chapter 9 lubrications - smlubritech.com · the same time, which accelerate the wear. ... bearing...
TRANSCRIPT
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LUBRICATION
Jariyaporn Saothong, (Ph.D.)
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LubricationLubrication
Preventive MaintenancePreventive Maintenance
Fixed Time Maintenance Condition Based ConditionFixed Time Maintenance
Cl i
Condition Based Condition
Cleaning
Changing of filter
O f i Lubrication One of important activities of PM
Inspection
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Objectives of lubricationObjectives of lubrication
Reduce Minimize Provide Prevent Coating to seal out
Flush away
friction of wear cooling corrosion contaminators
contamination
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TribologyTribologyTribologyTribology
Th i f f i ti l b i ti d The science of friction, lubrication, and wear.Friction transmits the forces of the press to the
k h h d d workpiece to achieve the desired strains.Lubrication is used primarily to control friction
fand prevent adhesion. It may also function to prevent corrosion. Adhesion is the most prevalent and problematic form of wear. Uncontrolled friction causes high local stresses , and machine breakdown.
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FrictionFriction
Friction Force : due to two surfaces in contact with each other and the tendency of the two surfaces to oppose each others motionmotion.Cause of friction is the combination of molecular adhesion, surface roughness, and deformation effects.g ,
Sliding Friction Rolling Friction Sliding Friction Rolling Friction
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Different types of wearDifferent types of wear
Adhesive wear
C i FatigueCorrosion
Abrasive wear
Several different types of wear are present at the same time, which accelerate the wear
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ขอบเขตของสภาวะการหลอลน
ไ 1. สภาวะไรการหลอลน หรอการหลอลนแบบแหง
ผวสมผสของควสดสมผสกนโดยตรง ทาใหเกดการเสยหาย หรอสกหรออยางรนแรง
บนผวหนาของคผววสด เนอวสดสญเสยเปนปรมาณสงมาก
2. สภาวะการหลอลนแบบบาวนดาร
เปนสภาวะทเกดฟลมหลอลนขนาดบางมากทชนผวหนาของวสด เมอเกดการเสยดเปนสภาวะทเกดฟลมหลอลนขนาดบางมากทชนผวหนาของวสด เมอเกดการเสยด
ส เชน บรเวณทอณหภมสง มปรมาณสารหลอลนไมเพยงพอ
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ขอบเขตของสภาวะการหลอลน
3 สภาวะการหลอลนแบบกงสมบรณ3. สภาวะการหลอลนแบบกงสมบรณ
จะเกดเมอสารหลอลนมชวงเวลาทเหมาะสมในการสรางชนผวทมความแขงแรงตอการเฉอนตวตามาก ซงจะเปนผลดตอคาสมประสทธการเสยดทานและการสกหรอ
การหลอลนแบบผสมหรอการหลอลนแบบกงสมบรณบงบอกถงรปแบบผสมของหลอลนทเกดขน ซงจะมอยางนอย 2 ลกษณะของการสมผสกนของควสด เกดขนพรอมกน
ใ เปนลกษณะของสภาวะทเกดขนในการสลบเปลยนสถานะระหวางประสทธการเสยดทานของการเสยดสของของแขงคสมผสกบสมประสทธการเสยดทานในชนของสารหลอลนในชนของสารหลอลน
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ขอบเขตของสภาวะการหลอลน
4. สภาวะการหลอลนแบบสมบรณ
เปนขอบเขตทมการใชสารหลอลน ทาใหเกดฟลมนามนหนา พอทจะแยกผวค
ของวสดทมการเคลอนทออกจากกนโดยสนเชง เปนการหลอลนแบบเตมฟลม
สมประสทธของการเสยดทานจะขนอยกบสมประสทธการเสยดทานของชนสารหลอ
ลนกบคาความหนดของสารหลอลนนนเพยงอยางเดยว
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ความสมพนธความสมพนธระหวางสภาวะสารหลอระหวางสภาวะสารหลอลนลน, ,
ป ป คาคาสมประสทธการเสยดทานและสมประสทธการเสยดทานและการสกหรอการสกหรอ
สภาวะการหลอลน คาสมประสทธการเสยดทาน การสกหรอ
การลนไถลแบบไรสารหลอลน > 0.3 สงมาก
การหลอลนแบบบาวนดาร < 0.005 เลกนอย
การหลอลนกงสมบรณ 0 005 - 0 3 เลกนอยมากการหลอลนกงสมบรณ 0.005 - 0.3 เลกนอยมาก
การหลอลนแบบสมบรณ 0 005 0 1 แทบไมเกดขนการหลอลนแบบสมบรณ 0.005 - 0.1 แทบไมเกดขน
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ระหวางพนผวสมผสจะตองมสารหลอลน เปรยบเสมอนกาแพงกน และเปนการลดแรง
เสยดทานขณะมการเคลอนทเสยดทานขณะมการเคลอนท
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What happen if it is not lubricate properly?
