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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
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Methods of lubrication
Two main methods
Hydrodynamic lubrication
Boundary lubrication
Hydrodynamic 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
Hydrodynamic lubrication
Boundary lubrication
Boundary lubrication
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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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 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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Properties of lubricants
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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Properties of lubricants
Pour Point
Lowest temperature at which the fluid
will flow Indicates lowest operating
temperature
Measured in C
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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
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Properties of lubricants
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
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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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Surface Protective additives- Automotive Lubricants
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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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 andvarnish percursors to neutralize themand keep them soluble
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Surface Protective additives- Automotive Lubricants
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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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 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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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 elastomerto cause slight swell.
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Performance additives- Automotive Lubricants
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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Performance additives- Automotive Lubricants
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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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
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Performance additives- Automotive Lubricants
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
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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
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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,
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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,
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Category Related IndDefinitions
Engine Test Requirements
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,
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Category RelatedUS 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-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,
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Category Related IndSpec
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-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)
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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)
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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
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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