Lecture 7 Lubrications.ppt

The Basics of Lubricants and lubrication

Hussam Adeni

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Lubricant Specialist

Meaning of lubricationFriction - is created when there is relative motion between two surfacesResistance to motion is defined as frictionLubrication is use of a material between surfaces to reduce frictionAny material used is called a lubricant

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Methods of lubricationTwo main methodsHydrodynamic lubricationBoundary lubrication

Hydrodynamic lubricationAlso called complete or full flowOccurs when two surfaces are completed separated by a fluid film


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Methods of lubrication cont..Two main methodsHydrodynamic lubricationBoundary lubrication

Boundary lubricationOccurs when Hydrodynamic lubrication fails.By adsorption or chemical reaction


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Types of Lubricant - PhysicalLiquidSolidSemi solidGases


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Types of Lubricant - PhysicalLiquidTypical lubricants are liquid/fluidsMineral oil or synthetic oilsSolidGraphite, MoS2Semi solidGreasesGasesAtomised 2 stroke oils


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Typical lubricants - ApplicationEngine oilsGear OilsTurbine OilsHydraulic OilsMetal working oils Cutting oilsForming OilsRust preventives


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Typical lubricants - ApplicationHeat Transfer OilsHeat Treatment OilsQuenching OilsTempering OilsRefrigeration OilsRubber Process OilsInk process OilsHussam [email protected]

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Lubricant - ComponentsBase OilsMineral by-products of crude oil refining process.Base oils are polymerized or synthesized further and called syntheticAdditivesNaturalSynthetic


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Function of a lubricantLubricate - Reduce frictionCooling - Heat transferCleaning - DetergencyNoise pollution - dampeningSealing prevent leakageProtection prevent wear


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Lubricate reduce frictionThe effects of frictionMetal to metal contactLeads to wear and tearGenerates heatResults in Power lossLubricant reduces friction by forming a filmReduces ill effect of friction


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CoolingWhen fuel is burnt in an engine33% is useful power33% removed by cooling water33% by lube oil and radiationLube 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.


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CleaningCleans carbon and varnish depositsFlushes the entire system removingSootDepositsAcidsWear productsMoistureRemoves external contaminants dust, moisture (external)


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Noise reductionReduce noiseBy preventing metal to metal contactDampens noiseAs between camshaft and tappet


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SealingOil filmBetween piston ring and linerHelps in creating a gas tight seal


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ProtectionProtection against acids and moisture

Very important to increase life of component and equipment


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Properties of lubricantsKinematic viscosityViscosity indexPour PointFlash PointTotal Base Number (TBN)


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Properties of lubricantsKinematic viscosityMeasure of internal resistance to flowThickness of fluid (in laymen terms)Decreases with increase in temperatureImportant in lubricant selectionIncrease in used oil indicates oxidation Specified at 40C and 100CMeasured in Centi Stokes (CSt)


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Kinematic Viscosity - RecommendationsLow Viscosity oils usedHigh speedsLow pressureLow temperatureHigh Viscosity oils usedLow speedsHigh pressureHigh temperature


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Properties of lubricantsViscosity indexMeasure of fluids change of viscosity with temperature.Empirical numberHigher the VI lower will be the change of viscosity with temperatureIndicator operating temperature rangeHussam [email protected]

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Properties of lubricantsPour PointLowest temperature at which the fluid will flowIndicates lowest operating temperatureMeasured in C


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Properties of lubricantsFlash PointLowest temperature at which the vapor above the liquid will ignite under flameIndicated safe maximum operation temperature .Indicator of volatilityTest method - COC and PMCCMeasured in C


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Properties of lubricantsTotal Base Number (TBN)Measured the acid neutralizing reserve in oil.Important for deciding discard of oilDecreases due toOxidation of oilWater contaminationFuel contaminationMeasured in Mg KOH/gm of oil


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Lab Tests - for lubricants

ASTM D 445ASTM D 2250ASTM D 97ASTM D 92 (COC)ASTM D 93 (PMCC)ASTM D 664Hussam [email protected] viscosityViscosity 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 additives What they do in Engine Oils Protect metal surfaces -(rings, bearings, gears, etc.) Extend the range of lubricant applicability Extend lubricant lifeHussam [email protected]

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Surface Protective additives Anti wear and EP Agent Corrosion & Rust inhibitor Detergent Dispersant Friction modifierHussam [email protected]

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Surface Protective additives - Automotive LubricantsAdditive typePurpose

Typical compounds

FunctionAnti wear & EP AgentReduce friction & wear.Prevent scoring & seizureZDDP, Organic Phosphates, acid phosphates, organic sulfur and chlorine compounds etc.Chemical reaction with metal surface and forms a film.Prevents metal-to-metal contactHussam [email protected]

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Typical compounds

FunctionCorrosion and Rust InhibitorPrevent corrosion and rusting of the metallic parts in contact with lubricantZDDP, Metal phenolates, Basic Metal sulphonates, fatty acid & Amines.