Gear tooth damageBearing damage Gear tooth damageg
Because of not have lubrication
Because of lubrication not clean and dirty
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สารหลอลน : ไดมาจากการกลนลาดบสวนจากนามนดบ
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AdditivesAdditivesAdditivesAdditives
Oxidation InhibitorsOxidation InhibitorsRust InhibitorsAntiwear AdditiveAntiwear AdditiveExtreme-Pressure AdditivesPour-point DepressantsViscosity Index ImproverDetergents & DispersantsDefoamantsEtc.
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AdditivesAdditivesAdditivesAdditives
T P ti Ch i l Type Properties Chemicals
Oxidation Inhibitors สารตานออกซเดชน
•ลดการทาปฏกรยากบออกซเจน•ลดการเกดกรด
•Zinc dialkydithiophosphate
•ลดการเกดตะกอน•ยดอายการใชงาน
•Bis-phenols•Aromatic Amines
Rust Inhibitors สารปองกนสนม
•ลดการทาปฏกรยากบออกซเจน•ลดการเกดกรด•ลดการเกดตะกอน
•Metallicsoaps•Organic acid•Amines
•ยดอายการใชงาน
Antiwear Additive •ปองกนการสกหรอของผว •Zinc dialkyAntiwear Additive สารปองกนการสกหรอ •เครองจกรกลทมภาระงานสง
Zinc dialkydithiophosphate•Tricresal phosphate
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AdditivesAdditivesAdditivesAdditives
T P ti Ch i l Type Properties Chemicals
Extreme-pressure Additives
•เพมความแขงแรงของฟลมนามน•รบภาระงานสง
•Organic compound of •Sulfur
สารรบแรงกดสง •ชวยปองกนการสกหรอ •Phosphorous•Chlorine
•Lead naphthenate
Pour-point Depressants สารลดการอดตน
•ลดการตกผลกของขผง•ลดจดแขงตวของนามน
•Methacrylate polymer •Wax alkylated phenol
•ทาใหนามนไหลไดทอณหภมต าy p
and polymer
Viscosity index improver •ลดอตราการเปลยนแปลงความหนด •PolysobutyleneViscosity index improver สารปรบปรงดชนความหนด ใส
ของนามนเมออณหภมเปลยนไป
Polysobutylene•Methacrylate•Crylatecopolymers
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AdditivesAdditivesAdditivesAdditives
T P ti Ch i l Type Properties Chemicals
Detergents & Dispersantsสารชะลางและกระจายความ
•ชะลางความสกปรกออกจากผวของชนสวน
•Metallic sulfonate•Amines,pheno
•กระจายไมใหรวมตวเปนโคลน•ทาใหเครองเดนเรยบ
•Alkyl substituatesalicylate•Succinimides
Defoamants
สารปองกนฟอง
•ปองกนการเกดฟองของนามนทหมนเวยนในระบบ
•Silicone polymer •Organic polymerg p y
DyesEtcEtc.
