30 / 40 Servo Pride Super 15W40 Servo Premium CF4 15W40 Servo Pride XL( CH4) 15W40 Servo Pride Supreme ( CI4) 15W40


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SYSTEM OILS

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


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ADVANTAGES OF RR606 MG

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


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SAVINGS BY RR606MG SFC IS 2.6-3.0 LTRS/ 100KM FROM 4-5

LTRS/100 KM CONSUMPTION 15YEARS BACK- 25000 KL ESTIMATED CONSUMPTION- 32000KL ACTUAL CURRENTCONSUMPTION-17500KL

SAVINGS ON ACCOUNT OF LUBE OIL- 6400KL

APPROXIMATE VALUE- Rs 64 croreSAVINGS ON FUEL IS 5% OF100000 MT

APPROXIMATE VALUE IS –Rs 450 Crore


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NEW GENERATION OILS

RR 606MG PLUS- LUDHIANA

RR 606MG ALTERANATE VII- JHANSI

RR 520 MG


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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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ULTRA SERIES OF OILS

ENHANCE THE DRAIN PERIOD CURRENT RECOMMENDED IS 1000 HRS DRAIN PERIOD TO BE INCREASED TO 1800

HRS


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GEAR OILS- MESH SERIES

SHIFTED TO SYNGEAR OIL- SYTHETIC OILS

CURRENT OTHER GRADES USED IN MESH SP OILS

RECOMMENDED IS SERVO MESH PLUS SERIES OILS – ANTI MICRO PITTING OILS- SEMI SYNTHETIC OILS


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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 Characterized by the presence of fine surface pits, showing

Fractured lower surfaces Fractured lower surfaces Driving stress for micro pitting arises from the Roughness Driving stress for micro pitting arises from the Roughness

of the gear surfacesof the gear surfaces Therefore, surface roughness & lubricant additives have an Therefore, surface roughness & lubricant additives have an

important impactimportant 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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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

COMMERCIALLY AVAILABLE IN ISOVG GRADES OF 220 / 320/460


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TURBINE OILS- PRIME OILS

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


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GREASES

SERVO GREASE WR2- WATER RESISTANCE SERVO PLEX SHC 120- SYNTHETIC GREASE SERVO CHAIN TEXT- SYNTHETIC OILS – HIGH

TEMPERATURE SERVO CHAIN KOTE – CHAIN LUBRICATION


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TRANSFORMER OILS

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


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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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TRANSFORMER OIL

Specific resistance 1012 : 3920 (ohm @27 degreeC)

OXIDATION STABILITY :0.01mgKOH/gm Water content ppm : 14

GASSING TENDENCY IS 1/3 RD OF THE NORMAL CONVENTIONAL OILS


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DISPOSAL OF OILS

BURNING INCERENATING BURYING UNDER GROUND


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Lubrication is any procedure that has theeffect of reducing friction and wear

Friction– resistance to motion encountered

during sliding

Wear– loss or destruction of surface

material

FUNDAMENTALS OF LUBRICATION


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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


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CAUSES OF FRICTION

Molecular attraction between bodies in contact Interlocking of the opposing surface

irregularities Surface waviness


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TYPES OF FRICTION

Static

Kinetic...................

Rolling............................................


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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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MODES OF LUBRICATION

HYDRODYNAMIC MIXED FILM ELASTO HYDRODYNAMIC BOUNDARY


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Hydrodynamic

Hydrodynamic Pressure

Stationary Surface

Moving Surface

Liquid ‘wedge’ formed under the inclined plate causes lift



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Hydrodynamic

static

high speed

Lubricant film thickness greater than surface asperities

laminar flow

Low Load



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Mixed

Some surface contact

Lubricant film thickness of similar order to surface asperities

High load

Low speed



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Elasto-hydrodynamic

Very thin layer of oilunder extremepressure

Elastic deformationof gear tooth surfaces

W

Example:Loaded Gears

“Model” Gear tooth surfaces

W

Unloaded

Loaded



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Boundary

Lubricant film thickness less than surface asperities

Surface Contact

Very High Load

Very low speed

Lubricant Film



1 10 100 1,000 100,000

1.0

0.1

0.01

0.001

Mixed Lubrication

Boundary Lubrication

ZN/P

Coeffi

cie

nt

of

Fri

cti

on

Full Fluid Film Lubrication0.0001

Z= Viscosity N= Speed P= Pressure

Lubrication Regimes



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PRIMARY FUNCTIONS OF A LUBRICANT

Reduce Friction Reduce Wear Removal of Heat ( Due to Frictional Work,

Combustion Heat)


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IMPORTANT PROPERTIES

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


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IMPORTANT PROPERTIES

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


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CLASSIFICATION OF LUBRICANTS

PHYSICAL STATE SOLID : Graphite Powder , Molebdenum

disulphide , Talc Liquid: Mineral Oils, Vegetable Oils, Synthetic

Oils Gases : Air, Helium, Carbon dioxide Plastics: Greases


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APPLICATIONS

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.


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CLASSIFICATION BASED ON APPLICATION

Engine Oils Gear Oils Hydraulic Oils Compressor Oils Turbine Oils Cutting Oils Circulation bearing oils


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CLASSIFICATION OF LUBRICANTS BASED ON VISCOSITY

SAE Classification for Automotive Engine Oils & Gear Oils

ISO VG Classification for Industrial Oils NLGI Classification for Greases


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SAE CLASSIFICATION - ENGINE OILS


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SAE CLASSIFICATION OF AUTOMOTIVE GEAR OILS

SAE VISCOSITY GRADE

MIN TEMP FOR VISC OF 150000

cP °C

VISC AT 100°CcSt

MINIMUM MAXIMUM

70W -55 4.1 -

75W -40 4.1 -

80W -26 7.0 -

85W -12 11.0 -

90 - 13.5 24.0

140 - 24.0 41.0

250 - 41.0 -


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ISO VG CLASSIFICATION

Min. Max. 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

Viscosity Limit cSt

@ 40oC

Viscosity Limit cSt

@ 40oCISO

Visosity Grade

Midpoint cSt @

40oC

ISO Viscosity

Grade

Midpoint cSt @

40oC


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NLGI CLASSIFICATION

NLGI No. ASTM Penetration at 25o C000 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


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HOW LUBRICANTS ARE MADE

ADDITIVES: Detergents,Dispersants,Oxidation Inhibitors,VI Improvers,Antifoam,Antiwear

BASE OIL Additives


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BASE OIL PRODUCTION

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.


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SERVO NOMENCLATURE

SERVOPRIME – FOR TURBINES ( PRIME MOVER) SERVOSYSTEM- FOR HYDRAULIC SYSTEMS SERVOMESH – FOR INDUSTRIAL GEARS SERVOPRESS- FOR COMPRESSORS SERVOSPIN – FOR TEXTILE/GRINDING HIGH

SPEED SPINDLES SERVOSTEEL – FOR STEEL INDUSTRY BEARINGS SERVOFRIZ – FOR REFRIGERATION COMPRESSOR SERVONEUM FOR PNEUMATIC TOOLS SERVOWAY- FOR MACHINE TOOL GUIDE WAYS SERVOCYL FOR STEAM CYLINDER SERVO SM FOR SUGAR MILL BEARINGS SERVOSHAFT FOR MARINE SHAFT BEARINGS


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SERVO NOMENCLATURE

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

Documents

Lubricants Fundamentals Ioci