Preferential adsorbtion of polar component on metal surface.Provide protective filmNeutralize corrosive acids Hussam [email protected]

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Surface Protective additives - Automotive LubricantsAdditive typePurposeTypical compounds

FunctionDetergentsKeep surface free of depositsMetallo organic compounds of Sodium, Calcium and Magnesium phenolatesPhosphonates and sulphonatesChemical reaction with sludge and varnish percursors to neutralize them and keep them solubleHussam [email protected]

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Typical compoundsFunctionDispersantKeep insoluble contaminants dispersed in the lubricantAlkylsuccinimides, alkylsuccinic esters and mannich reaction productsContaminants are bonded by polar attraction to dispersant molecules.Prevented from Accumulate or collectKept in suspension due to solubility of dispersantHussam [email protected]

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Surface Protective additives - Automotive LubricantsAdditive typePurposeTypical compounds

FunctionFriction modifierAlters coefficient of friction Organic fatty acids and amides.Lard Oil, high molecular weight organic phosphorus.Phosphoric acid esters adsorption of surface active materialsHussam [email protected]

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Performance additives - Automotive LubricantsAdditive typePurpose

Typical compounds

FunctionPour Point DepressantEnable lubricant to flow at lo temperatureAlkylated naphthalenePhenolic polymers, PloymethacrylatesMaleate/fumerate copolymer esters Modify wax crystal formation to reduce interlockingHussam [email protected]

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Performance additives - Automotive LubricantsAdditive typePurposeTypical compoundsFunctionSeal swell AgentSwell elastomeric seals, gasketsOrganic phosphatesAromatic hydro carbonsChemical reaction with with elastomer to cause slight swell.Hussam [email protected]

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Typical compounds

FunctionViscosity modifierReduce the rate of viscosity change with temperaturePolymers and copolymers of olefins, methacrylates, dienesAlkylated styrenes.Polymers expand with increasing temperatures This counteract oil thinningHussam [email protected]

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Typical compoundsFunctionAntifoamantPrevent lubricant from forming a persistent foamSilicone polymers Organic copolymersReduce Surface tension to speed collapse of foamHussam [email protected]

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Performance additives - Automotive LubricantsAdditive typePurposeTypical compounds

FunctionAntioxidantRetard oxidative decompositionZDDP, Hindered phenols, Aromatic Amines, sulfurized phenols Decompose peroxidesTerminates free-radical reactionsHussam [email protected]

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Typical compounds

FunctionMetal deactivatorReduce catalytic effect of metals on oxidation rateOrganic complexes containing nitrogen or sulfurAmines, sulphides and PhosphatesForms inactive film on metal surfaces by complexing with metallic ionsHussam [email protected]

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Lubricant - Nomenclature and Specifications NomenclatureCrankcase oils - SAE numbers Viscosity classification ISO 3448Grease NLGI NumbersPerformance Crankcase oils - Performance levelsCrankcase oils OEM SpecificationsUS Military US-MIL-2104


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Viscosity Grade Classification SystemsISO Industrial OilscSt @ 40CAGMA Industrial Gear OilscSt @ 40C SAE Engine OilscSt @100C, cP @150C cP @ -10C to -40CSAE Gear OilscSt @100CcP @ -12C to -55C

Lubricant - Specifications

Crankcase oils - SAE numbers Crankcase oils - Performance levelsCrankcase oils OEM SpecificationsViscosity classificationGrease specification


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Major specifying organizations SAE Society of Automotive Engineers (USA)API - American Petroleum InstituteUS Military Specs US - MIL 2104 - CCMC European Specification ISO International Standard Organization ISO 3348NLGI National Lubricating Grease Institute


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SAE viscosity grades for engine oils Designated With corresponding viscosityFor high temperature applicationWarmer areas/regionsSAE 20 SAE 30SAE 40SAE 10SAE 50SAE 60


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SAE viscosity grades for engine oils Designated With corresponding viscosityFor low temperature applicationColder areas/regionsSAE 0 W SAE 5 WSAE 10 WSAE 15 WSAE 20 WSAE 25 W


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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 gradesAvailable as Engine oil and Gear Oils


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SAE viscosity grades for Multi grades - Engine Oils Multi grades are designated with two SAE number Widely in use todaySAE 10w/30, 15w/30, 25w/50 SAE 5W/30, 20W/40Suitable for use in winter and summer months or seasonsAvailable in Engine oils & Gear oil


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SAE Crankcase Oil - Viscosity classification Winter Service