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Lubrication by additive typesLubrication by additive types
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Lubrication TypesLubrication TypesLubrication TypesLubrication Types
SolidGraphiteMolybdenumdisulphite (MoS2) Polytetrafluoroethylene (PTFE) (Plastic)
Semi-fluidGrease
FluidMineral oil (Paraffin, Naphthenic )Synthetic oil (Poly-alfa-olefines (PAO), Polyglycoles, Esters, Silicone oil )
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Properties of solid lubricantsProperties of solid lubricantsProperties of solid lubricantsProperties of solid lubricants
Graphite MoS2 PTFE
ส เทา - ดา เทา - ดา โปรงแสง
ความถวงจาเพาะ 1.4-2.4 4.8-4.9
ความแขง (Mohs) 1-2 1-2( )อณหภมใชงาน (ºC) (-18) – (450) (-180) – (400) (-280) – (200)
ความตานทานตอปฏกรยาเคม ดมาก ด ดความตานทานตอปฏกรยาเคม ดมาก ด ด
ความตานทานตอการกดกรอน ด เลว ด
ความตานทานตอกมมนตภาพรงส ด ด เลวความตานทานตอกมมนตภาพรงส ด ด เลว
สมประสทธการเสยดทาน 0.1-0.2 0.04-0.09 0.04-0.09
ผลลพธจากปฏกรยาออกซเดชน CO CO MoO SO Fe Cผลลพธจากปฏกรยาออกซเดชน CO, CO2 MoO3, SO2 Fe2C
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Lubrication TypesLubrication Types
Grease LubricationGrease lubrication is used for about 90% of all Grease lubrication is used for about 90% of all
rolling bearings. The main advantage of grease lubrications are:
A very simple design. It enhances the sealing effect. Long service life but little maintenance is required. Enable for heavily stressed (load, speed and temp)
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Lubrication TypesLubrication Types
Oil Lubrication:
Solution for applications where adjacent pp jmachine elements are already supplied with oil or where heat (high loads and/or high speeds ) has to ( g / g p )be removed by means of the lubricant. e.g. Oil-mist-lubrication or oil-air-lubricationlubrication or oil air lubrication
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แนใจแนใจแลวหรอแลวหรอ? ? ..วาสารหลอวาสารหลอลนมความสะอาดเพยงพอ ไมมสงเจอปน ลนมความสะอาดเพยงพอ ไมมสงเจอปน ( ( สงสกปรกตางๆสงสกปรกตางๆ))แนใจแนใจแลวหรอแลวหรอ? ? ..วาสารหลอวาสารหลอลนมความสะอาดเพยงพอ ไมมสงเจอปน ลนมความสะอาดเพยงพอ ไมมสงเจอปน ( ( สงสกปรกตางๆสงสกปรกตางๆ))
เพราะสงสกปรกเหลานจะทา อนตรายเพราะสงสกปรกเหลานจะทา อนตรายแกชนสวนแกชนสวนเครองจกรเครองจกร
ถงแมจะมสารหลอลนระหวางชนสวนทงสองกตามถงแมจะมสารหลอลนระหวางชนสวนทงสองกตาม ถงแมจะมสารหลอลนระหวางชนสวนทงสองกตามถงแมจะมสารหลอลนระหวางชนสวนทงสองกตาม
นามนทไมสะอาด......มอนภาคของสงสกปรก
ชนสวนเกดการสก
หรอ....!!!
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การใชสารหลอลนเครองจกร นอกจากจะ
คานงถง ชนดและคณสมบตแลว ยงตอง
คานงถงความสะอาดดวย เพอปองกนสง
สกปรกปะปนไปกบสารหลอลนนน
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Lubrication ManagementLubrication Management
For all equipments; need to indentifyProper lubricantLubrication frequency
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Lubrication ManagementLubrication Management
A fA master lubrication card consists ofMachine numberMachine nameMachine locationLubrication pointsType of lubricant at each lubrication pointLubrication frequency at each lubrication pointCheck off space to show that lubrication is completedSpace to identify any observed irregularity at each lubrication point
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Equipments for grease lubricationEquipments for grease lubrication
Grease Lubrication
Grease GunGrease Gun Grease PumpGrease Pump
Automatic Grease CapAutomatic Grease CapAutomatic Grease CapAutomatic Grease CapAutomatic Grease PumpAutomatic Grease Pump
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ExampleExamplepp
“DO NOT ” ‘ DO ”Do not by Hand. Do by Greas Gun.Do not by Hand. y
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ExampleExamplepp
Grease Gun
Grease Fittingg
Bearing
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ExampleExamplepp
INSPECTION
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Equipments for oil lubricationEquipments for oil lubrication
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Question! Question! Question! Question!
If your company has various to machines, which are diversified require different type of lubricants. Is it important to stock all lubricants? How to do?
See cross-reference chart so that different producers’ lubrication numbers can be correlated.
