1. Lubrication Training - Basics of Lubrication

2. Types of Lubrication
Hydrodynamic
Boundary
Mixed

3. Hydrodynamic Lubrication
Occurs when machine parts are completely separated by a full and continuous film of lubricant
Contact between the parts does not occur.
Full-fluid-film lubrication is hydrodynamic lubrication, the oil adheres to the moving part and is drawn into the area between the rotating surfaces, where it forms a pressure, or hydrodynamic, wedge.
A less common form of full-fluid-lubrication is hydrostatic lubrication, where the oil is supplied to the bearing area under pressure to separate the sliding surfaces.

4. Hydrodynamic Lubrication

5. Boundary Lubrication
Under certain conditions such as shock loading, heavy loads, high temperature, slow speed and critically low viscosity, the lubricant is no longer hydrodynamic
Frequent contact between the surfaces, resulting in a significant rise in temperature and subsequent destruction of the contacting surfaces.
Under these circumstances, the fluid film is no longer capable of adequately protecting the surfaces.
EP capabilities in the lubricant are essential
Solid additives are mixed into the grease

6. Mixed Lubrication
Although not a true “mode” of lubrication in the sense of hydrodynamic or boundary, mixed lubrication occurs more frequently then is realized.
Mixed lubrication is a transitional mode of lubrication between hydrodynamic and boundary
Mixed lubrication is characterized by the likelihood of intermittent surface contact
EP and anti-wear are essential properties in the lubricant

7. How is a lubricant made?
Select a base fluid:
MINERAL OIL or
SYNTHETIC FLUID?

8. Selecting a base fluid:
MINERAL OIL
Paraffinic or Naphthenic
Readily available
Comparatively low cost
Limited performance.

9. Selecting a base fluid:
SYNTHETIC FLUIDS
PAO, PAG, Ester
Synthetically manufactured
Comparatively high cost
Improved performance
Longevity
Temperature
Viscosity Index

10. OTHER SYNTHETIC FLUIDS
Selecting a base fluid:
OTHER SYNTHETIC FLUIDS
Silicones
Fluorinated
Ultra Performance
Ultra Temperature
Long Life
Lube for Life

11. NOW SELECT THE REQUIRED VISCOSITY.
Base fluid selected:
Mineral or Synthetic
NOW SELECT THE REQUIRED VISCOSITY.

12. Selecting the required viscosity:
Generally thinner fluids are used for:
Lighter loads
Faster speeds.

13. So how do we measure viscosity?.
Selecting the required viscosity:
Generally thicker fluids are used for:
Heavier loads
Slower speeds
So how do we measure viscosity?.

14. Viscosity (Thick) Viscosity (Thin)
400C & 1000C
mm2 per second
=centistokes (cSt)
High
Viscosity
(Thick)
Low
Viscosity
(Thin)

15. What are the units of viscosity?
mm2s = centistokes (cSt) = ISO VG (at 400C)
32 cSt - typical low viscosity (thin)
680 cSt - typical high viscosity (thick)
ISO VG etc

16. Extreme Pressure (EP) Additives
Product enhancements:
Extreme Pressure (EP) Additives
CHEMICAL SOLUTIONS
Chlorine
Sulphur
Phosphorous
SOLID LUBRICANTS
Graphite
Molybdenum disulphide (MoS2)
PTFE (Teflon)

17. Product enhancements OXIDATION INHIBITORS CORROSION INHIBITORS
Longer wet life
CORROSION INHIBITORS
Improves corrosion protection.
TACKY ADDITIVES
Improves adhesion

18. Thickener Systems – turn fluids into greases
Improved Performance
-Temperature
-Mechanical stability
Lithium complex
Calcium complex
Aluminium complex
Soap
Thickeners
Lithium soap Calcium soap Aluminium soap
General Purpose

19. Thickener Properties Lithium Lithium Complex Calcium Complex
Good multi-purpose, good mechanical stability, limited other properties
Lithium Complex
Excellent high temp & mechanical stability capability
Calcium Complex
Excellent load carrying and water resistance
Aluminium Complex
Excellent temperature capability & water resistance

20. Other grease thickeners:
Other Thickener Systems
Other grease thickeners:
Bentonite clay
Silica
PTFE.

21. NLGI PENETRATION TEST How is the grease thickness checked ? NATIONAL
LUBRICATING
GREASE
INSTITUE of America.

22. NLGI Numbers - WHAT DO THEY MEAN?
NLGI No 6
BLOCK GREASE
Old Technology
NLGI No 5
SEMI-SOLID ELASTIC-LIKE GREASE
Very rarely used, but can be found in marine or shipping applications
NLGI No 4
VERY TACKY GREASE
Rarely used now, but found sometimes found in heavy open gears or mining equipment
NLGI No 3
HEAVIER GREASE
Used mainly for hand applied or caulking guns
NLGI No 2
85% OF MARKET
Generally used in grease guns
NLGI No 1
THINNER GREASE
Generally used in grease guns, slightly more pump- able for short pipe lines
NLGI No 0
TREACLE LIKE GREASE
Used in semi-auto and auto systems with shorts pipelines
NLGI No 00
SEMI FLUID GREASE
Used in semi-auto and automatic systems
NLGI No 000
FLUID GREASE
Used in some gearboxes and semi & auto lube systems with longer pipe lines
SEMI FLUID/
FLUID GREASE
Generally applied by
Automatic Lubricator

23. Premium EP 2 Premium EP 1 Premium EP 000
HOW IS GREASE THICKNESS MEASURED?
Premium EP 2
Premium EP 1
Premium EP 000
NLGI 6
NLGI 5
NLGI 4
NLGI 3
NLGI 2
NLGI 1
NLGI 0
NLGI 00
NLGI 000

24. Summary Base fluid EP additives Corrosion inhibitors
Mineral or synthetic
Viscosity
EP additives
Chemical and/or solids
Corrosion inhibitors
Oxidation inhibitors
Thickeners for greases.

25. TO SUPPORT A ROTATING SHAFT
BASIC FUNCTION OF A PRECISION BEARING
TO SUPPORT A ROTATING SHAFT
Outer Race
Balls or Rollers
Shaft
Inner Race
Lubricant

26. TO SUPPORT A ROTATING SHAFT
BASIC FUNCTION OF A PLAIN BEARING
TO SUPPORT A ROTATING SHAFT
Plain Bush
Lubricant
Shaft

27. BASIC FUNCTION OF A SLIDE
TO SUPPORT A SLIDING LOAD

28. ALL BEARINGS/SLIDES HAVE ONE SURFACE MOVING AGAINST ANOTHER
FRICTIONAL HEAT
WHY LUBRICATE?

29. FRICTIONAL HEAT
FRICTIONAL WEAR
WHY LUBRICATE?

30. BASIC FUNCTION OF A LUBRICANT.
Introduction of a lubricant film
REDUCES FRICTIONAL HEAT & WEAR
BASIC FUNCTION OF A LUBRICANT.

31. Reasons for bearing failure

32. Breakdown of “improper lubrication” section

33. Potential failures due to over lubrication
Standard grease gun can develop 3,000 psi
High pressure grease guns can develop >6,000 psi
Potentially resulting in excessive drag causing:
Increased power demand
Ball/roller skid
Increased friction
Excessive heat
Excessive race wear
Degradation of the lubricant.

34. Correct Application of a lubricant
LITTLE & OFTEN!
Precision Bearings:
Typically fill 1/3 to 1/2 of vacant area in bearing
High speed bearings require approx. 1/3 fill
Plain Bearings
Typically fill until clean grease shows.

35. Thank You Any Questions?