Low temp viscositiesHigh temp viscositiesSAE Viscosity GradeEngine cranking Max. cPs at Temp (C)Max. Temp for pumping viscosity of 60,000 cP(C)Vis. at 100C, cStHigh shear (cP) 150C & 106 S- MinMinMaxWinter Service0W6200@ -35-403.8---5W6200@ -30-353.8-10W7000@ -25-304.1-15W7000@ -20-255.6-20W9500@ -15-205.6-25W13000@ -10-159.3

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SAE Crankcase Oil - Viscosity classification Summer Service


Low temp viscositiesHigh temp viscositiesSAE Viscosity GradeEngine cranking Max. cPs at Temp (C)Max. Temp for pumping viscosity of 60,000 cP(C)Vis. at 100C, cStHigh shear (cP) 150C & 106 S- MinMinMaxSummer Service20---5.6

API Automotive Gasoline Engine Service Categories SA, SB,


CategoryRelated IndDefinitionsEngine Test RequirementsSAStraight MinNoneSBInhibited onlyCRC L-4Sequence IIASequence IIIASC1964 ModelsCRC L-38 Sequence IVSequence IIASequence VSequence IIIAFuel -1% SSD1968 ModelsCRC L-38Sequence IVCaterpillar L-1Sequence IIBSequence VBCaterpillar IHSequence IIIBFalcon Rust

SE1972 ModelsCRC-L-38Sequence IIIDSequence IIBSequence VCSequence IIICSequence VDSF1980 ModelsCRC-L-38Sequence IIIESequence IIDSequence VDSequence IIID

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API Automotive Gasoline Engine Service Categories SA, SB,


CategoryRelated IndDefinitionsEngine Test RequirementsSG1989 ModelsCRC-L-38Sequence VESequence IIDCaterpillar IH2Sequence IIIE

SH1994 ModelsCRC-L-38Sequence VESequence IIDSequence IIIE

Category SA, SB, SC, SD, SE,SF,SG,SH have been declared as obsolete.SJ1997 ModelsCRC-L-38Sequence VESequence IIDSequence IIIE

SL2001 ModelsSequence IIIFSequence VIIISequence IVASequence VG

SM2004 ModelsSequence IIIGSequence VIIISequence IVASequence VG

Category SJ, SL, SM, are currently valid.

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API Automotive Diesel Engine Service Categories CA, CB,


CategoryRelated US Mil specEngine Test RequirementsCAMIL-L-2104ACRC L-38Caterpillar L-1Fuel 0.4% SCBMIL-L-2104ASupplement 1CRC L-38Caterpillar L-1Fuel 0.4% SCCMIL-L-2104BMIL-L-46152BCRC L-38Sequence IIDCaterpillar IH2CDMIL-L-2104C/D/E,MIL-L-45199B, Series 3CRC L-38Caterpillar I G2CD-II MIL-L-2104D/E2 stroke Hvy DtyCRC L-38Caterpillar 1 G2Detroit Diesel 6V53TCENoneCRC L-38Mack T-6Caterpillar 1 G2Mack T-7Cummins NTC 400

CFNoneCRC L-38Caterpillar 1M-PC

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API Automotive Diesel Engine Service Categories CA, CB,


CategoryRelated IndSpecEngine Test RequirementsCF-2NoneCRC L-38Detroit Diesel 6V92TACaterpillar 1M-PCCF-4NoneCRC L-38Mack T-7Cummins NTC-400Caterpillar 1KCG-4NoneCRC L-38Mack T-8Sequence IIIERFWTCaterpillar 1NCH-4NoneMack T8ERFWTSequence IIIEMach T-9Caterpillar 1P, 1KCummins M 11CI-4NoneRFWTEOATCummins M11 EGRMack T-8E, T-10Caterpillar 1R, 1KSequence IIIFCI-4PlusNoneRFWTEOATCummins M11 EGRMack T-8E, T-10,T-11Caterpillar 1R, 1KSequence IIIFCA to CE obsolete; CF onwards are currently valid

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ISO 3448 Kin Vis - CSt 40C vs SUS 100F (40C)


MidpointMinimumMaximumSUS 100FVG 22.21.982.42VG 33.22.883.52VG 54.64.145.06VG 76.86.127.48VG 101091160VG 151513.516.575VG 222219.824.2105VG 323228.835.2150VG 464641.450.6215

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ISO 3448 Kin Vis - CSt 40C versus SUS 100F (40C)


MidpointMinimumMaximumSUS 100FVG 686861.274.8315VG 10010090110465VG 150150135165700VG 2202201982421000VG 3203202883521500VG 4604604145062150VG 6806806127483150VG 1000100090011004650VG 15001500135016507000

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National Lubricating Grease Institute - NLGI Numbers


NLGI Grade NumberASTM worked penetration 77F (25C)000445 - 47500400 - 4300355 - 3851310 - 3402265 - 2953220 - 2504175 - 2055130 - 160685 - 115

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Lecture 7 Lubrications.ppt

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