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Property of oilsProperty of oilsProperty of oilsProperty of oils
Viscosity determines the lubrication ability of a lubricant (How easily the oil runs)Lubrication oils are usually classified by kinetic viscosity (measure without movement)y ( )Kinetic viscosity is measured by viscosimeter. Its unit is called Centistoke (cSt) and is expressed as mm2/sis called Centistoke (cSt) and is expressed as mm /s
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Property of oilsProperty of oilsProperty of oilsProperty of oils
Kinetic viscosity can be convert into dynamic viscosity (measure during movement)dynamic viscosity is defined as the resistance due to friction between two lubricated surface of area 1m2 that are gliding against each other with a speed of 1m/s. Its unit is Newton seconds (Ns/m2) or speed of 1m/s. Its unit is Newton seconds (Ns/m ) or Pascal seconds (Pa s)
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Property of oilsProperty of oilsProperty of oilsProperty of oils
ISO VG : The international Standard of Viscosity Grade. ISO standard measures viscosity at two temperatures (40°Cand 100 °C). ISO VG properties measures at 40°C .Ex. ISO VG 46: That means an oil according to ISO VG 46 gis 46 Centistokes at 40 °C. For other temperatures, need to use a Viscosity-temperature diagram. Viscosity Index (VI): indicates how the viscosity is dependent on temperature. (High VI: viscosity change little p p ( g y gwith temp., Low VI: viscosity change much with temp. )
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Viscosity-temperature diagramViscosity temperature diagram
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EX: ISO VG of lubricantsEX: ISO VG of lubricants
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Example of gear oilsExample of gear oilsExample of gear oilsExample of gear oils
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Example of grease Example of grease Example of grease Example of grease
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LubricantLubricant ClassificationClassification
Shape symbol of sticker
Oil type
Grease typeGrease type
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Lubricant ClassificationLubricant ClassificationLubricant ClassificationLubricant Classification
Mobil 360 M bil EP 2
OilOil GreaseGreaseMobil 360Mobil 632Mobil 634Mobil DTE 24
Mobilux EP – 2Shell alvania R – 3Aralub MKL – 3Mobil DTE 25
Mobil DTE 15Mobil SHC 629Mobilarma 524
Aralub MKL 3Kluber staburags N-12Kluber grease BH72 –422Mobilarma 524
Kluber primium super Kluberplex GE – 11 680Shell vitrea oil 150
Kluber grease petamoGHY 443Silicon paste uni silicon Silicon oil DC 704
Silicon oil fluid PH 1000 BAVERLub oil GS – 77
Silicon paste uni silicon TKM 1011Molykote P - 37
Lub oil N - 62
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Classification of oil by color codingClassification of oil by color codingy gy g
0
1
9Mobil 360
Mobil 632
Kluberplex GE – 11 680White
Red
Blue
1
210
11
Mobil 632
Mobil 634Shell vitrea oil 150
Silicon oil DC 704Yellow
Red +White
Red +Grey
3
412
11Mobil DTE 24
M bil DTE 25
Silicon oil fluid PH 1000 BAVERMarine
Green
Red +Yellow
4
513
14
Mobil DTE 25
Mobil DTE 15Lub oil GS – 77
Lub oil N 62
Green
Pink
Red +Blue
Red +Green
67
14Mobil SHC 629
M bil 524
Lub oil N - 62Orange
15 For future7
8
Mobilarma 524
Kluber primium super
Grey
Black
15
16 For future
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Classification of oil by color codingClassification of oil by color codingy gy g
Push on equipment
Push on Oil drum
Push on Machine
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Classification of grease by color codingClassification of grease by color coding
21 26Aralub MKL – 321 26
27
White
Silicon paste uni silicon TKM 1011
Pink
Molykote P - 37
Kluber grease BH72 – 4222227
RedGrey
Kluber greasepetamo GHY 443KluberKluber staburags NN--121223 28
Yellow Black
Mobilux EP – 224Marine
For future29
White
Shell alvania R – 325
Marine White
30Shell alvania R – 3
Green For futureWhite
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Classification of grease by color codingClassification of grease by color coding
Push on equipment
C ass ca o o g ease by co o cod gC ass ca o o g ease by co o cod g
Push on Bearing
Push on drum
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The 5 rights of lubricationsThe 5 rights of lubrications
Right typeRight qualityRight amountRight placeRight time
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Lube oil analysisLube oil analysis
Regular lube oil analysis will help to assure reliable equipment performance and reduce unscheduled downtime. Can provide the condition of a facility and condition of the lubricating oil
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Oxidation process time at different temperaturesOxidation process time at different temperaturesp pp p
T t A i t d lif tiTemperature Approximated life time
30 °C 30 Years
40 °C 15 Years40 C 15 Years
50 °C 7.5Years
60 °C 3.7Years
70 °C 1.8 Years
80 °C 0.9 Years
90 °C 0.4 Years
100 °C 0.2 Years
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Oil analysisy
Physical analysis Chemical Analysis
ViscosityFiltration
Acid numberBase number
UltracentifugualAsh content
Water contentOxidationMetal analysis
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Lube room detail
Grease Equipment
Oil Equipment
Floor coating
Drum support
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Oil pump zone
Ball valve
Lubrication name
Lubrication code Sticker code
Oil pump
Sticker code
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Pressure regulator & water drain
Pressure gauge Pressure adjustment
Water drain
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Shelve
Oil Shelve Grease ShelveSticker coding
Lubrication name
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Grease equipment
Other equipment
Grease gun
Sticker coding
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Oil equipment
Oil container
Container numbers
Sticker codingg
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Lubrication service
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Key locker